BLACKMER LIQUEFIED GAS PUMPS
FOR CO2 SERVICE TRUCK AND BASE MOUNTED
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: CRL2, CRL3, CRL3-OE1
DISCONTINUED MODELS: TCRL2, TCRL3
Patent Protected by U.S. Patent 6030191 and Related Foreign Patents.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the product, or in the manual,
look for one of the following signal words and be alert to the
potential for personal injury, death or major property
964480
INSTRUCTIONS NO. 701-B00
Section
Effective
Replaces
701
Nov 2007
Oct 2007
SAFETY DATA
damage
TABLE OF CONTENTS Page
PUMP DATA
Technical Data ......................................................2
Initial Pump Start Up Information...........................2
INSTALLATION
Pre-Installation Cleaning ....................................... 3
Location and Piping...............................................3
Pump Relief Valve and Bypass valve....................4
Check Valves ........................................................ 4
Mounting ...............................................................4
Pump Drives..........................................................4
Coupling Alignment..........................................4
V-Belt ...............................................................5
PTO..................................................................5
Hydraulic..........................................................6
Pump Rotation.......................................................6
To Change Pump Rotation....................................6
OPERATION
Pre-Start Up Check List.........................................7
Start Up Procedures.............................................. 7
MAINTENANCE
Strainers...................................................................8
Lubrication................................................................8
Vane Replacement...................................................9
Pump Disassembly ..................................................9
Parts Replacement...................................................9
Pump Assembly.....................................................10
TROUBLE SHOOTING .................................................11
Warns of hazards that WILL cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
NOTICE:
Indicates special instructions which are very
important and must be followed.
NOTICE:
Blackmer CO2 pumps MUST only be installed in
systems which have been designed by qualified
engineering personnel. The system MUST conform to
all applicable local and national regulations and
safety standards.
This manual is intended to assist in the installation
and operation of the Blackmer CO
MUST be kept with the pump.
Blackmer CO
pump service shall be performed by
2
qualified technicians ONLY. Service shall conform to
all applicable local and national regulations and
safety standards.
pumps, and
2
NOTE: Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts List No.
701-B01.
Blackmer pump manuals and parts lists may be obtained
from Blackmer's website (www.blackmer.com) or by
contacting Blackmer Customer Service.
Thoroughly review this manual, all Instructions and
hazard warnings, BEFORE performing any work on
the Blackmer CO
pumps.
2
Maintain ALL system and Blackmer liquefied gas
pump operation and hazard warning decals.
SAFETY DATA
p
(
(
)
(
(
)
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
Hazardous
machinery can
cause serious
personal injury.
severe personal injury or death
Hazardous voltage.
Can shock, burn or
cause death.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
Hazardous pressure
can cause serious
personal injury or
property damage
injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
Hazardous or toxic
fluids can cause
serious injury.
performing service or maintenance
machinery can cause
Hazardous
severe personal
injury or property
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Failure to relieve system pressure prior
to performing pump service can cause
serious personal injury or property
damage.
Systems with meters will still
be pressurized even after the hose is
emptied
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
PUMP DATA
PUMP IDENTIFICATION
A pump Identification tag, containing the pump serial number, I.D. number, and model designation, is attached to each pump. It is
recommended that the data from this tag be recorded and filed for future reference. If replacement parts are needed, or if
information pertaining to the pump is required, this data must be furnished to a Blackmer representative.
TECHNICAL DATA
CRL2
TCRL2
Maximum Pump Speed 640 RPM 640 RPM
Minimum Operating
Tem
erature
Maximum Differential
Pressure
Maximum Working Pressure
-30°F (-34°C) -30°F (-34°C)
100 psi
6.9 Bar)
525 psi
36.2 Bar)
* Technical Data is for standard materials of construction.
Consult Blackmer Material Specs for optional materials of
construction.
CRL3
TCRL3
CRL3-OE1
100 psi
6.9 Bar
525 psi
36.2 Bar
INITIAL PUMP START UP INFORMATION
Model No.: ____________________________________
Serial No.: ____________________________________
ID No.: _______________________________________
Date of Installation: _____________________________
Inlet Gauge Reading: ____________________________
Discharge Gauge Reading: _______________________
Flow Rate: _____________________________________
701-B00 page 2/12
INSTALLATION
NOTICE:
Blackmer pumps must only be installed in systems
designed by qualified engineering personnel. System
design must conform with all applicable regulations and
codes and provide warning of all system hazards.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Disconnect and lockout electrical power
Hazardous voltage.
Can shock, burn or
cause death.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
before installation or service
Electrical supply MUST match motor
nameplate specifications.
NOTICE:
Pump with welded connections contain three nonmetallic o-ring seals that will be damaged if welding is
done with these o-rings installed.
Prior to welding the piping, remove the O-rings from under the
inlet flange, outlet flange and relief valve cover as indicated in
Figure 1.
Reinstall the inlet and outlet flanges. Weld the piping to the
the inlet and outlet flanges. After the welding is complete,
reinstall the O-rings.
LOCATION AND PIPING
Pump life and performance will be significantly reduced when
installed in an improperly designed system. Before starting
the layout and installation of the piping system, review the
following suggestions:
1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.
2. The inlet line should be at least as large as the intake
port on the pump. It should slope downward to the pump,
and should not contain any upward loops. Eliminate
restrictions such as sharp bends; globe valves,
unnecessary elbows, and undersized strainers.
3. It is recommended a strainer be installed in the inlet line
to protect the pump from foreign matter. The strainer
should be located at least 24" (0.6m) from the pump, and
have a net open area of at least four times the area of
the intake piping. Strainers must be cleaned regularly to
avoid pump starvation.
4. The intake and discharge piping system must be free of
all leaks.
5. Expansion joints, placed at least 36" (0.9m) from the
pump, will compensate for expansion and contraction of
the pipes. Contact the flexible connector/hose
manufacturer for required maintenance/care and design
assistance in their use.
6. Install pressure gauges in the NPT ports provided in the
pump casing to check pump performance at start up.
7. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
8. Check alignment of pipes to pump to avoid strains which
might later cause misalignment. See Figure 2. Unbolt
flanges or break union joints. Pipes should not spring
away or drop down. After pump has been in operation
for a week or two, completely recheck alignment.
Figure 1 – Flange O-Rings
PRE-INSTALLATION CLEANING
NOTICE:
New pumps contain residual test fluid and rust inhibitor.
If necessary, flush pump prior to use.
Foreign matter entering the pump WILL cause extensive
damage. The supply tank and intake piping MUST be
cleaned and flushed prior to pump installation and operation.
Figure 2
9. The use of a vapor return line will speed up delivery by
preventing back pressure from building up at the
receiving tank and reducing pressure in the supply tank.
10. Keeping the liquefied gas systems full of liquid, even
when idle, will keep the O-rings from changing shape,
shrinking or super cooling. Evaporation of liquefied gas
leaves an abrasive powder on the surface which can
cause wear to the pump, meter, and seals.
701-B00 page 3/12
INSTALLATION
PUMP RELIEF VALVE AND BYPASS VALVE
NOTICE:
The pump internal relief valve is designed to protect the
pump from excessive pressure and must not be used as
a system pressure control valve.
For ALL liquefied gas applications, install an external bypass
valve, and any necessary piping, back to the tank. DO NOT
pipe the bypass valve back to the intake line. The setting on
the external bypass valve must be at least 25 psi (1.7 bar)
lower than the pump internal relief valve setting. The valve
and piping must be of adequate size to accommodate the full
flow from the pump when the discharge line is closed. The
non-adjustable pump internal relief valve is factory set a
approximately at 150 PSI (10.3 bar).
Refer to Blackmer Bypass Valve Installation and Maintenance
Instructions for bypass valve settings and adjustments.
Figure3 – Bypass Valve Mounting
CHECK VALVES
The use of check valves or foot valves in the supply tank is
not recommended with self-priming, positive displacement
pumps.
If the possibility of liquid backflow exists when the pump is off,
a check valve in the pump discharge piping is recommended
because the pump can motor in the reverse rotation and
create undue stress on all attached components. Never start
a pump when it is rotating in the reverse rotation as the added
starting torque can damage the pump and related equipment.
PUMP MOUNTING
Stationary Pumps
A solid foundation reduces noise and vibration, and will
improve pump performance. On permanent installations it is
recommended the pumping unit be secured by anchor bolts
as shown in Figure 4. This arrangement allows for slight
shifting of position to accommodate alignment with the
mounting holes in the base plate.
For new foundations, it is suggested that the anchor bolts be
set in concrete. When pumps are to be located on existing
concrete floors, holes should be drilled into the concrete to
hold the anchor bolts.
Figure 4 - Pipe Type
Anchor Bolt Box
When installing units built on channel or structural steel type
bases, use care to avoid twisting the base out of shape when
anchor bolts are tightened. Shims should be used under the
edges of the base prior to tightening of the anchor bolts to
prevent distortion.
Truck Mounted Pumps
CRL pump models can be bolted to the truck frame or on a
saddle hung below the frame, and MUST be adequately
supported.
PUMP DRIVES
Stationary pumps are typically driven via a V-belt drive or via
a flexible coupling and gear reducer. Truck mounted pumps
are typically driven via the truck’s PTO drive or via a hydraulic
motor.
COUPLING ALIGNMENT
The pump must be directly coupled to a gear and/or driver
with a flexible coupling. Verify coupling alignment after
installation of new or rebuilt pumps. Both angular and parallel
coupling alignment MUST be maintained between the pump,
gear, motor, etc. in accordance with manufacturer’s
instructions. See Figure 5.
1. Parallel alignment: The use of a laser alignment tool or
dial indicator is preferred. If a laser alignment tool or dial
indicator is not available, use a straightedge. Turn both
shafts by hand, checking the reading through one
complete revolution. Maximum offset should be less
than .005" (.127 mm).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90° increments
around the coupling (four checkpoints). Maximum
variation should not exceed .005" (.127 mm). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
Figure 5 – Coupling Alignment
701-B00 page 4/12
INSTALLATION
V-BELT DRIVE
For installation of Blackmer V-belt units, first mount the pump
and the motor base to the unit base. Do not fully tighten the
motor mounting bolts until properly installing and adjusting the
belts as follows:
1. Wipe the cone surface of the pump QD hub (152A) and
the inside of the pump sheave hub with a clean cloth
moistened with a light grade of machine oil. This will
allow for a more uniform draw and prevent the cone
surfaces from “freezing” before being tightened.
2. With the pump shaft key (35) in place, align the key seat
and slide the QD hub (152A) on the shaft, flange end
first. Slide the large end of the sheave (152) bore over
the taper on the QD hub. Insert the three sheave
capscrews (152G) through the clearance holes in the
sheave, and start them into the tapped holes of the QD
hub (152A). Repeat this procedure to assemble the
motor QD hub (152E) and sheave (152D).
3. To install the belts (181), shorten the center distance of
the drive by moving the motor towards the pump, until the
the belts can be put on the sheaves (152 & 152D) without
forcing.
4. Align the sheaves so that the faces are parallel, then
snug up the sheave capscrews (152C & G).
5. Measure the span length as shown in Figure 6.
Figure 6 – V-Belt Adjustment
6. Adjust the motor base (183) and apply a specified force
(refer to Table 1) against the belt, at the center of the
span, so that the belt is deflected 1/64 inch (0.04 mm) for
every inch (25.4 mm) of span. For example, the
deflection of a 20 inch (508 mm) span would be 20/64 or
5/16 inch (7.9 mm). The force required should be within
the range given in Table 1 for a properly tensioned drive.
A new set of belts should be initially tensioned to the
upper limit.
Table 1 – V-Belt Deflection
SMALL SHEAVE BELT DEFLECTION FORCE
OUTSIDE DIAMETER Minimum Maximum
2.5" to 4.5"
(63.5 mm to 114.3 mm) (1.4 kgs.) (2.2 kgs.)
4.75" to 7.0"
(120.7 mm to 177.8 mm) (1.8 kgs.) (2.7 kgs.)
7. Check again to ensure the sheaves (152 & 152D) are
parallel, then tighten the sheave capscrews (152C &
152G), the motor mounting nuts (183B) and the adjusting
screw locknut (183B).
8. Assemble the belt guard (182) and the belt guard brace
(182A) to the unit base (32).
3.0 lbs. 4.75 lbs.
4.0 lbs. 6.0 lbs.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
9. Check the belt tension after 24-48 hours of operating.
Recheck the tension periodically and tighten the belts as
required. DO NOT overtighten belts. Inspect belts
periodically for signs of excessive wear, and replace as
required.
V-BELT DISASSEMBLY
1. Remove the belt guard (182) and the guard base (182A).
2. Loosen the adjusting screw locknut (183B) on the motor
base (183) and the motor mounting nuts.
3. Ease the tension on the belts (181) by moving the motor
towards the pump to shorten the center distance of the
drive. Remove the belts by sliding them over the sheaves
(152 & 152D). DO NOT force the belts over the grooves.
4. To remove the sheave from the hub, first remove the
three sheave capscrews (152C or 152G). Then screw
two of the capscrews into the threaded holes in the
sheave hub (152A or E). If the cone grip is hard to break
loose, tap the end of the shaft or the QD hub with softfaced mallet while maintaining pressure on the screw.
5. The QD hub should slide smoothly off the shaft. If it is
tight on the shaft, gently pry it loose with a screwdriver or
a small wedge placed in the split part of the flange.
Refer to Blackmer V-Belt Parts List and Instructions for
V-belt drive and guard part numbers.
PTO DRIVE
The pump may be driven by a power take-off through
universal joints. When using universal joints, a splined slip
joint, properly lubricated, must be used on the connecting jack
shaft to prevent end thrust on the pump shaft.
A proper drive line must be installed to avoid excessive wear,
vibration and noise (see Figure 7 and Table 2).
General guidelines to follow for proper pump drive:
1. Do not use square slip joints.
2. Use the least number of jack shafts as is practical.
3. Use an even number of universal joints.
4. The pump shaft and power take-off shaft must be parallel
in all respects. Use an angular level measuring device to
ensure the PTO and pump shaft are parallel to each
other. If necessary, the pump can be shimmed to correct
any misalignment. The PTO shaft coming off at the
transmission does not need to be perfectly horizontal as
long as the pump is shimmed to have its shaft parallel in
all respects to the PTO shaft.
701-B00 page 5/12
INSTALLATION
5. The yokes of the universals at both ends of the jack
shaft must be parallel and in phase.
6. The maximum recommended angle between the jack
shaft and the pump shaft is 15 degrees. See Table 1.
Failure to follow any of these guidelines may result in a
gallop or uneven turning of the pump rotor, which will in turn
cause a surging vibration to the liquid stream and piping
system. Contact the supplier of the drive line components for
specific design assistance.
PTO driven units MUST contain speed control devices to
prevent pump speeds above the maximum RPM
specifications, regardless of the truck engine unloading
speeds. Should fluid delivery be appreciably less than
expected, see the "General Pump Troubleshooting" section.
A drive shaft guard between the pto
and pump must be provided to prevent
personal injury, property damage, or
Do not operate
without guard
in place
1othrough 5
Very Good Good Fair
death.
Tabel 2 - Angle of Drive Shaft
o
6othrough 10
o
11othrough 15
o
HYDRAULIC DRIVE
Truck mounted pumps may also be driven hydraulically.
Hydraulic motors should be well supported with their shafts
parallel to the pump shaft in all respects. Blackmer provides an
optional close-coupled hydraulic motor adapter. The adapter
provides for straight alignment of a hydraulic motor drive
through a solid coupling connected to a straight key pump
shaft. This coupling connection requires grease lubrication
every three months at minimum. Refer to the "Lubrication"
section of this manual.
Hydraulically driven units MUST contain speed control devices
to prevent pump speeds above the maximum RPM
specifications, regardless of the truck engine unloading
speeds. Should fluid delivery be appreciably less than
expected, see the "General Pump Troubleshooting" section.
PUMP ROTATION
NOTICE:
Confirm correct pump rotation by checking the pump
rotation arrows respective to pump driver rotation.
TO CHANGE PUMP ROTATION
Blackmer 2 and 3” CRL pump models are equipped with a
double ended rotor and shaft, enabling them to be driven from
either shaft end. To change rotation, rotate the pump 180
degrees so that the opposite shaft becomes the driven shaft.
The shaft protector (186) MUST be mounted over the nondriven shaft end.
NOTE: A Drive Shaft Guard between the pump and the
PTO MUST be provided. (Not shown)
Figure 7 – PTO Drive
OPERATION
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
Failure to relieve system pressure prior
to performing pump service can cause
serious personal injury or property
Systems with meters will still
Hazardous pressure
can cause serious
personal injury or
property damage
damage.
be pressurized even after the hose is
emptied
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
Hazardous pressure
can cause serious
personal injury or
property damage
injury or property damage.
Pumps operating against a closed valve
can cause system failure, personal
injury and property damage
Hazardous pressure
can cause personal
injury or property
damage
701-B00 page 6/12
OPERATION
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes
should be supported so that they do not spring away or
drop down when pump flanges or union joints are
disconnected.
2. Verify proper coupling or V-belt alignment.
3. Blackmer helical gear reducers (if supplied) are shipped
from the factory without oil in the gearcase. Fill with the
grade of oil indicated on the reducer tag. For more
specific instructions on Blackmer gear reducers, refer to
the appropriate Gear reducer Installation, Operation and
Instruction Manual.
4. Check the entire pumping system to verify that the proper
inlet and discharge valves are fully open, and that the
drain valves and other auxiliary valves are closed.
5. Ensure that any hoses are properly secured.
6. Install suction and discharge pressure gauges on the
pump in the threaded connections provided. These can
be used to check actual suction and discharge conditions
after pump start-up.
7. Check the wiring of the motor.
8. Briefly start the pump to make sure the pump rotates in
the direction of the rotation arrow.
START UP PROCEDURES
NOTICE:
Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are experienced.
Stationary Pumps
1. SLOWLY build pressure in the pump.
2. Start the pump. Priming should occur within one minute.
3. Check the suction and discharge pressure gauges to see
if the pump is operating within the expected conditions.
4. Check for leakage from the piping and equipment.
5. Check for excessive noise, vibration or overheating of the
pump, reducer, and motor.
6. If possible, check the flow rate.
7. Close the discharge valve and check the differential
pressure across the pump. Pressure must not exceed the
pressure setting of the external bypass valve.
8. With the discharge valve still closed, momentarily close
the manual shut-off valve in the bypass return line to
check the pump internal relief valve. The differential
pressure should be 150 - 170 psi (10.3 - 11.7 bar).
9. The external bypass valve must always be set at least 25
psi (1.7 bar) lower than the internal pump relief valve.
NOTE: The normal operating pressure must be at least 5
- 15 psi (0.3 -1.0 bar) less than the external bypass valve
setting. Pump speeds which result in higher pressures
(nearing the valve setting) forces the liquid to recirculate,
creating excessive wear on the pump and equipment.
Truck Pumps
1. Open the shut-off valve in the bypass return line.
2. If the tank outlet valve is:
a. Lever Operated - Pull the control knob all the way out.
Manually check the lever under the truck to see that it is
in the completely OPEN position.
b. Discharge Pressure Operated - Keep the discharge line
valve closed. When pump is started, it will build up
enough pressure to open the tank outlet valve. NOTE:
This type of valve usually requires approximately 20 psi
(1.4 bar) differential pressure to open and approximately
15 psi (1.0 bar) differential pressure to keep it open. If the
piping is quite large, it may be necessary to restrict the
discharge line shut-off valve in order to maintain
sufficient pressure to keep the tank outlet valve open.
3. Start the pump. Confirm proper pump rotation by
checking the pump rotation arrows.
4. Check the pump speed. Pump speed must never exceed
the recommended maximum. Refer to “Technical Data”
section of this manual.
5. Check the pressure gauges to ensure the system is
operating within expected parameters. Record the gauge
readings in the "Initial Start Up Information" section of
this manual for future reference.
6. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
7. Check the flow rate to ensure the pump is operating
within the expected parameters. Record the flowrate in
the “Initial Start Up Information” section of this manual.
8. Close the discharge valve and check the differential
pressure across the pump. It must not exceed the
pressure setting of the external bypass valve.
9. With the discharge valve still closed, momentarily close
the manual shut-off valve in the bypass return line to
check the internal pump relief valve. The differential
pressure should be 150 to 170 psi (10.3 to 11.7 bar).
10. The external bypass valve must always be set at least 25
psi (1.7 bar) lower than the pump internal relief valve.
NOTE: The normal operating pressure must be at least 5
- 15 psi (0.3 - 1.0 bar) less than the external bypass valve
setting. Pump speeds which result in higher pressures
(nearing the valve setting) forces the liquid to recirculate,
creating excessive wear on the pump and equipment.
701-B00 Page 7/12
MAINTENANCE
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
Hazardous
machinery can
cause serious
personal injury.
severe personal injury or death
Hazardous voltage.
Can shock, burn or
cause death.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
Hazardous pressure
can cause serious
personal injury or
property damage
injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior
Hazardous or toxic
fluids can cause
serious injury.
to performing service or maintenance
machinery can cause
Hazardous
severe personal
injury or property
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Failure to relieve system pressure prior
to performing pump service can cause
serious personal injury or property
damage.
Systems with meters will still
be pressurized even after the hose is
emptied
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
NOTICE:
Maintenance shall be performed by qualified technicians only.
Following the appropriate procedures and warnings as presented in this manual.
SCHEDULED MAINTENANCE
STRAINERS
Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.
LUBRICATION
NOTICE:
To avoid possible entanglement in moving parts do not
lubricate pump bearings, gear reducer or any other parts
while the pump is running.
Pump bearings should be lubricated every one to twelve
weeks (AT MINIMUM), depending on the application, and
operating conditions.
Recommended Grease:
Dow Corning® - MOLYKOTE 44
DuPont® - KRYTOX GPL 203
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
covers (27A).
2. SLOWLY apply grease with a hand gun until grease
begins to escape from the grease relief fitting port. (76)
3. Replace the grease relief fittings (76A).
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
lubrication, excessive grease on pumps equipped with
mechanical seals can cause seal failure.
IF EQUIPPED: Blackmer gear reducers are shipped from the
factory without oil in the gearcase. Fill with the grade of oil
indicated on the reducer tag. The oil should be changed after
the first 48 hours of use and approximately every 500 hours of
use thereafter.
701-B00 Page 8/12
MAINTENANCE
VANE REPLACEMENT
NOTICE:
Maintenance shall be performed by qualified technicians
only. Following the appropriate procedures and
warnings as presented in manual.
1. Drain and relieve pressure from the pump and system as
required.
2. Remove the head assembly from the outboard
(nondriven) side of the pump according to steps 4 - 9 in
the "Pump Disassembly" section of this manual.
3. Turn the shaft by hand until a vane (14) comes to the top
(12 o'clock) position of the rotor. Remove the vane.
4. Install a new vane (14), ensuring that the rounded edge is
UP, and the relief grooves are facing towards the direction
of rotation. See Figure 8.
5. Repeat steps 3 and 4 until all vanes have been replaced.
6. Reassemble the pump according to the "Pump
Assembly." section of this manual.
Figure 8 – Vane Replacement
PUMP DISASSEMBLY
NOTICE:
Follow all hazard warnings and instructions provided in
the “maintenance” section of this manual.
NOTE: The numbers in parentheses following individual parts
indicate reference numbers on the Pump Parts List.
1. Drain and relieve pressure from the pump and system as
required.
2. Starting on the inboard (driven) end of the pump, clean
the pump shaft thoroughly, making sure the shaft is free
of nicks and burrs. This will prevent damage to the
mechanical seal when the inboard head assembly is
removed.
3. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket. On the 2inch models, the dirt shield (123A) will come off with the
bearing cover.
4. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket. On the 2inch models, the dirt shield (123A) will come off with the
bearing cover.
5. To remove locknuts and lockwashers (24A and 24B):
a. Bend up the engaged lockwasher tang and rotate the
locknut (24A) counterclockwise to remove it from the
shaft
b. Slide the lockwasher (24B) off the shaft. Inspect the
lockwasher for damage and replace as required.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21) and carefully pry the
head (20) away from the casing (12).
7. Slide the head (20) off the shaft. The head O-ring (72),
bearing (24), mechanical seal stationary seat and
stationary O-ring (153A & 153D) will come off with the
head assembly. Remove and discard the head O-ring.
a. Pull the bearing (24) from the housing in the head
(20).
b. To remove the mechanical seal stationary seat
(153A), use the blunt end of a screw driver to gently
push the backside of the stationary seat from the
head. Place a cloth under the seal to avoid damage.
Be careful not to contact the polished face of the seal
during removal. Remove and discard mechanical seal
stationary O-ring.
8. Carefully pull the rotating seal assembly, consisting of
seal jacket (153C), rotating seal face and rotating O-ring
(153B & 153E) from the shaft. Remove and discard the
rotating O-ring (153E).
9. Carefully remove the disc (71).
10. Carefully pull the rotor and shaft (13) from the casing
(12). While one hand is pulling the shaft, cup the other
hand underneath the rotor to prevent the vanes (14) and
push rods (77) from falling out. Carefully set the rotor and
shaft aside for future vane replacement and reassembly.
NOTICE: The rotor and shaft weighs approximately 34
pounds (15 kg). Be careful not to pinch the hand under
the rotor and shaft when removing from casing.
11. Lay the pump flat with the remaining head (20) facing
upward to remove the head assembly mechanical seal
(153) and disc (71) from the outboard side of the pump,
as instructed in steps 6 - 9 above. 12. If necessary,
remove the liner (41) by tapping around the outside
diameter of the liner with a hard wood drift and a hammer
until it is driven from the casing (12).
PARTS REPLACEMENT
1. If any of the O-rings have been removed or disturbed
during disassembly, they be replaced with new O-rings.
NOTE: PTFE O-rings should be heated in hot water to aid
installation.
2. Excessive or continuous leakage from the tell-tale hole in
the bearing cover may be an indication of a damaged
mechanical seal. If a mechanical seal has been leaking, it
is recommended the entire seal be replaced. Refer to
"General Pump Troubleshooting" for possible causes of
seal leakage.
701-B00 Page 9/12
MAINTENANCE
PUMP ASSEMBLY
Before reassembling the pump, inspect all component
parts for wear or damage, and replace as requi red. Wash
out the bearing/seal recess of the head and remove any
burrs or nicks from the rotor and shaft.
Reassemble the OUTBOARD side of the pump first:
1. On 2-inch pump models, apply grease to the liner key
groove in the pump casing to hold the key (74) in place
during liner installation. Install key in groove before
starting liner (41) into pump casing (12). On 3-inch pump
models, install the liner key (74) in the groove on top of
the liner (41).
2. Align the liner key (74) with the pump casing keyway and
start the liner (41) into the casing (12) with the slots in the
liner towards the INTAKE port, and the hole pattern in the
liner towards the DISCHARGE port. Uniformly tap the
outer edge of the liner with a rubber mallet to fully insert
into the casing. NOTE: If the liner is installed backwards,
it will restrict the port openings and cause cavitation,
noise and loss of capacity.
b. Leave part of the rotor outside of the casing (12) so
that the bottom vanes (14) can be installed and held
in place as the push rods (77) are installed in the
push rod holes of the rotor. Insert the new vanes into
the rotor slots with the rounded edges outward, and
the vane relief grooves facing TOWARDS the
direction of rotation. See Figure 10.
c. After the bottom vanes and push rods are installed,
insert the rotor and shaft (13) fully into the casing
(12).
d. Install the remaining vanes (14) into the top positions
of the rotor.
6. Install the disc (71) on the inboard side of the pump with
the seal cavity facing outward and the disc relief hole
located as shown in Figure 9.
7. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 11.
Figure 9 – Disc Relief Hole Location
3. Place the disc (71) against the liner (41) with the seal
cavity outward and disc relief hole located as shown in
Figure 9.
4. Without installing the head O-ring or mechanical seal
components, temporarily attach the outboard head (20)
and bearing (24) to the casing (12). Install and
handtighten two head capscrews (21), 180 degrees
apart. This head will be used to hold and align the rotor
and shaft (13) while the inboard side of the pump is
assembled.
5. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly (13). Inspect for wear and damage,
and replace as follows:
Figure 10 –
Pushrod
Installation
a. Partially install the non-driven end of the rotor and
shaft (13) into the open side of the pump casing (12).
701-B00 Page 10/12
Figure 11 – Head O-Ring Installation
8. MECHANICAL SEAL INSTALLATION
Rotating Assembly -
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor.
b. Slide the seal jacket assembly (153C) over the shaft
and into the disc cavity with the drive tangs of the
jacket towards the rotor. Rotate the jacket assembly
to engage the drive tangs in the rotor slots.
c. Install a new rotating O-ring (153E) in the rotating
seal face (153B). Align and insert the rotating
assembly into the the seal jacket with the polished
face outward. Clean the polished face with a clean
tissue and alcohol.
Stationary Seat -
a. Apply a small amount of motor oil in the seal recess
of the head (20).
b. Install a new stationary O-ring (153D) in the
stationary seat (153A). Align the pin in the stationary
seat with the slot in the head recess and push the
seat fully into the seal recess with the polished face
outward. Clean the polished face with a clean tissue
and alcohol
9. Carefully install the head assembly (20) over the shaft.
Do not contact the end of the shaft with the polished face
of the stationary seat. Rotate the head so that the drain
hole (tell-tale hole), located at the back of the bearing
cavity, faces downward when the pump is mounted for
operation. Install and uniformly tighten four head
capscrews (21) 90° apart, torquing to 30 lbs ft (40.7 Nm).
10. Hand pack the ball bearing (24) with grease. Refer to the
"Lubrication" section for the recommended grease.
MAINTENANCE
11. Install the bearing (24) into the head recess. The bearing
balls should face outward, with the grease shield inward.
Ensure the bearing is fully and squarely seated in the
head (20).
12. Turn the pump casing around and remove the outboard
head previously attached.
13. Install the outboard head (20), mechanical seal (153) and
bearing (24) as instructed in steps 6 through 11.
14. Rotate the shaft by hand to engage the mechanical seal
drive tangs, and to test for binding or tight spots. If the
rotor does not turn freely, lightly tap the rims of the heads
with a soft faced mallet until the correct position is found.
Install all of the remaining head capscrews (21) for each
head (20) and uniformly torque to 30 lbs ft (40.7 Nm).
15. LOCKNUT ADJUSTMENT
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightening locknuts can cause bearing failure or a broken
lockwasher tang. Loose locknuts will allow the rotor to shift
against the discs (71), causing wear. See Figure 12.
a. On both ends of the pump shaft, Install a lockwasher
(24B) with the tangs facing outward, followed by a
locknut (24A) with the tapered end inward. Ensure the
inner tang "A" of the lockwasher is located in the slot
in the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts (24A) to ensure that the
bearings (24) are bottomed in the head recess. DO
NOT overtighten and bend or shear the lockwasher
inner tang.
c. Loosen both locknuts one complete turn.
e. Back off the nut the width of one lockwasher tang "B".
Secure the nut by bending the closest aligned
lockwasher tang into the slot in the locknut. The pump
should turn freely when rotated by hand.
f. Tighten the opposite locknut (24A) by hand until it is
snug against the bearing (24). Then, using a spanner
wrench, tighten the nut the width of one lockwasher
tang. Tighten just past the desired tang, then back off
the nut to align the tang with the locknut slot. Secure
the nut by bending the aligned lockwasher tang into
the slot in the locknut. The pump should continue to
turn freely when rotated by hand.
g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
done, one or both locknuts are too tight and should
be alternately loosened one stop at a time (.001" – 25
microns). Begin by loosening the locknut adjusted
last.
16. Inspect the grease seal (104) for wear or damage and
replace as required. Grease the outside diameter of the
grease seal and push it into the inboard bearing cover
(27) with the lip of the seal inward.
17. Attach a new bearing cover gasket (26) and the bearing
cover (27) to the inboard head (20). Make sure the
grease fittings (76) are accessible. Install and torque the
bearing cover capscrews (28) to 30 lbs ft (40.7 Nm).
18. Install the grease seal (104) and bearing cover (27) on
the opposite side of the pump per steps 16 and 17.
19. On 2-inch pump models, push the dirt shield (123A) over
the inboard and outboard shafts and firmly against the
bearing cover (27).
20. Attach the shaft protector (186) to the non-driven shaft
end.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard in
place.
Figure 12 – Locknut Assembly
d. Tighten one locknut until a slight rotor drag is felt
when turning the shaft by hand.
21. Reinstall coupling, shaft key, and coupling guards.
22. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to restarting
pump operation.
TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only,
following the appropriate procedures and warnings as presented in this manual.
SYMPTOM PROBABLE CAUSE
Pump Not Priming
1. Pump not wetted.
2. Worn vanes.
3. Internal control valve closed.
4. Strainer clogged.
5. Inlet line or valves clogged or too restrictive.
6. Broken drive train (truck mounted pumps).
7. Pump vapor-locked.
8. Pump speed too low for priming.
9. Relief valve partially open, worn or not seating properly.
701-B00 Page 11/12
TROUBLESHOOTING ….. cont.
SYMPTOM PROBABLE CAUSE
Reduced Capacity
1. Pump speed too low.
2. Internal control valve not fully open.
3. Excessive restriction in the inlet line (i.e.: undersized piping, too many elbows & fittings,
clogged strainer, etc.).
4. Damaged or worn parts (vanes, discs, liner or rotor).
5. Excessive restriction in discharge line causing partial flow through the relief valve.
6. Relief Valve worn, set too low, or not seating properly.
7. External Bypass Valve set too low.
8. Operating without a vapor return line.
9. Vanes installed incorrectly (see "Vane Replacement").
10. Liner installed backwards
Noise
Damaged Vanes
Broken Shaft
1. Excessive pressure drop on the pump due to:
a. Undersized or restricted fittings in the inlet line.
b. Pump speed too fast.
c. Pump too far from fluid source.
2. Running the pump for extended periods with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line - truck mounted pumps (see "Pump Drive").
5. Misalignment of pump, reducer or motor - base mounted pumps.
6. Bearings worn or damaged.
7. Vibration from improperly anchored piping.
8. Bent shaft, or drive coupling misaligned.
9. Excessively worn rotor.
10. Malfunctioning valve in the system.
11. Relief valve setting too low.
12. Liner installed backwards.
13. Damaged vanes (see following category).
1. Foreign objects entering the pump.
2. Running the pump dry for extended periods of time.
3. Cavitation.
4. Excessive heat.
5. Worn or bent push rods, or worn push rod holes.
6. Hydraulic hammer - pressure spikes.
7. Vanes installed incorrectly (see"Vane Replacement").
8. Incompatibility with the liquids pumped.
1. Foreign objects entering the pump.
2. Relief valve not opening.
3. Hydraulic hammer - pressure spikes.
4. Pump/driver, driveline/drive shaft misalignment.
5. Excessively worn vanes or vane slots.
Mechanical Seal Leakage
Visit www.blackmer.com for complete information on all Blackmer products
1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Mechanical seal faces cracked, scratched, pitted or dirty.
1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.
Telephone: (616) 241-1611 • Fax: (616) 241-3752
E-mail: blackmer@blackmer.com • Internet Address: www .blackmer.com
701-B00 Page 12/12
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