BLACKMER GNXH2A, GNXH2.5A, GNXH3A, GNXH4A, GNX2A Installation, Operation And Maintenance Instructions

BLACKMER POWER PUMPS

A

INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS

MODELS: GNX(H)2A, GNX(H)2.5A, GNX(H)3A, GNX(H)4A

This is a SAFETY ALERT SYMBOL.

When you see this symbol on the product, or in the

TABLE OF CONTENTS Page PUMP DAT

Technical Data .................................................... 2

Initial Pump Start Up Information ........................ 2

INSTALLATION

Pre-Installation Cleaning ..................................... 3

Location and Piping ............................................. 3

Mounting ............................................................. 3

Coupling Alignment ............................................. 4

Motor Coupling Installation………………………...4

Gear Reducer Alignment – GNX(H) Models ....... 4

Pump Rotation .................................................... 6

To Change Pump Rotation .................................. 6

Check Valves ...................................................... 6

OPERATION

Pre-Start Up Check List ...................................... 7

Start Up Procedures ............................................ 8

Running the Pump in Reverse Rotation .............. 9

Flushing the Pump .............................................. 9

Pump Relief Valve ............................................... 9

Relief Valve Setting and Adjustment ................... 9

PUMP MAINTENANCE

Pump Lubrication ................................................. 10

Strainers............................................................... 11

Vane Replacement .............................................. 11

Pump Disassembly .............................................. 11

Parts Replacement .............................................. 11

Pump Assembly ................................................... 12

GEAR REDUCER MAINTENANCE ............................ 14

PUMP TROUBLE SHOOTING .................................... 16

GEAR REDUCER TROUBLE SHOOTING ................. 17

NOTE: Numbers in parentheses following individual parts

indicate reference numbers on Blackmer Parts Lists.
Blackmer pump manuals and parts lists may be obtained

from Blackmer's website (www.blackmer.com) or by
contacting Blackmer Customer Service.

PUMP PUMP PARTS LIST
MODEL 2” 2.5” 3” 4”
GNX(H)

101-C01 101-C02 101-C03 101-C04

manual, look for one of the following signal words and be

alert to the potential for personal injury, death or major

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

Indicates special instructions which are very

important and must be followed.

Blackmer 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 power pumps, and MUST be kept
with the pump.

Pump service shall be performed by qualified technician s
ONLY. Service shall conform to all applicable local and
national regulations and safety standards.

Thoroughly review this manual, all instructions and hazard
warnings, BEFORE performing any work on the pump.

Maintain ALL system and pump operation and hazard
warning decals.

961224

INSTRUCTIONS NO. 101-C00

Section

Effective

Replaces

101
Mar 2019
Oct 2018

SAFETY DATA

property damage

or property damage.

NOTICE:

NOTICE:

SAFETY DATA

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.

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

Operation without guards in place can
cause serious personal injury, major
property damage, or death.

Do not operate

without guard

in place

Hazardous pressure

can cause personal

injury or property

Hazardous pressure

can cause personal

injury or property

damage

damage

Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death

Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage

Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.

PUMP DATA

PUMP IDENTIFICATION

A pump Identification tag, containing the pump serial number, I.D. number, and model designation, is attached to each p ump. 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

Maximum Pump
Speed

2”, 2.5”

815 RPM 700 RPM 563 RPM

Maximum
Viscosity

Maximum
Operating
Temperature *

Maximum
Differential
Pressure

125 psi

(8.6 Bar)

(115 – 149°C)

Maximum
Working
Pressure

* Maximum operating limits are dependent on the materials of
construction. See Blackmer Material Specs 101-096.

3” 4”

20,000 SSU

(4,250 cP)

240 – 300°F

100 psi

(6.9 bar)

100 psi

(6.9 bar)

175 psi

(12.1 Bar)

INITIAL PUMP START UP INFORMATION

Model No.: __________________________ __________
Serial No.: _______________________________ _____
ID No.: _______________________________________
Date of Installation: _____________________________
Inlet Gauge Reading: ____________________________
Discharge Gauge Reading: _______________________
Flow Rate: ________________________ _____________

101-C00 page 2/20

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.

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.

LOCATION AND PIPING

Pump life and performance can be significantly reduced
when installed in an improperly designed system. Before
starting the layout and installation of the piping system,
review the following:

1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.

2. The inlet line MUST be at least as large as the intake
port on the pump. The inlet piping should slope
downward to the pump without 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. For viscosities greater than 1000
SSU, consult the strainer manufacture instructions.
Strainers must be cleaned regularly to avoid pump
starvation.

4. The intake system must be free of air 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 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 1. 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

9. When pumping liquids at elevated temperatur e,
provisions should be made to compensate for expansion
and contraction of the pipes, especially when long pipe
lines are necessary. Steel pipe expands approximately
3/4” (1.9 cm) per 100 feet (30.49 m) per 100°F (37.8°C)
rise in temperature.

PUMP MOUNTING

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 2. This arrangement allows for slight
shifting of position to accommodate alignment with the
mounting holes in the base plate.

Figure 2 - Pipe Type Anchor Bolt Box

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.

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.

101-C00 page 3/20

COUPLING ALIGNMENT – FOOTED
GEARBOX

The following pertains to units with non-standard, footed
gearboxes only. Standard GNX(H) units will not require
manual 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 3.

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 3 – Alignment Check

Operation without guards in place can
cause serious personal injury, major
property damage, or death.

Do not operate

without guard

in place

ALIGNMENT – GNX(H) MODELS

The motor, gearbox, and pump are rigidly connected with
bolted, flange connections. These flanges ensure the motor
shaft, gearbox shafts, and pump shaft are aligned correctly,
without the need for manual alignment. However, due to
variations in base and foundation geometry the unit will
require shimming to reduce stress on the gearbox and pump
adapter. See PRESTART CHECKLIST section for details.

NEMA MOTOR COUPLING ADAPTER

Motor adapters allow for easy installation and removal of
industry standard motors. Motor adapters consist of a
coupling and an adapter housing that connects the motor to
the gear reducer.

NORD Gear supplies a coupling that is to be mounted on the
motor shaft. It is important that the coupling is properly
positioned.

• For NEMA Input Adapters, follow the Motor Installation
Instructions on page 5.

• For IEC Input Adapters, the supplied coupling will mount
directly against the motor shaft shoulder. No locating
measurements need to be taken.

Couplings

Couplings are made with tough abrasion resistant materials,
which resist most chemicals and petroleum products. They
are electrically isolated (prevent metal to metal contact) and
require no lubrication or maintenance. Depending upon the
size of the C-face input, NORD provides either a gear or a
jaw type coupling.

NORD supplies three different types of couplings depending
on the size of input: “J” style, “M” style and “Jaw” style
coupling.

Following are instructions on how to properly mount each
type of coupling onto the motor.

BoWex® Couplings

NORD C-face adapter input shafts have a machined spline
on the end. NORD incorporates two styles of BoWex®
couplings, the “J” and “M” styles. The “J” style is a one-piece
coupling with a metal hub and nylon spline. The “M” style is a
two-piece coupling – the metal hub and a nylon sleeve. Nylon
and steel components allow them to operate in high ambient
temperatures without lubrication or maintenance.

• Nylon sleeves resist dirt, moisture, most chemicals and
petroleum products

• No lubrication required

• Operating Conditions: -22ºF - 212ºF (-30ºC - 100ºC)

• Higher temperature coupling sleeve available up to 250ºF
(120ºC)

• Special bore available

Hazardous

machinery can

cause serious

personal injury.

Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death

NEMA Motor Coupling Styles

101-C00 Page 4/20

BoWex® Couplings Mechanical Ratings “J” Style (NEMA & IEC)

Coupling

Type

BoWex®
J14
BoWex®
J24
BoWex®
J28

Rated Torque

Cont. Peak

(Lb-in)

(N-m)

44.3
5

106

12

398

45

88.5
10

212

24

1,195

135

Input

Adapter

Sizes

N56C 5/8”
N140TC 7/8”
N180TC

N180TC1

Bore

Size

1-1/8”

BoWex® Couplings Mechanical Ratings “M” Style (NEMA & IEC)

Coupling

Type

BoWex®
M38

BoWex®
M42
BoWex®

M48
*GNX(H)2/2.5 N250TC Frame size uses BoWex® M38
*GNX(H)3/4 N250TC Frame size uses BoWex

Rotex® Couplings

The cast iron jaw type couplings have an integral urethane
“spider” that provides smooth transmission of the motor
torque. A set screw on the coupling prohibits axial movement
along the motor shaft.

• Excellent shock and vibration dampening

• Excellent resistance to oils and most chemicals

• No metal-to-metal contact

• Operating Conditions: -22ºF - 195ºF (-30ºC - 90ºC)

• Higher temperature material (Hytrel) spider available up to
230ºF (110ºC)

• Low temperature materials available upon request

• Special bores available

Rated Torque

Cont. Peak

(Lb-in)

(N-m)

708

80

885
100

1,239

140

2,124

240

2,655

300

3,717

420

Input

Adapter

Sizes

N180TC,
N210TC,
N250TC*
N250TC* 1-5/8”

N280TC 1-7/8”

®

M42

Bore
Size

1-1/8”,

1-3/8”

Rotex® Couplings Mechanical Ratings “R” Style (NEMA & IEC)

Coupling

Type

Rotex®

R65

Rotex®

R90

Rated Torque

Cont. Peak

(Lb-in)

(N-m)

5,532

625

21,242

2400

11,063

1,250

42,484

4800

Input

Adapter

Sizes
N320TC 2-3/8”
N360TC 1-5/8”

Bore

Size

“J” Style Coupling NEMA C-face Motor Installation

1. Measure the distance from the face of the input adapter
to the face of the splined shaft and record that
measurement as A in the equation below.

2. Measure depth of coupling engagement zone and record
the measurement as “B” in the equation below.

101-C00 Page 5/20

3. Add “A” + “B” and subtract 0.08” (~2mm) from the
distance. This needs to be done so that the coupling will
not be preloaded after installation!

4. Use that measurement to locate the coupling from the
face of the motor onto the shaft.

5. Once in place, tighten the set screw to lock the coupling
in place. It is recommended that the key is staked or
bonded (Loctite) in place to prohibit the key from
vibrating out.

6. Mount the motor onto the input adapter with customer
supplied bolts. Make sure that the coupling from the
adapter and the motor engage securely. Use lock
washers or Loctite to prohibit bolts from becoming loose
from vibration.

“J” Style NEMA Motor Coupling Installation

“M” Style Coupling NEMA C-face Motor Installation

1. Measure the distance from the face of the input adapter
to the face of the splined shaft & record that
measurement.

2. Subtract 0.31” (~8mm) from the distance. This needs to
be done so that the coupling will not be preloaded after
installation!

3. Use that measurement to locate the coupling from the
face of the motor onto the shaft.

4. Once in place, tighten the set screw to lock the coupling
in place. It is recommended that the key is staked or
bonded (Loctite) in place to prohibit the key from
vibrating out.

5. Mount the motor onto the input adapter with customer
supplied bolts. Make sure that the coupling from the
adapter and the motor engage securely. Use lock
washers or Loctite to prohibit bolts from becoming loose
from vibration.

“M” Style NEMA Motor Coupling Installation

“Jaw” Style Coupling NEMA C-face Installation

1. Measure the distance from the face of the input adapter
to the face of the coupling as shown and record that
measurement.

2. Subtract the “X” dimension from the measured distance.
This needs to be done so that the coupling will not be
preloaded after installation!

3. Use that measurement to locate the coupling from the
face of the motor onto the shaft.

4. The metal portion of the coupling should be heated up
prior to assembly, generally 250ºF to 300ºF (120ºC to
150ºC).

Notice: DO NOT HEAT URETHANE SPIDER

5. Once in place, tighten the setscrew to lock coupling in
place. Let the coupling cool down before placing the
spider into the jaws. It is recommended that the key is
staked or bonded (Loctite) in place to prohibit the key
from vibrating out.

6. Mount the motor onto the input adapter with customer
supplied bolts. Make sure that the coupling from the
adapter and the motor engage securely. Use lock
washers or Loctite to prohibit bolts from becoming loose
from vibration.

PUMP ROTATION

A right-hand pump rotates clockwise with the intake and relief
valve on the right side, when viewed from the driven end.

A left-hand pump rotates counterclockwise with the intake
and relief valve on the left side, when viewed from the driven
end.

NOTICE:

On GNX(H) models, the gear reducer input shaft will
rotate in the opposite direction of the pump shaft. For
example, on a right-hand GNX(H) pump, the gear reducer
shaft will rotate counterclockwise. The motor fan can be
used to ensure proper rotation.

NOTICE:

Confirm correct pump rotation by checking the pump
rotation arrows respective to pump driver rotation.

TO CHANGE PUMP ROTATION

To reverse rotation, the pump must be disassembled then
reassembled with the shaft on the opposite side of the pump.
See the ‘Maintenance’ section for instructions.

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.

Jaw Style NEMA Motor Coupling Installation

Coupling

Size

R14 0.06” (1.5 mm)
R19 & 24 0.08” (2.0 mm)
R28 0.10” (2.5 mm)
R38 & 42 0.12” (3.0 mm)
R48 0.14” (3.5 mm)
R65 0.18” (4.5 mm)
R90 0.22” (5.5 mm)

(Subtract this value from measured distance)

“X”

101-C00 Page 6/20

OPERATION

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 personal

injury or property

damage

injury, death or major property damage

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 alignment on long coupled units.

3. For GNX(H) models:

3a. Bolt down the pump foot, while supporting the motor
with an appropriate lifting device (e.g. crane)

3b. Place a .125” thick shim under each of the motor
mounting holes
3c. Slowly lower the motor until it is unsupported
3d. Try pulling out each of the shims, while noticing the
the pull tension
3e. If the shims closest to the motor shaft easily pull out,
increase the shim thickness the same at all
locations and recheck
3f. If the shims furthest from the motor shaft easily pull
out, decreas e the shim thickness the same at all
locations and recheck

3g. The unit is properly shimmed when all 4 motor

shims have the same amount of tension when
pulled

3h. Bolt down the motor with the appropriate fastener.

4. The GNX(H)2 and GNX(H)2.5 gearbox will be shipped
with Mobil SHC630 synthetic oil. The GNX(H)3 and
GNX(H)4 will be shipped with Mobil SHC Gear 220
synthetic oil. If replacing the oil, refer to the GEAR

REDUCER MAINTENANCE section.

Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury

Hazardous pressure
can cause personal

injury or property

damage

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

after installation of the gear reducer and prior to
initial pump start up. See “Pump Lubrication” in the

Maintenance section of this manual.

6. 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.

7. Install vacuum and pressure gauges on the pump in the
1/4” NPT connections provided to check suction and
discharge conditions after pump start-up.

8. Check the wiring of the motor, and briefly turn on the
power to make sure that the pump rotates in the direction
of the rotation arrow.

NOTICE:

The GNX(H) Gear Reducer is shipped with the correct
amount of synthetic oil. If the unit will be orientated in a
non-standard way, please consult the factory for
lubrication information

5. On GNX(H) models shipped without the gear reducer

attached, the inboard bearings are NOT greased at
the factory. The inboard bearing MUST be greased

101-C00 Page 7/20

START UP PROCEDURES

NOTICE:

Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are
experienced.

1. Start the motor. Priming should occur within one minute.

2. Check the suction and discharge pressure to see if the
pump is operating within the expected conditions.
Record pressures in the ‘Initial Start Up Information’
section.

3. Check for leakage from the piping and equipment.

4. Check for overheating, excessive noise or vibration of the
pump, reducer, and motor.

5. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
‘Initial Start Up Information’ section.

6. Check the pressure setting of the relief valve by briefly
closing a valve in the discharge line and reading the
pressure gauge. This pressure should be 20 psi (1.4 bar)
higher than the maximum operating pressure.

Do not run the pump for more than 15 seconds with
the discharge valve completely closed.

If adjustments need to be made, refer to "Relief Valve
Setting & Adjustment."

Hazardous pressure

can cause personal

injury or property

damage

Incorrect settings of the pressure relief
valve can cause pump component
failure, personal injury, and property
damage.

101-C00 Page 8/20

RUNNING THE PUMP IN REVERSE ROTATION

NOTICE:

Pump should be operated in reverse rotation for no more
than 10 minutes and only when a separate pressure relief
valve is installed to protect the pump from excessive
pressure.

It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation for a LIMITED time, at a reduced

performance level.

FLUSHING THE PUMP

NOTICE:

If flushing fluid is to be left in the pump for an extended
time, it must be a lubricating, non-corrosive fluid. If a
corrosive or non-lubricating fluid is used, it must be
flushed from the pump immediately.

1. To flush the pump, run the pump with the discharge
valve open and the intake valve closed. Bleed air into
the pump through the intake gauge plug hole or through
a larger auxiliary fitting in the intake piping. Pump air for
30 second intervals to clean out most of the pumpage.

2. Run a system compatible flushing fluid through the pump
for one minute to clear out the remainder of the original
pumpage.

3. To remove the flushing fluid, follow step 1 above.

NOTICE:

After flushing the pump some res idual fluid will remain in
the pump and piping.

NOTICE:

Properly dispose of all waste fluids in accordance with
the appropriate codes and regulations.

PUMP RELIEF 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.

GNX(H) series pumps are fitted with an internal pressure
relief valve that bypasses back to the suction side of the
pump.

Pumping volatile liquids under suction lift may cause
cavitation. Partial closing of the discharge valve WILL result
in internal relief valve chatter and is NOT recommended. For
these applications, install an external system pressure
control valve, and any necessary bypass piping, back to the
storage tank.

A system pressure control valve is also recommended when
operating for extended periods (more than 1 minute) against
a closed discharge valve.

RELIEF VALVE SETTING AND ADJUSTMENT

The relief valve pressure setting is marked on a metal tag
attached to the valve cover. Generally, the relief valve should
be set at least 15 - 20 psi (1.0 - 1.4 Bar) higher than the
operating pressure, or the external bypass valve setting (if
equipped).

Incorrect settings of the pressure relief
valve can cause pump component
failure, personal injury, and property

Hazardous pressure
can cause personal

injury or property

damage

Hazardous or toxic

fluids can cause

serious injury.

DO NOT remove the R /V Cap OR adjust the relief valve
pressure setting while the pump is in operation.

1. To INCREASE the pressure setting, remove the relief
valve cap (1) and gasket (88). Loosen the locknut(3), if
equipped. Turn the adjusting screw (2) inward, or
clockwise. Inspect the R/V cap gasket (88) and replace
as required. Reattach the R/V cap gasket and cap.

2. To DECREASE the pressure setting, remove the relief
valve cap (1) and gasket (88). Loosen the locknut(3), if
equipped. Turn the adjusting screw (2) outward, or
counterclockwise. Inspect the R/V cap gasket (88) and
replace as required. Reattach the R/V cap gasket and
cap.

Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. Unless specified otherwise, pumps
are supplied from the factory with the relief valve adjusted to
the mid-point of the spring range.

damage.

Relief valve cap is exposed to pumpage
and will contain some fluid

101-C00 Page 9/20

Hazardous

machinery can

cause serious

personal injury.

Hazardous voltage.

Can shock, burn or

cause death.

Hazardous pressure

can cause personal

injury or property

damage

Hazardous pressure

can cause personal

injury or property

damage

Hazardous or toxic

fluids can cause

serious injury.

Do not operate

without guard

in place

Failure to disconnect and lockout
electrical power or engine drive
before attempting maintenance can
cause severe personal injury or death

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 or
maintenance can cause personal
injury or property damage.

Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage

If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior
to performing service or maintenance

Operation without guards in place can
cause serious personal injury, major
property damage, or death.

MAINTENANCE

NOTICE:

Maintenance shall be performed by qualified technicians
only. Follow the appropriate procedures and warnings
as presented in this manual.

SCHEDULED MAINTENANCE
PUMP 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.

NOTICE:

The inboard bearings of GNX(H) models shipped without
the gear reducer attached are NOT greased at the
factory. The inboard bearing MUST be greased after
installation of the gear reducer and prior to initial pump
start up.

NOTICE:

If pumps are repainted in the field, ensure that the grease
relief fittings (76A) are functioning properly after painting.
Do NOT paint them closed. Remove any excess paint
from the fittings.

Pump bearings should be lubricated every three months at
minimum. More frequent lubrication may be required,
depending on the application and operating conditions.

Recommended Grease:

Mobil® - Mobilgrease XHP222,
Exxon® - RONNEX MP Grease,
or equivalent Lithium grease..

Greasing Procedure:

1. Remove the grease relief fittings (76A) from the bearing
covers (27, 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 with a Blackmer gear reducer, refer to the ‘Gear
Reducer Lubrication’ section of this manual.

PUMP SHAFT/GEARBOX COUPLING

An Anti-Seize compound should be applied to the end of the
pump shaft to help minimize fretting wear between the
gearbox coupling and pump shaft.

Recommended Anti-Seize Compound:

Loctite ® 39901 or equivalent

STRAINERS

Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.

101-C00 Page 10/20

VANE REPLACEMENT

NOTICE:

Maintenance shall be performed by qualified technicians
only. Follow the appropriate procedures and warnings as
presented in manual.

1. Flush the pump per instructions in this manual. 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 5 - 8 in
the "Pump Disassembly" section of this manual.

3. Turn the shaft by hand until a vane comes to the top (12
o'clock) position of the rotor. Remove the vane.

4. Install a new vane, ensuring that the rounded edge is UP,
and the relief grooves are facing towards the direction of
rotation. See Figure 4.

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.

6. GNX(H)4 pump models are equipped with bearing lock
collars (24A). To remove:

a. Remove the jam nuts (24C) and loosen the two set

screws (24B).
b. Slide the lock collar off the shaft.
c. Repeat steps a and b on the opposite shaft end.

7. Remove the head capscrews (21). Gently pry the head
away from the cylinder.

8. Slide the head off the shaft. The head O-ring (72),
bearing (24), and mechanical seal (153) will come off with
the head assembly. Remove and discard the head O­ring.

a. Pull the bearing (24) from the housing in the head.
b. To remove the mechanical seal, use two screw

drivers against the backside of the seal jacket to
gently push the seal from the head (see Figure 5.
Use care when placing the screw drivers to prevent
damage to the seal faces. Remove and discard the
seal O-rings.

Figure 4 – Vane Replacement

PUMP DISASSEMBLY

NOTICE:

Follow all hazard warnings and instructions provided in
the “Pump Maintenance” section of this manual.

1. Flush the pump per instructions in this manual. Drain and
relieve pressure from the pump and system as required.

2. Remove the four adapter capscrews (20C) to release the
adapter (135). Remove the motor mounting bolts. With
the aid of a lifting device, slide the motor and gearbox
away from the pump. Refer to “Gear Reducer
Maintenance” for reducer disassembly instructions.

3. 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.

4. Remove the outboard bearing cover capscrews (28) and
the outboard bearing cover (27) and bearing cover gasket
(26). Discard the bearing cover gasket.

5. The GNX(H)2, 2.5, and 3 are equipped with locknuts
(24A) and lockwashers (24B). To remove:

a. Bend up the engaged lockwasher tang and rotate the

locknut counterclockwise to remove it from the shaft.

b. Slide the lockwasher off the shaft. Inspect the

lockwasher for damage and replace as required.

c. Repeat steps a and b on the opposite shaft end.

101-C00 Page 11/20

Figure 5 – Mechanical Seal Removal

9. Pull the rotor and shaft (13) from the cylinder. While one
hand is pulling the shaft, the other hand should be
cupped 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.

10. Remove the remaining components from the outboard
side of the pump, as instructed in steps 7 and 8 above.

PARTS REPLACEMENT

1. If any of the O-rings have been removed or disturbed
during disassembly, they should be replaced with new O­rings.
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.

PUMP ASSEMBLY

Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
out the bearing/seal recess of the head and remove any
burrs or nicks from the rotor and shaft.

1. Reassemble the OUTBOARD side of the pump first:
For a CLOCKWISE rotation pump, position the pump
cylinder with the INTAKE port to the left.

For a COUNTERCLOCKWISE rotation pump, position
the pump cylinder with the INTAKE port to the right.

2. Apply a small amount of quality O-ring lubricant in the
head recess. With new O-rings installed, push the
mechanical seal assembly (153) into the recess of the
head with the seal jacket drive tangs inward. The pin in
the seal stationary seat MUST be between the lugs in the
back of the head recess.

3. Apply a small amount of O-ring lubricant to the O-ring
groove on the inside face of the head to facilitate
installation. Install a new head O-ring (72) in the groove
by laying the O-ring flat and starting in on one side of the
groove, stretching ahead with the fingers, as shown in
Figure 8.

9. Apply a thin coating of quality O-ring lubricant on the
inboard shaft to aid installation. Install the inboard head,
mechanical seal, and bearing as instructed in steps 2
through 6.

10. Rotate the shaft by hand to engage the 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 for each head and
uniformly tighten, then torque to 25 lbs ft (34 Nm).

Figure 8 – Head O-Ring Installation

4. Install the head (20) on the outboard side of the cylinder.
Install and snug up four head capscrews (21) 90° apart.

5. Hand pack the ball bearing (24) with grease. Refer to
"Lubrication" in the Pump Maintenance Section for the
recommended grease.

6. Install the bearing into the head recess. The bearing balls
should face outward, with the grease shield inward.
Ensure the bearing is fully and squarely seated against
the mechanical seal.

7. Turn the pump cylinder around and begin assembly on
the opposite, inboard end.

8. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly. Inspect for wear and damage, and
replace as follows:

a. Partially install the non-driven end of the rotor and

shaft (13) into the open side of the pump cylinder.

b. Leave part of the rotor outside of the cylinder so that

the bottom vanes can be installed and held in place
as the push rods 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.
Refer to Figure 4 in “Vane Replacement.”

c. After the bottom vanes an d push rods are installed,

insert the rotor and shaft fully into the cylinder.

d. Install the remaining vanes into the top positions of

the rotor. Rotate the shaft by hand to engage the

drive tangs of the mechanical seal jacket in the
rotor slots.

Figure 9 – Locknut Assembly

11. LOCKNUT ADJUSTMENT –
GNX(H)2,GNX(H)2.5, and GNX(H)3 Models Only

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, causing wear. See Figure

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 to ensure that the bearings are

bottomed in the head recess. DO NOT overtighten

and bend or shear the lockwasher inner tang.
c. Loosen both locknuts one complete turn.
d. Tighten one locknut until a slight rotor drag is felt

when turning the shaft by hand.
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 by hand until it is snug

against the bearing. Then, using a spanner wrench,

tighten the nut the width of one lockwasher tang “B”.

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 0.001"

(0.025mm). Begin by loosening the locknut adjusted

last.

101-C00 Page 12/20

12. LOCK COLLAR INSTALLATION – GNX(H)4 Models

a. Slide the lock collar (24A) over the shaft and against

the bearing (24), with the counterbored side towards
the bearing

b. Push the collar (24A) forcibly against the bearing (24)

by hand, while tightening the two setscrews (24B).
Install and tighten the two jam nuts (24C) against the
collar

c. Rep eat this procedure on the opposite pump end.

After installing both lock collars, verify the shaft turns
freely when rotated by hand

13. Attach a new bearing cover gasket (26) and the outboard
bearing cover (27) to the outboard head. Install and
torque the bearing cover capscrews (28) to 15 ft-lbf (20
Nm).

14. Lightly oil Adapter O-ring (135B) and install on inboard
head.

15. Ensure the key (35) is installed on the pump shaft. With
the aid of a lifting device, slide the motor and gearbox
assembly towards the pump engaging gearbox shaft
receiver with the pump shaft.

16. Install the Adapter screws (20C) into the inboard head
and torque to 23 ft-lbf.

17. RELIEF VALVE ASSEMBLY

a. Insert the valve (9) into the relief valve bore of the

casing with the fluted end inward.

b. Install the relief valve spring (8) and spring guide (7)

against the valve.

c. Attach a new relief valve O-ring (10) and the valve

cover (4) on the cylinder.

d. Screw the relief valve adjusting screw (2) with locknut

(3) into the valve cover (4) until it makes contact with
the spring guide (7).

e. After the relief valve has been adjusted, tighten the

Locknut (3) and install the relief valve cap (1) and O­ring (88).

NOTICE:

The relief valve setting MUST be tested and adjusted
more precisely before putting the pump into service.
Refer to "Relief Valve Setting and Adjustment"

Operation without guards in place can
cause serious personal injury, major
property damage, or death.

Do not operate

without guard in

place.

18. Reinstall coupling, shaft key, and coupling guards.

19. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to restarting
pump operation.

101-C00 Page 13/20

GEAR REDUCER MAINTENANCE

NOTICE:
Detailed maintenance instructions for the gearbox
can be found at www.nord.com/docs. The
following are excerpts from those documents and
should be treated as reference only.

STORAGE

NOTICE:
For storage periods longer than 9 months, or for
storage in less than desirable conditions, please
consult NORD for recommendations.

 Storage for up to 9 months is possible, so long as the

following conditions are observed:

 Store the gear unit in its actual mounting position in

accordance with the specified oil fill-level, in a clean and
dry temperature controlled area. Avoid temperature
fluctuations within the range of 0°C and 40°C (32°F to
104°F) and avoid relative humidity conditions in excess
of 60%.

 Protect all exposed or unpainted shaft and flange

surfaces with an anti-corrosion agent or grease.

 Store in a location free from shock and vibration, to

avoid false brinelling of bearing elements and
raceways.

 Whenever possible, rotate the shafts periodically, by

hand if necessary, to help prevent brinelling (bearing
damage) and to help keep the shaft seals pliable.

 Avoid direct exposure to the sun or UV light and

aggressive or corrosive materials in the environment
(ozone, gases, solvents, acids, caustic solutions, salts,
radioactivity, etc.

Commissioning

Prior to gear unit start-up, complete the following:
 Please check your gear unit for a vent and if applicable

to your product, remove the sealing plug to activate

NOTICE:
To prevent build-up of excessive pressure, sealed
vents must be activated as shown prior to gear
unit start up. Excessive pressure may cause
damage to internal gearbox components and
leakage.

 Check the lubricant and be sure the gear unit is filled

with the proper oil type, to the proper level, as
determined by the mounting position.

 Check the condition of all shaft seals and all assembled

flange gasket areas. If any change is detected in the
shape, color, hardness or permeability, or if any leaks
are detected, the corresponding shaft seals and/or
gaskets must be replaced.

 Remove all anti-corrosive metal protectant from

otherwise bare metal surfaces. Follow product
manufacturer’s directions and warnings during surface
protection removal.

 Check the resistance of all motor and brake windings to

verify the integrity of the winding insulation and inspect
all terminal box openings and wire connection areas to
verify that all components are dry and free of corrosion.

Long Term Storage

By taking special precautions, problems such as seal
leakage and reducer failure due to the lack of lubrication,
improper lubrication quantity, or contamination can be
avoided. The following precautions will protect gear
reducers during periods of extended storage:
 Store the gear unit in its actual mounting position in

accordance with the specified oil fill-level, in a clean and
dry temperature controlled area. Avoid temperature
fluctuations within the range of 0°C and 40°C (32°F to
104°F) and avoid relative humidity conditions in excess
of 60%.

 Fill the reducer full with oil that is compatible with the

product normally used or recommended during service.

 Apply grease to all unpainted or unprotected shafts,

bores, keyways, flange surfaces, tapped holes, and to
the exterior of all oil seals.

 Store in a location free from shock and vibration, to

avoid false brinelling of bearing elements and
raceways.

 Once every few months rotate the input shaft

approximately 10-20 revolutions to redistribute the
weight of gears and shafts and to prevent brinnelling of
the bearings and drying of the seal track.

 Avoid direct exposure to the sun or UV light and

aggressive or corrosive materials in the environment
(ozone, gases, solvents, acids, caustic solutions, salts,
radioactivity, etc.)

Commissioning After Long-Term Storage

 Please check your gear unit for a vent and if applicable

to your product, remove the sealing plug to activate.

NOTICE:

To prevent build-up of excessive pressure, sealed vents
must be activated as shown prior to gear unit start up.
Excessive pressure may cause damage to internal
gearbox components and leakage.

 Remove all anti-corrosive metal protectant from

otherwise bare metal surfaces. Follow product
manufacturer’s directions and warnings during surface
protection removal.

 Drain the reducer and refill it with the proper type and

amount of lubricant.

 Observe start-up and initial operation to make sure

there are no seal or gasket leaks, or unusual sounds,
vibration or heat rise during operation.

 Check the resistance of all motor and brake windings to

verify the integrity of the winding insulation and inspect
all terminal box openings and wire connection areas to
verify that all components are dry and free of corrosion.

101-C00 Page 14/20

Lubrication

V

V

Proper gearbox lubrication is essential in order to reduce
friction, heat, and component wear. Lubricants reduce heat
and wear by inserting a protective “fluid boundary” between
mating parts and preventing direct metal to metal contact.
Lubricants also help prevent corrosion and oxidation,
minimize foam, improve heat transfer, optimize reducer
efficiency, absorb shock loads and reduce noise. Most
NORD reducers are shipped from the factory with a pre­determined oil fiIl level in accordance to the specified
reducer size and mounting position.

The standard orientation for the gearbox is shown in Figure

10. The gearbox is filled with the correct amount of oil and
is the correct configuration for this orientation. For any other
orientation, please consult the factory.

Lubrication Table

ISO
Viscosity

G220 PAO-

G220 PAO -31 to 140 Mobil

VG220 MIN­VG220 FG 23 to 104 Fuchs

VG460 PAO -31 to 176 Mobil SHC
*Standard Oil Shipped with Gearbox
Oil Formulation Codes:

MIN-EP - Mineral Oil with EP Additive
PAO - Synthetic Polyalphaolefin Oil
PAO-EP – Synthetic Polyaphoalefin Oil with EP Additive
FG - Food-Grade Oil

Oil
Type

EP

EP

Ambient
Temp
Range
(°F)

-31 to 140 Mobil SHC

32 to 104 Mobilgear

Brand Pump

Gear 220*

SHC630*

600XP220
FM220
634

Model:
Standard Oil
Shipped with
Gearbox

GNX(H)3,
GNX(H)4
GNX(H)2,
GNX(H)2.5

The “Ambient Temperature” is intended to be an
operation guideline based upon the typical properties of
all the lubricant. The viscosity and other properties of
the lubricant change based upon load, speed, ambient
conditions, and reducer operating temperatures. The
user should consult with their lubrication supplier &
NORD gear before considering changes in oil type or
viscosity.

Do not to mix different oils with different additive
packages or different base oil formulation types.
Polyglycol (PG) oils are not miscible with other oil types
and should never be mixed with mineral oil or
polyalphaolefin (PAO) synthetic oil.

UP

Figure 10 - Standard Gearbox Orientation

NOTICE:

 To prevent reducer overheating, observe the

maximum operating oil temperature limits:
Mineral Oil: 176 – 180 °F
Synthetic Oil: 225 °F

 In the following instances, please consult NORD for

specific recommendations:

o Gear units will operate in high ambient

temperature conditions exceeding 40°C
(104°F).

o Gear units will operate in cold ambient

temperature conditions approaching 0°C
(32°F) or lower.

o Lo wer than an ISO VG100 viscosity oil is

being considered for a cold-temperature
service.

o Fluid grease is required for lubricating the

gear unit.

 Observe the general lubrication guidelines outlined

in user manual U10750.

NOTICE:

101-C00 Page 15/20

PUMP TROUBLESHOOTING

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

Reduced Capacity

Noise

Damaged Vanes

Broken Shaft

Mechanical Seal
Leakage

1. Pump not wetted.

2. Worn vanes

3. Suction valve closed.

4. Air leaks in the suction line.

5. Strainer clogged.

6. Suction line or valves clogged or too restrictive.

7. Pump vapor-locked.

8. Pump speed too low for priming.

9. Relief valve partially open, worn or not seating properly.

1. Pump speed too low.

2. Suction valves not fully open.

3. Air leaks in the suction line.

4. Excessive restriction in the suction line (undersized piping, too many elbows & fittings, clogged
strainer, etc.).

5. Damaged or worn parts.

6. Excessive restriction in discharge line causing partial flow through the relief valve.

7. Relief Valve worn, set too low, or not seating properly.

8. Vanes installed incorrectly (see "Vane Replacement").

1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid so urce.

2. Running the pump for extended periods with a closed discharge line.

3. Pump not securely mounted.

4. Bearings worn or damaged.

5. Vibration from improperly anchored piping.

6. Bent shaft, or drive coupling misaligned.

7. Excessively worn rotor.

8. Malfunctioning valve in the system.

9. Relief valve setting too low.

10. Damaged vanes (see following category).

11. Vanes installed incorrectly (see "Vane Replacement").

1. Foreign objects entering the pump.

2. Running the pump dry for extended periods of time.

3. Cavitation.

4. Viscosity too high for the vanes and/or the pump speed.

5. Incompatibility with the liquids pumped.

6. Excessive heat.

7. Worn or bent push rods, or worn push rod holes.

8. Settled or solidified material in the pump at start-up.

9. Hydraulic hammer - pressure spikes.

10. Vanes installed incorrectly (see "Vane Replacement").

1. Foreign objects entering the pump.

2. Viscosity too high for the pump speed

- EC Rotor & Shaft required for fluid viscosities over 20,000 SSU.

3. Relief valve not opening.

4. Hydraulic hammer - pressure spikes.

5. Pump/driver misalignment.

6. Excessively worn vanes or vane slots.

7. Settled or solidified material in the pump at start-up.

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.

101-C00 Page 16/20

NOTICE:

GEAR REDUCER TROUBLESHOOTING

NOTICE:

Maintenance shall be performed by qualified technicians only,

following the appropriate procedures and warnings as presented in this manual.

101-C00 Page 17/20

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101-C00 Page 18/20

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101-C00 Page 19/20

Sliding Vane Pumps: 5 to 2200 GPM

Refined Fuels, Liquefied Gases, Solvents,Process

®

System One

Centrifugal Pumps

10 to 7500 GPM; Process, Marine

L 6, 8 & 10”

HX
Sliding Vane Pumps

130 to 2,220 GPM
Refineries

Terminals
Barges
Ships

Stainless Steel Sliding Vane Pumps

1 to 265 GPM: Acids, Brines, Sugars, Syrups,

Beer, Beet Juice, Cider, Flavor Extracts, etc.

Magnetic Drive Pumps

Stainless Steel: 14 to 215 GPM

Reciprocating Gas Compressors

Liquefied Gas Transfer, Boosting, Vapor Recovery

Hand Opera

Dispensing, Transfer, In-line

ted Pumps

Accessories

Gear Reducers, Bypass Valves, Strainers

Visit www.blackmer.com for complete information on all Blackmer products

1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.

Telephone: [phone] • Fax: [phone]

E-mail: [email protected] • Internet Address: www .blackmer.com