BLACKMER LLIQUEFIED GGAS PPUMPS
FFOORR CCOO2 SSEERRVVIICCEE TTRRUUCCKK AANNDD BBAASSEE MMOOUUNNTTEEDD
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS
MODELS: CRL4A
Discontinued Model: CRL4, TCRL4 & TCRLF4A
962009
INSTRUCTIONS NO. 701-C00
Page 1 of 12
Section 700
Effective January 2002
Replaces December 2001
TABLE OF CONTENTS Page
SAFETY DATA..................................................................1-2
PUMP DATA
..........................................................................2
Technical Data.......................................................2
Initial Start Up Information.....................................2
Pump With Welded Connections...........................2
Installation and Operation - CRL Motor Driven
..........3-5
Pre-Installation Cleaning.......................................3
Location and Piping...............................................3
Pump Mounting.....................................................3
Coupling Alignment...............................................3
V-Belt Drive...........................................................4
Internal Pump Relief Valve and Bypass Valve ......4
Pump Rotation.......................................................5
To Change Pump Rotation....................................5
Pre-Start Up Check List.........................................5
Start Up Procedures..............................................5
Relief Valve Setting and Adjustment.....................5
Installation and Operation - CRL Truck Mount
...........6-8
Truck Mounting......................................................6
Pre-Installation Cleaning.......................................6
Location and Piping...............................................6
Auxiliary Inlet.........................................................6
Pump Drive............................................................6
Hydraulic Drive......................................................6
Internal Pump Relief Valve and Bypass Valve ......7
Pump Rotation.......................................................7
To Change Pump Rotation....................................7
Pre-Start Up Check List.........................................7
Start Up Procedures..............................................7
Relief Valve Setting and Adjustment.....................8
Pump Speed..........................................................8
MAINTENANCE
....................................................................8-11
Lubrication.............................................................8
Vane Replacement................................................9
Pump Disassembly................................................9
Pump Assembly ....................................................9
GENERAL PUMP TROUBLESHOOTING
................11-12
NOTICE:
Blackmer CO
2
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
2 pumps, and MUST
be kept with the pump.
Blackmer CO2 pump service shall be performed by
qualified technicians 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 Blackmer CO
2 pumps.
Maintain ALL system and Blackmer CO
2 pump
operation and hazard warning decals.
SAFETY DATA
NOTE: Numbers in parentheses following individual
parts indicate reference numbers on the corresponding
Blackmer Parts List.
NOTICE:
Indicates special instructions which are very
important and must be followed.
DISCONNECTING FLUID OR
PRESSURE CONTAINMENT
COMPONENTS DURING PUMP
OPERATION CAN CAUSE SERIOUS
PERSONAL INJURY, DEATH OR MAJOR
PROPERTY DAMAGE.
Hazardous pressure
can cause
personal injury or
property damage.
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 damage.
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.
SAFETY DATA
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SHOCK, BURNS OR
DEATH.
Hazardous voltage.
Can shock, burn
or cause death.
Hazardous
machinery can
cause serious
personal injury.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SERIOUS PERSONAL
INJURY OR DEATH.
Hazardous or toxic
fluids can cause
serious injury.
IF PUMPING HAZARDOUS FLUIDS
SYSTEM MUST BE FLUSHED PRIOR
TO PERFORMING SERVICE.
DO NOT ATTEMPT TO OPEN THE PUMP
UNTIL YOU HAVE BLED OFF THE
PRESSURE. ON SYSTEMS WITH
METERS, THE DIFFERENTIAL VALVE
WILL KEEP LIQUID UNDER PRESSURE
IN THE PUMP, METER AND PIPING
EVEN WHEN THE HOSE IS EMPTIED.
Hazardous pressure
can cause personal
injury or property
damage.
PUMP DATA
Model Designations:
Motor Drive & Truck Mount CRL4A
Discontinued TCRL4, TCRLF4A
Torque Required @ 100 psi 205 lbs ft
(6.9 bar) (278 Nm)
Maximum Temperature 240oF (115oC)
Minimum Temperature -30oF (-34oC)
Maximum Pump Speed 640 RPM
Maximum Differential Pressure 100 psi ( 6.9 bar)
Maximum Working Pressure 525 psi ( 36.2 bar)
(Inlet Pressure + Differential Pressure)
INITIAL START UP INFORMATION
TECHNICAL DATA
PUMP WITH WELDED CONNECTIONS
NOTICE:
FOR PIPING CONNECTIONS REQUIRING WELDING THE
PUMP’S NON-METALLIC O-RINGS MUST BE REMOVED
PRIOR TO WELDING. FAILURE TO DO SO WILL
DAMAGE THE O-RINGS.
Before 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.
Figure 1
2
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE.
Hazardous machinery
can cause severe
personal injury or
property damage.
FAILURE TO RELIEVE SYSTEM
PRESSURE PRIOR TO PERFORMING
PUMP SERVICE OR MAINTENANCE
CAN CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Hazardous pressure
can cause personal
injury or property
damage.
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
Model No. ________________________________
Serial No. ________________________________
I.D. No. __________________________________
Date of Installation: ________________________
Discharge Gauge Reading: __________________
Inlet Gauge Reading: _______________________
Flow Rate: ________________________________
NOTICE:
THIS PUMP CONTAINS SOME RESIDUAL TEST FLUID
AND RUST INHIBITOR. IF NECESSARY, FLUSH PUMP
PRIOR TO USE.
Hazardous voltage.
Can shock, burn
or cause death.
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
before installation or service.
Electrical supply MUST match motor nameplate
specifications.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
NOTICE:
BLACKMER CO2 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.
INSTALLATION AND OPERATION
CRL BASE MOUNTED MOTOR DRIVEN PUMPS
PRE-INSTALLATION CLEANING
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
An improperly designed piping system or improper unit
installation WILL significantly reduce pump performance and
life. Blackmer recommends the following piping system layout
and unit installation. See Figure 2.
1. To minimize intake losses, locate the pump as close as
possible to the source of supply and a minimum of two
feet (0.6 m) below the tank outlet.
2. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection. Inlet piping must
be insulated.
3. Use high strength Schedule “80” piping.
4. Minimize the number of intake line fittings (valves, elbows,
etc.) and piping turns or bends. The nearest fitting on the
intake line must be at least 6 inches (152 mm) from the
pump to permit access to the pump relief valve .
5. Install an intake strainer 5 - 10 pipe diameters from the
pump intake. The strainer must have a net open area of at
least four times the area of the intake pipe. Strainers must
be cleaned regularly to avoid pump starvation.
6. Intake and discharge piping MUST be free of all leaks.
7. To facilitate piping expansion and contraction, expansion
joints must be placed 3 feet (0.9 m) from the pump intake
and discharge.
8. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
9. Install pressure gauges in the NPT ports provided in the
pump casing to check pump performance at start up.
10. The use 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.
11.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.
PUMP MOUNTING
Permanently mount the unit by securing the base plate with
adequately sized anchor bolts to a level concrete floor
following recommended
industry standards (See
Figure 3). A solid foundation
will reduce system noise and
vibration, and will improve
pump performance. Refer to
ANSI/HI standards or a
suitable pump handbook for
information on typical pump
mounting and foundations.
Check coupling alignment
after pump and base
assembly is secured to the
foundation.
BOLT
BASE
STANDARD
PIPE
WASHER
Figure 3
BOLT
BASE
STANDARD
PIPE
WASHER
COUPLING ALIGNMENT
The pump must be directly coupled to a gear, gear reducer,
and/or driver with a flexible coupling.
Both angular and parallel coupling alignment MUST be
maintained between the pump, gear reducer, motor, etc. in
accordance with manufacturer’s instructions. See Figure 4.
1. To check for parallel alignment, the use of a dial indicator is
preferred. If a dial indicator is not available use a straight
edge. Turn both shafts by hand, checking the reading
through one complete revolution. Maximum offset must be
less than .005" (125 microns).
2. To check for angular alignment, insert a feeler gauge
between the coupling halves. Check the spacing in 90
degree increments around the coupling (four check points).
Maximum variation must not exceed .005" (125 microns).
Figure 4 - Alignment Check
3
Storage Tank
Figure 2
Unions
Bypass Valve
Gate or Ball
Valves
Intake Connection
for unloading tank
cars or tank trucks
Do no start
pump unless
this valve is
open.
Alternate
Discharge
to Storage
Tank
Discharge
Strainer
4
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE OR DEATH.
Hazardous
machinery can
cause serious
personal injury.
INSTALLATION AND OPERATION
CRL BASE MOUNTED MOTOR DRIVEN PUMPS
V-BELT DRIVE
Blackmer also offers V-belt drive for CRL pumps. 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 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 bore over the taper on
the QD hub. Insert the three sheave capscrews (152C)
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 & 152G).
5. Measure the span length as shown in Figure 5.
Figure 5 - 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 (25.3 mm) of span. For example, the deflection of a
20 inch span (508 mm) would be
20
/64 or 5/16 inch (7.9
mm). The force required must be within the range given in
Table 1 for a properly tensioned drive. Initially tension a
new set of belts to the upper limit.
7. Check again to ensure the sheaves (152 & 152D) are
parallel, then tighten the sheave capscrews (152C &
152G), the motor mounting nuts (184) and the adjusting
screw locknut (183B).
8. Assemble the belt guard (182) and the belt guard brace
(182A) to the unit base (32).
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 (184).
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
(152D or 152E). DO NOT force the belts over the grooves.
4. To remove the sheave from the hub, first remove the three
sheave capscrews (152C & 152G). Then screw two of the
capscrews into the threaded holes in the sheave hub
(152A or 152E). If the cone grip is hard to break loose, tap
the end of the shaft or the QD hub with soft-faced mallet
while maintaining pressure on the screw.
5. Carefully and smoothly slide the QD hub 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 Parts List and Instructions 786/C14 for
V-belt drive and guard part numbers.
SMALL SHEAVE
BELT DEFLECTION FORCE
OUTSIDE DIAMETER Minimum Maximum
2.5" to 4.5" 3.0 lbs. 4.75 lbs.
(63.5 mm to 114.3 mm) (1.4 kgs.) (2.2 kgs.)
4.75" to 7.0" 4.0 lbs. 6.0 lbs.
(120.7 mm to 177.8 mm) (1.8 kgs.) (2.7 kgs.)
Table 1 - Deflection Force Per Belt
Deflection
1
/64
" (0.04 mm)
per inch (25.3 mm)
of span
Span Length
Force
INTERNAL PUMP RELIEF VALVE AND
EXTERNAL 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 storage 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 internal pump relief valve setting.
5
The bypass valve and piping must be of adequate size to
accommodate the full flow from the pump when the discharge
line is closed. Shut off valves and couplings must be provided
on both sides of the pump and bypass valve for removal and
servicing. The pump internal relief valve is factory set at
approximately 125 psi (8.6 bar).
Refer to Blackmer Bypass Valve Installation and Maintenance
Instructions for bypass valve installation, setting and
adjustment procedures.
PUMP ROTATION
NOTICE:
CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
TO CHANGE PUMP ROTATION
Blackmer CRL4A motor driven 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 the opposite shaft becomes the driven
shaft. The shaft protector (186) MUST be mounted over the
non-driven shaft end.
START UP PROCEDURES
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING START
UP ARE EXPERIENCED.
1. Start the motor.
2. If priming does not occur, shut off the pump and close the
pump discharge. Open the bleed valve on the pump
discharge gauge hole until “snow” appears at the exhaust.
Close the bleed valve, open the discharge line and start
the pump. Repeat if necessary.
3. 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.
4. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
5. Check the flow rate to ensure the pump is operating within
the expected parameters. Record flow rate in the “Initial
Start Up” section of this manual for future reference.
6. Close the discharge valve and check the differential
pressure across the pump. It must not exceed the
pressure setting of the external bypass valve.
7. With the discharge valve still closed, momentarily close the
manual shut-off valve in the bypass return line to check the
pump relief valve. The pressure must be at least 25 psi
(0.7 - 1.4 bar) higher than the operating pressure or the
system pressure control valve setting. Refer to “Relief
ValveSetting and Adjustment” section of this manual.
8. 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 setting.
Pump speeds which result in higher pressures (nearing the
valve setting) forces the liquid to be recirculated, creating
excessive wear on the pump and equipment.
PRE-START UP CHECK LIST
1. Inspect complete piping system and supports to ensure
that no piping loads are being placed on the pump.
2. Install pressure gauges in the
1
/
4" NPT intake and
discharge ports located on the pump casing to check pump
performance after start-up.
3. Build pressure in the pump by SLOWLY cracking the valve
in the discharge line. When the internal pump pressure
equals tank pressure, check for system leaks.
4. Ensure all valves and fittings in piping system are in the
start-up or operating positions.
5. Jog the pump motor to verify proper pump rotation.
INSTALLATION AND OPERATION
CRL BASE MOUNTED MOTOR DRIVEN PUMPS
RELIEF VALVE SETTING AND ADJUSTMENT
The factory relief valve pressure setting is marked on a metal
tag attached to the valve cover. It is recommended the relief
valve be set at least 10 - 20 psi (0.7 - 1.4 bar) higher than the
operating pressure or the system pressure control valve
setting.
Hazardous pressure
can cause personal
injury or property
damage.
INCORRECT SETTINGS OF THE PRESSURE
RELIEF VALVE CAN CAUSE SYSTEM
COMPONENT FAILURE, PERSONAL INJURY
AND PROPERTY DAMAGE.
OPERATING PUMP AGAINST A
CLOSED VALVE CAN CAUSE
SYSTEM COMPONENT FAILURE,
PERSONAL INJURY AND PROPERTY
DAMAGE.
Hazardous pressure
can cause personal
injury or property
damage.
Relief Valve Adjustment Procedure:
1. To INCREASE the pressure setting, remove the relief
valve cap (1), loosen the locknut (3), and turn the adjusting
screw (2) inward, or CLOCKWISE.
2. To DECREASE the pressure setting, remove the relief
valve cap (1), loosen the locknut (3), and turn the adjusting
screw (2) outward, or COUNTERCLOCKWISE.
Refer to corresponding Blackmer pump Parts List for
relief valve spring pressure ranges.
OPERATION WITHOUT SHAFT
PROTECTOR IN PLACE CAN CAUSE
SERIOUS PERSONAL INJURY,
PROPERTY DAMAGE, OR DEATH.
Hazardous
machinery can
cause serious
personal injury.
INSTALLATION AND OPERATION - CRL TRUCK MOUNTED PUMPS
6
TRUCK MOUNTING
CRL pump models can be bolted to the truck frame or on a
saddle hung below the frame, and MUST be adequately
supported.
Discontinued TCRLF4A pump models are designed to flange
mount directly to bob tail or transport tank in combination with
a commercial internal control valve. See Figure 6.
PRE-INSTALLATION CLEANING
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
An improperly designed piping system or improper unit
installation WILL significantly reduce pump performance and
life. Blackmer recommends the following piping system layout
and unit installation.
1. When locating the pump on the tank, safety must be the
first consideration. Other considerations include length of
drive line, accessibility for maintenance and convenience
of connections. See Figure 6.
2. The discharge hose and fittings must be large enough to
minimize the pressure drop in the system. The lower the
friction loss, the higher the flow rate.
3. Use a 1
1
/2" or 2" vapor return line for all transport loading
and unloading. Without a vapor return line, back pressure
will build up in the receiving tank and pressure will be
reduced in the supply tank, resulting in reduced flow rate
and fluid bypassing.
4. 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.
AUXILIARY INLET - DISCONTINUED TCRLF4A
PUMP MODELS
The auxiliary inlet port can be used as a fill connection for
bottom loading of the tank by stationary pumps at the terminal
or bulk plant. It can also be used as an auxiliary pump inlet,
allowing the pump to unload another tank in an emergency. To
minimize vapor formation, the auxiliary intake line must be as
large in diameter as the intake connection and as short as
possible. The line must be connected through a suitable
strainer, minimum 40 mesh. Reduce pump speed to a
maximum 400 RPM when using the auxiliary inlet to reduce
cavitation.
PUMP 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.
It is very important to install a proper drive line to avoid
excessive wear, vibration and noise (see Fig. 6 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.
The PTO shaft coming off at the transmission does not
need to be perfectly horizontal as long as the pump shaft is
parallel in all respects to the PTO shaft.
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. Refer to Table 2.
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.
NOTICE:
BLACKMER CO2 TRUCK 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.
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE.
Hazardous machinery
can cause severe
personal injury or
property damage.
Table 2
Angle of Drive Shaft
1
o
through 5
o
6othrough 10
o
11othrough 15
o
Very Good Good Fair
HYDRAULIC DRIVE
CRL pumps may also be driven hydraulically. Hydraulic
motors must 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.
Hazardous
machinery can
cause serious
personal injury.
A DRIVE SHAFT GUARD BETWEEN
THE PTO AND PUMP MUST BE
PROVIDED TO PREVENT PERSONAL
INJURY, PROPERTY DAMAGE, OR
DEATH.
INSTALLATION AND OPERATION - CRL TRUCK MOUNTED PUMPS
PRE-START UP CHECK LIST
1. Install pressure gauges in the 1/4" NPT ports located on the
pump casing. These can be used to check the actual inlet
and discharge conditions after pump start-up.
7
2. Inspect complete piping system to ensure that no piping
loads are being placed on the pump.
3. Connect the hose to the receiving tank.
START UP PROCEDURES
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING
START UP ARE EXPERIENCED.
1. Open the shut-off valve in the bypass return line.
2. If the tank outlet valve is:
INTERNAL PUMP RELIEF VALVE AND
EXTERNAL 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 internal pump 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
pump internal relief valve is factory set at approximately 125
psi (8.6 bar).
Refer to Blackmer Bypass Valve Installation and Maintenance
Instructions for bypass valve settings and adjustments.
PUMP ROTATION
NOTICE:
CONFIRM CORRECT PUMP ROTATION BY CHECKING THE
PUMP ROTATION ARROWS RESPECTIVE TO PUMP DRIVER
ROTATION.
TO CHANGE PUMP ROTATION
Blackmer CRL4A and discontinued TCRLF4A 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. Mount the shaft protector (186)
over the non-driven shaft end.
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 and flowrate to ensure the
system is operating within expected parameters. Record
the gauge readings and flowrate 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. Close the discharge valve and check the differential
pressure across the pump. It 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 relief valve. The differential pressure will be
approximately 100 psi (6.9 bar).
Figure 6 - Pump Drive
Tank
Tank Flange
Relief Valve
Intake Gauge
Discharge Gauge
Discharge Hose
Strainer
4" Internal Control Valve
Auxiliary Intake Port
Grease Fitting
Removable
Section
Grease
Relief
Tell-Tale
Hole
Shafts
Parallel
15
o
Max.
Universal
Joints
PTO
NOTE: A DRIVE SHAFT GUARD
BETWEEN THE PUMP AND PTO
MUST BE PROVIDED.
(NOT SHOWN)
OPERATION WITHOUT SHAFT
PROTECTOR IN PLACE CAN CAUSE
SERIOUS PERSONAL IN JURY,
PROPERTY DAMAGE, OR DEATH.
Do not operate
without guards in
place.
8
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE.
Hazardous machinery
can cause severe
personal injury or
property damage.
Hazardous or toxic
fluids can cause
serious injury.
IF PUMPING HAZARDOUS FLUIDS
SYSTEM MUST BE FLUSHED PRIOR
TO PERFORMING SERVICE.
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
THIS MANUAL.
INSTALLATION AND OPERATION - CRL TRUCK MOUNTED PUMPS
MAINTENANCE
Hazardous
machinery can
cause serious
personal injury.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SERIOUS PERSONAL
INJURY OR DEATH.
DO NOT ATTEMPT TO OPEN THE PUMP
UNTIL YOU HAVE BLED OFF THE
PRESSURE. ON SYSTEMS WITH
METERS, THE DIFFERENTIAL VALVE
WILL KEEP LIQUID UNDER PRESSURE
IN THE PUMP, METER AND PIPING
EVEN WHEN THE HOSE IS EMPTIED.
Hazardous pressure
can cause personal
injury or property
damage.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SHOCK, BURNS OR
DEATH.
Hazardous voltage.
Can shock, burn
or cause death.
10. 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
setting. Pump speeds which result in higher pressures
(near the valve setting) forces the liquid to be recirculated,
creating excessive wear on the pump and equipment.
RELIEF VALVE SETTING AND ADJUSTMENT
The pump internal relief valve factory pressure setting is
marked on a metal tag attached to the valve cover. The relief
valve must be set at least 10 - 20 psi (0.7 -1.4 bar) higher than
the operating pressure or the system pressure control valve
setting.
Relief Valve Adjustment Procedure:
1. To INCREASE the pressure setting, remove the relief
valve cap (1), loosen the locknut (3), and turn the adjusting
screw (2) inward, or CLOCKWISE.
2. To DECREASE the pressure setting, remove the relief
valve cap (1), loosen the locknut (3), and turn the adjusting
screw (2) outward, or COUNTERCLOCKWISE.
PUMP SPEED
PTO and 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.
DISCONNECTING FLUID OR
PRESSURE CONTAINMENT
COMPONENTS DURING PUMP
OPERATION CAN CAUSE SERIOUS
PERSONAL INJURY, DEATH OR MAJOR
PROPERTY DAMAGE.
Hazardous pressure
can cause personal
injury or property
damage.
LUBRICATION
Ball bearings and hydraulic motor adapter couplings (if
equipped) must be lubricated every three months at a
minimum. More frequent lubrication may be required,
depending on the application and operating conditions.
Recommended Grease:
Exxon®- RONNEX MP Grease;
Mobil®MOBILITH AW-2 (64353-6) Grease, or equivalent
Lithium grease.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
covers (27) or hydraulic motor adapter (135).
2. SLOWLY apply grease with a hand gun until grease begins
to escape from the grease relief fitting port. Discard
excess grease in accordance with the proper codes and
regulations.
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 can cause mechanical seal
failure. The tell-tale hole is located in the head (20) between
the bearing (24) and the mechanical seal (153).
INCORRECT SETTINGS OF THE PRESSURE
RELIEF VALVE CAN CAUSE SYSTEM
COMPONENT FAILURE, PERSONAL INJURY
AND PROPERTY DAMAGE.
Hazardous pressure
can cause personal
injury or property
damage.
PUMP DISASSEMBLY
NOTICE:
FOLLOW ALL HAZARD WARNINGS AND
INSTRUCTIONS PROVIDED IN THE "MAINTENANCE"
SECTION OF THIS MANUAL.
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.
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.
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
MAINTENANCE
9
VANE REPLACEMENT
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
THIS MANUAL.
1. Drain and relieve pressure from the pump and system as
required.
2. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 4 - 7 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 7.
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 7 - Vane Installation
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),
disc (71), bearing (24), and mechanical seal (153) will
come off with the head assembly. Remove and discard the
head O-ring.
a. Remove the four disc machine screws and lockwashers
(71A & 71B) to release the disc (71) from the head (20).
b. Carefully pull the rotating seal assembly, consisting of
seal jacket (153C), rotating seal face and rotating Oring (153B & 153E) from the head (20). Remove and
discard the rotating O-ring.
c. Pull the bearing (24) from the housing in the head (20).
d. 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 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
(13) aside for future vane replacement and reassembly.
NOTICE:
THE ROTOR AND SHAFT WEIGHS APPROXIMATELY 69
POUNDS (31KG). BE CAREFUL NOT TO PINCH THE
HAND UNDER THE ROTOR AND SHAFT WHEN
REMOVING FROM THE CASING.
9. 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 - 7 above.
10. 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).
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. Remove any
burrs from the liner.
Reassemble the OUTBOARD side of the pump first:
1. Apply a small amount of grease to the liner key (74) to hold
the key in place during liner installation. Install the liner
key in groove of the liner before starting liner into pump
casing (12).
MAINTENANCE
10
Figure 8 - Disc Relief Hole Location
4. Place the disc (71) against the head (20) with disc relief
hole located so that when the head is mounted on the
pump with the “Blackmer” name in an upright position, the
relief hole will be at the pump intake, 9 o’clock position on
CRL4 pump and 12 o’clock position on discontinued
TCRLF4A pumps (see Figure 8). Install and tighten the
disc machine screws and lockwashers (71A & 71B). The
drive tangs of the seal jacket must protrude through the
center hole of the disc.
5. 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 9.
6. Carefully install the head assembly (20) on the pump
casing (12). Rotate the head so that the drain hole,
located at the back of the bearing cavity, faces downward
when the pump is mounted for operation and the disc relief
hole is located at the intake port. Install and uniformly
tighten four head capscrews (21) 90
o
apart, torquing to 30
lbs ft (47 Nm).
7. Hand pack the ball bearing (24) with grease. Refer to the
"Lubrication" section for the recommended grease.
8. Install the bearing (24) into the head recess. The bearing
balls must face outward, with the grease shield inward.
Ensure the bearing is fully and squarely seated in the head
(20).
9. Turn the pump casing around to begin work on the
opposite side of the pump.
10. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly (13). Inspect for wear and damage,
and replace as follows:
a. Apply a small amount of lubricating oil on the shaft
between the shaft threads and the rotor.
b. Partially install the non-driven end of the rotor and shaft
(13) into the open side of the pump casing (12).
c. 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.
Refer to Figure 7.
d. After the bottom vanes (14) and push rods (77) are
installed, carefully insert the rotor and shaft (13) fully
into the casing (12) and through the installed head (20).
e. Install the remaining vanes (14) into the top positions of
the rotor.
f. Turn the shaft by hand to engage the seal drive tangs.
11. Install the inboard head with O-ring (72), mechanical seal
(153), disc (71) and bearing (24) as instructed in steps 3
through 8.
12. 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
(20) 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 (47 Nm).
Figure 9 - Head O-ring Installation
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 noise and loss of
capacity.
3. MECHANICAL SEAL INSTALLATION
Stationary Seat -
a. Apply a small amount of lubricating oil in the seal
recess of the head.
b. Install a new stationary O-ring (153D) in the stationary
seat (153A). Clean the polished face with a clean
tissue and alcohol. 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.
Rotating Assembly -
a. Install a new rotating O-ring (153E) in the rotating seal
face (153B). Clean the polished face with a clean
tissue and alcohol. Place the polished face of the
rotating seal against the face of the stationary seat in
the head recess.
b. Align the seal jacket assembly (153C) with the notches
of the rotating face and install jacket with the drive
tangs of the jacket outward.
CRL4A, TCRL4
TCRLF4A
INTAKE
INTAKE
Disc Relief Hole
Disc Relief Hole
MAINTENANCE
11
Figure 10 - Locknut Adjustment
13.LOCKNUT ADJUSTMENT
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightening locknuts can cause bearing (24) failure or a
broken lockwasher tang. Loose locknuts will allow the rotor
to shift against the discs (71), causing wear. See Figure 10.
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 over-
tighten and bend or shear the lockwasher inner tang.
c. Loosen both locknuts (24A) one complete turn.
d. Tighten one locknut (24A) until a slight rotor drag is felt
when turning the shaft by hand.
e. Back off the locknut (24A) the width of one lockwasher
tang "B". Secure the locknut by bending the closest
aligned lockwasher tang into the slot in the locknut. The
pump must turn freely when rotated by hand.
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, PROPERTY
DAMAGE, OR DEATH.
Do not operate
without guard
in place.
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 must continue to turn
freely when rotated by hand.
g. To check adjustment, grasp the locknut (24A) and
lockcollar (24B) with fingers and rotate back and forth.
If this cannot be done, one or both locknuts are too tight
and must be alternately loosened one stop at a time
(.001" - 25 microns). Begin by loosening the locknut
adjusted last.
14.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.
15. 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 (47 Nm).
16. Install the grease seal (104) in the outboard bearing cover
(27) as instructed in step 14.
17. Attach a new bearing cover gasket (26) and the outboard
bearing cover (27) to the outboard head (20). Make sure
the grease fittings (76) are accessible. Install and torque
the bearing cover capscrews(28) to 30 lbs ft (47 Nm).
18.Attach the shaft protector (186) to the non-driven shaft end.
GENERAL PUMP 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 or inlet 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.
Pump Troubleshooting continued on back page.
GENERAL PUMP TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE
Reduced Capacity 1. Pump speed too low.
2. Internal control valve and/or inlet control valves not fully open.
3. Excessive restriction in the inlet line (i.e.: undersized piping, too many elbows
& fittings, clogged strainer, etc.).
4. Damaged or wor n 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 1. Excessive pressure drop in inlet line 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 wor n rotor.
10. Malfunctioning valve in the system.
11. Relief valve setting too low.
12. Liner installed backwards.
13. Damaged vanes (see following category).
Damaged Vanes 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.
Broken Shaft 1. Foreign objects entering the pump.
2. Relief valve not opening.
3. Hydraulic hammer - pressure spikes.
4. Pump /driver, driveline/driveshaft misalignment.
5. Excessively wor n vanes or vane slots.
Mechanical Seal Leakage 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
Litho in U.S.A • © Copyright 2002
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