models: gx, x 2b, 2.5b, 3e, 4b; xu2a ul listed · vibration, and will improve pump performance....

BBLLAACCKKMMEERR PPOOWWEERR PPUUMMPPSSINSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

MODELS: GX, X 2B, 2.5B, 3E, 4B; XU2A UL® Listed

961222 INSTRUCTIONS of 12 NO. 101-B00Section 100Effective September 1999Replaces October 1995

TABLE OF CONTENTS Page

SAFETY DATA.....................................................................1-2

PUMP DATA ...........................................................................2Technical Data.................................................................2Initial Start Up Information...............................................2

INSTALLATION ......................................................................2Pre-Installation Cleaning .................................................2Location and Piping.........................................................2Pump Mounting ...............................................................3Coupling Alignment .........................................................3Gear Reducer Alignment - GX Models............................3Pump Rotation ................................................................3To Change Pump Rotation ..............................................3

OPERATION ...........................................................................4Pre-Start Up Check List...................................................4Start Up Procedures........................................................4Reverse Rotation ............................................................4Flushing the Pump ..........................................................4Pump Relief Valve...........................................................4Relief Valve Setting and Adjustment ...............................5

PUMP MAINTENANCE ..........................................................5Scheduled Maintenance..................................................5

Strainers .....................................................................5Pump Lubrication .......................................................5

Vane Replacement..........................................................5Pump Disassembly .........................................................6Pump Assembly ..............................................................6

GEAR REDUCER MAINTENANCE - GX MODELS...............8Gear Reducer Lubrication ...............................................8Oil Seal Replacement .....................................................8Gear Reducer Disassembly ............................................9Gear Reducer Assembly .................................................9

PUMP TROUBLESHOOTING ..............................................10

GEAR REDUCER TROUBLESHOOTING............................11

NOTICE:Blackmer power pumps MUST only be installed insystems which have been designed by qualifiedengineering personnel. The system MUST conform toall applicable local and national regulations and safetystandards.

This manual is intended to assist in the installationand operation of the Blackmer power pump, andMUST be kept with the pump.

Blackmer power pump service shall be performed byqualified technicians ONLY. Service shall conform toall applicable local and national regulations and safetystandards.

Thoroughly review this manual, all instructions andhazard warnings, BEFORE performing any work onthe Blackmer power pumps.

Maintain ALL system and Blackmer power pumpoperation and hazard warning decals.

SAFETY DATA

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 forpersonal injury, death or major proper ty damage.

Warns of hazards that WILL cause serious personal injury, death or major proper ty damage.

Warns of hazards that CAN cause serious personal injury, death or major proper ty damage.

Warns of hazards that CAN cause personal injuryor proper ty damage.

NOTICE:Indicates special instructions which are very

impor tant and must be followed.

NOTE: Numbers in parentheses following individual partsindicate reference numbers on the corresponding BlackmerPump Parts Lists shown in the table below.

PUMP PUMP PUMP PARTS LISTMODEL INSTRUCTION

MANUAL 2" 2.5" 3" 4"GX 185/C 185/C1 185/C3 185/C5A 185/C7

X 185/C 185/C9 185/C11 185/C13 185/C15

XU 185/C 185/C9 — — —

WHEN PUMP IS RUNNING,DISCONNECTING ANY PART OF THELIQUID SYSTEM, PIPE, STRAINER,HOSE, NOZZLE, ETC. CAN CAUSESERIOUS PERSONAL INJURY, DEATHOR MAJOR PROPERTY DAMAGE.

Hazardous pressurecan cause

personal injury orproperty damage.

INSTALLATION

PUMP DATA

SAFETY DATA

2

NOTICE:BLACKMER POWER PUMPS MUST ONLY BE INSTALLED INSYSTEMS DESIGNED BY QUALIFIED ENGINEERINGPERSONNEL. SYSTEM DESIGN MUST CONFORM WITH ALLAPPLICABLE REGULATIONS AND CODES AND PROVIDEWARNING OF ALL SYSTEM HAZARDS.

* Optional materials of construction may be required to meet the operating limitslisted. Consult Blackmer Material Specs 101/95-96.

1 Viscosity shown is in SSU (cP). cP = centistokes at fluid specific gravity of 1.0.

PRE-INSTALLATION CLEANINGForeign matter entering the pump WILL cause extensivedamage. The supply tank and intake piping MUST be cleanedand flushed prior to pump installation and operation.

LOCATION AND PIPINGAn improperly designed piping system or improper unitinstallation WILL significantly reduce pump performance andlife. Blackmer recommends the following piping system layoutand unit installation.

1. To minimize intake losses, locate the pump as close aspossible to the source of supply.

2. Intake piping and fittings MUST be at least as large indiameter as the pump intake connection.

3. Minimize the number of intake line fittings (valves, elbows,etc.) and piping turns or bends. When used, intake fittingsmust be located at least 5-10 pipe diameters from thepump intake.

TECHNICAL DATA* INITIAL START UP INFORMATION

Model No.

Serial No.

Date of Installation:

Pressure Gauge Reading:

Vacuum Gauge Reading:

Flow Rate:

GX, X PUMP MODELS PUMP SIZE

2", 2.5" 3" 4"

Maximum Pump Speed (RPM) 780 640 520

Maximum Viscosity1 - X Models 75,000 75,000 50,000(15,750) (15,750) (10,500)

Maximum Viscosity1 - GX Models 20,000 (4,250)

Maximum Temperature 300oF (149oC)

Maximum Differential Pressure 125 psi (862 kPa)

Maximum Working Pressure 175 psi (1207 kPa)

FAILURE TO RELIEVE SYSTEMPRESSURE PRIOR TO PERFORMINGPUMP SERVICE OR MAINTENANCECAN CAUSE PERSONAL INJURY ORPROPERTY DAMAGE.Hazardous pressure

can cause personal injury orproperty damage.

IF PUMPING HAZARDOUS OR TOXICFLUIDS, SYSTEM MUST BE FLUSHEDAND DECONTAMINATED, INSIDE ANDOUT, PRIOR TO PERFORMINGMAINTENANCE.Hazardous or toxic

fluids can causeserious injury.

FAILURE TO DISCONNECT ANDLOCKOUT ELECTRICAL POWERBEFORE ATTEMPTING MAINTENANCECAN CAUSE SHOCK, BURNS ORDEATH.Hazardous voltage.

Can shock, burn or cause death.

Hazardousmachinery cancause seriouspersonal injury.

FAILURE TO DISCONNECT ANDLOCKOUT ELECTRICAL POWERBEFORE ATTEMPTING MAINTENANCECAN CAUSE SERIOUS PERSONALINJURY OR DEATH.

Hazardous voltage.Can shock, burn or cause death.

Install, ground and wire to local andNational Electrical Code requirements.

Install an all-leg disconnect switch nearthe unit motor.

Disconnect and lockout electrical powerbefore installation or service.

Electrical supply MUST match motor nameplatespecifications.

Motors equipped with thermal protection automaticallydisconnect motor electrical circuit when overload exists.Motor can start unexpectedly and without warning.

INSTALLATION

3

4. It is recommended an intake strainer be installed 5 - 10pipe diameters from the pump intake. For viscosities lessthan 1000 SSU the strainer should have a net open area ofat least four times the area of the intake pipe. Forviscosities greater than 1000 SSU consult the strainermanufacturer instructions. Strainers must be cleanedregularly to avoid pump starvation.

5. Intake and discharge piping MUST be free of all leaks.

6. To facilitate piping expansion and contraction, expansionjoints should be placed 3 feet (0.9m) from the pump intakeand discharge.

7. ALL piping and fittings MUST be properly supported toprevent any piping loads from being placed on the pump.

8. Install vacuum and pressure gauges in the 1/4" NPT portsprovided in the pump cylinder to check pump at start up.

PUMP MOUNTINGIt is recommended the unit be permanently mounted bysecuring the base plate with adequately sized anchor bolts toa level concrete floor following recommended industrystandards. A solid foundation will reduce system noise andvibration, and will improve pump performance. Refer toANSI/HI standards or a suitable pump handbook forinformation on typical pump mounting and foundations. Checkcoupling alignment after pump and base assembly is securedto the foundation.

COUPLING ALIGNMENTThe pump must be directly coupled to a gear and/or driver witha flexible coupling.

Both angular and parallel coupling alignment MUST bemaintained between the pump, gear, motor, etc. in accordancewith manufacturer’s instructions. See Figure 1.

2. To check for angular alignment, insert a feeler gaugebetween the coupling halves. Check the spacing in 90degree increments around the coupling (four check points).Maximum variation should not exceed .005" (.127 mm).

GEAR REDUCER ALIGNMENT - GX MODELSThe reducer can be rotated on its mounting to raise or lowerthe input shaft to facilitate alignment to the motor shaft. To doso, first loosen the four clamp capscrews (20C) and the twosetscrews (33) in the gear reducer spool flange. The reduceris then free to rotate. If necessary, tap it lightly with a softfaced mallet. When aligning the reducer, verify the alignmentof the coupling halves as indicated in “Coupling Alignment”section.

NOTICE:TO DETERMINE MAXIMUM VARIATION OF GEAR REDUCERSHAFT ALIGNMENT, REFER TO BLACKMER GX MODELDIMENSIONS 101/105 - 101/108

PUMP ROTATION

To determine pump rotation:If the intake port and the relief valve are on the right, with thedrive end of the shaft pointing towards the observer, the pumpis right-hand, or CLOCKWISE rotation*.

If the intake port and relief valve are on the left, with the driveend of the shaft pointing towards the observer, the pump isleft-hand, or COUNTERCLOCKWISE rotation*.

*NOTICE:ON GX MODEL PUMPS, THE GEAR REDUCER INPUT SHAFTWILL ROTATE IN THE OPPOSITE DIRECTION OF THE PUMPSHAFT. FOR EXAMPLE, ON A RIGHT-HAND GX PUMP, THEGEAR REDUCER SHAFT WILL ROTATE COUNTERCLOCKWISE.

NOTICE:CONFIRM CORRECT PUMP ROTATION BY CHECKING THEPUMP ROTATION ARROWS RESPECTIVE TO PUMP DRIVERROTATION.

TO CHANGE PUMP ROTATION To reverse the pump rotation, remove both the inboard head(20) and outboard head (23), and rotate the cylinder 180o sothat the intake port is on the opposite side. Remove andreplace the vanes (14) with the relief grooves facing in thedirection of pump rotation. Refer to the "Maintenance" Sectionof this manual for instructions on pump disassembly andassembly.

Figure 1 - Alignment Check

1. To check for parallel alignment, the use of a dial indicator ispreferred. If a dial indicator is not available use a straightedge. Turn both shafts by hand, checking the readingthrough one complete revolution. Maximum offset shouldbe less than .005" (.127 mm).

OPERATION

4

5. Check the pressure sett ing of the relief valve bymomentarily closing a valve in the discharge line andreading the pressure gauge. This pressure should be 10 -20 psi (69 - 138 kPa) higher than the maximum systemoperating pressure, or the external bypass valve setting (ifequipped). DO NOT operate the pump against a closeddischarge valve for more than 15 seconds. Ifadjustments need to be made, refer to the "Relief ValveSetting and Adjustment" section of this manual.

REVERSE ROTATION

NOTICE:PUMP SHOULD BE OPERATED IN REVERSE ROTATION FORNO MORE THAN 10 MINUTES AND ONLY WHEN A SEPARATEPRESSURE RELIEF VALVE IS INSTALLED TO PROTECT THEPUMP FROM EXCESSIVE PRESSURE.

It may be desirable to run the pump in reverse rotation forsystem maintenance. The pump will operate satisfactorily inreverse rotation for a LIMITED time, at a reducedperformance level.

FLUSHING THE PUMP1. To flush the pump, run the pump with the discharge valve

open and the intake valve closed. Bleed air into the pumpthrough the intake gauge plug hole or through a largerauxiliary fitting in the intake piping. Pump air for 30 secondintervals to clean out most of the pumpage.

2. Run a system compatible flushing fluid through the pumpfor one minute to clear out the remainder of the originalpumpage.

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

NOTICE:SOME RESIDUAL FLUID WILL REMAIN IN THE PUMP AND PIPING.

NOTICE:PROPERLY DISPOSE OF ALL WASTE FLUIDS INACCORDANCE WITH THE APPROPRIATE CODES ANDREGULATIONS.

PUMP RELIEF VALVENOTICE:

THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TOPROTECT THE PUMP FROM EXCESSIVE PRESSURE ANDMUST NOT BE USED AS A SYSTEM PRESSURE CONTROLVALVE.

Pumping volati le l iquids under suction l i ft may causecavitation. Partial closing of the discharge valve WILL result ininternal relief valve chatter and is NOT recommended. Forthese applications, install an external system pressure controlvalve, and any necessary bypass piping, back to the storagetank.

A system pressure control valve is also recommended whenoperating for extended periods (more than 1 minute) against aclosed discharge valve.

HazardousPressure

INCORRECT SETTINGS OF THE PRESSURERELIEF VALVE CAN CAUSE SYSTEMCOMPONENT FAILURE, PERSONAL INJURYAND PROPERTY DAMAGE.

START UP PROCEDURES

NOTICE:CONSULT THE "TROUBLESHOOTING" SECTIONS OF THISMANUAL IF DIFFICULTIES DURING START UP AREEXPERIENCED.

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

2. Check the vacuum and pressure gauges to ensure thesystem is operating within expected parameters. Recordthe gauge readings in the "Initial Start Up Information"section of this manual for future reference.

3. Inspect piping, fittings, and associated system equipmentfor leaks, noise, vibration and overheating.

4. If possible, check the flow rate to ensure the pump isoperating within the expected parameters. Record flowrate in the “Initial Start Up” section of this manual.

PRE-START UP CHECK LIST

1. Inspect complete piping system and supports to ensurethat no piping loads are being placed on the pump.

2. Ensure all valves and fittings in piping system are in thestart-up or operating positions.

3. On GX models, check the oil level in the gear reducer.Refer to “Lubrication” in the “Gear Reducer Maintenance”section of this manual.

NOTICE:BLACKMER GEAR REDUCERS ARE NOT LUBRICATED ATTHE FACTORY. OIL MUST BE ADDED BEFORE INITIAL PUMPSTART-UP.

4. Jog the pump motor to verify proper pump rotation.

OPERATION WITHOUT GUARDS INPLACE CAN CAUSE SERIOUSPERSONAL INJURY, MAJORPROPERTY DAMAGE OR DEATH.

OPERATING PUMP AGAINST ACLOSED VALVE CAN CAUSESYSTEM COMPONENT FAILURE,PERSONAL INJURY AND PROPERTYDAMAGE.Hazardous pressure



PUMP MAINTENANCE

5

Relief Valve Adjustment Procedure:

1. To INCREASE the pressure setting , remove the reliefvalve cap (1) and gasket (88). Loosen the locknut (3), ifequipped. Turn the adjusting screw (2) inward, orCLOCKWISE. Inspect R/V cap gasket (88) and replace asrequired. Reattach R/V cap gasket and R/V cap.

2. To DECREASE the pressure setting, remove the reliefvalve cap (1) and gasket (88). Loosen the locknut (3), ifequipped. Turn the adjusting screw (2) outward, orCOUNTERCLOCKWISE. Inspect R/V cap gasket (88) andreplace as required. Reattach R/V cap gasket and R/V cap.

Refer to corresponding Blackmer Pump Parts Lists forrelief valve spring pressure ranges.



Hazardous or toxicfluids can causeserious injury.

IF PUMPING HAZARDOUS FLUIDSSYSTEM MUST BE FLUSHED ANDDECONTAMINATED, INSIDE AND OUT,PRIOR TO PERFORMING SERVICE.

NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIEDTECHNICIANS ONLY, FOLLOWING THE APPROPRIATEPROCEDURES AND WARNINGS AS PRESENTED IN THISMANUAL.

RELIEF VALVE CAP IS EXPOSED TOPUMPAGE AND WILL CONTAIN SOMEFLUID.

Hazardous or toxicfluids can causeserious injury.

Pump LubricationBlackmer recommends lubricating the ball bearings everythree months at minimum. More frequent lubrication may berequired, depending on the application and the operatingconditions.

Recommended Grease:Amoco® - Amolith All Weather Grease, or equivalent.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. 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 forsome grease to escape from the grease tell-tale hole afterlubrication, excessive grease on pumps equipped withmechanical seals can cause seal failure. The tell-tale hole islocated in the head between the bearing and the seal.

VANE REPLACEMENTNOTICE:

FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONSPROVIDED IN THE "PUMP MAINTENANCE" SECTION OF THISMANUAL.

1. Drain the pump and system as required.

OPERATION



RELIEF VALVE SETTING AND ADJUSTMENTThe factory relief valve pressure setting is marked on a metaltag attached to the valve cover. It is recommended the reliefvalve be set at least 10 - 20 psi (69-138 kPa) higher than theoperating pressure or the system pressure control valvesetting.

HazardousPressure

INCORRECT SETTINGS OF THE PRESSURERELIEF VALVE CAN CAUSE SYSTEMCOMPONENT FAILURE, PERSONAL INJURYAND PROPERTY DAMAGE.

SCHEDULED MAINTENANCE

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




PUMP MAINTENANCE

6

b. Slide the lockwasher off the shaft. Inspect for damageand replace as required.

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

7. Remove the head capscrews (21) and carefully pry thehead (20) away from the cylinder (12).

8. Slide the head off the shaft. The head O-ring (72), bearing(24), and mechanical seal (153) will come off with the headassembly. Remove and discard the head O-ring.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 pushthe seal from the head (see Figure 3). Use care whenplacing the screw drivers to prevent damage to the sealfaces. Remove and discard the seal O-rings.

9. Pull the rotor and shaft (13) from the cylinder. While onehand is pulling the shaft, the other hand should be cuppedunderneath the rotor to prevent the vanes (14) and pushrods (77) from falling out. Carefully set the rotor and shaftaside for future vane replacement and reassembly.

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

PUMP ASSEMBLYBefore reassembling the pump, inspect all componentparts for wear or damage, and replace as required. Washout the bearing/seal recess of the head and remove anyburrs or nicks from the rotor and shaft.

1. Reassemble the OUTBOARD side of the pump first:

a. For a CLOCKWISE rotation pump, position the pumpcylinder with the INTAKE port to the left.

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

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

3. Apply a small amount of quality O-ring lubricant to the O-ring groove on the inside face of the head to facilitateinstallation. Install a new head O-ring (72) in the groove bylaying the O-ring flat and starting in on one side of thegroove, stretching ahead with the fingers, as shown inFigure 4.

Figure 3 - Mechanical Seal Removal

PUMP DISASSEMBLYNOTICE:

FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONSPROVIDED IN THE "PUMP MAINTENANCE" SECTION OF THISMANUAL.

1. Drain the pump and system as required.

2. On GX model pumps, disengage the motor shaft couplingand remove the four clamp capscrews (20C) to release theclamps (20B). Loosen the two setscrews (33) in the gearreducer spool flange. The gear reducer can then berotated away from the motor shaft and lifted off the pump.Refer to “Gear Reducer Maintenance” for reducerdisassembly instructions.

3. Starting on the inboard (driven) end of the pump, clean thepump shaft thoroughly, making sure the shaft is free ofnicks and burrs. This wil l prevent damage to themechanical seal when the inboard head assembly isremoved.

4. On X model pumps, remove the inboard bearing covercapscrews (28) and slide the inboard bearing cover (27A)and gasket (26) off the shaft. Discard the gasket. On theX2 and X2.5-inch pump models, the dirt shield will come offwith the bearing cover. Inspect dirt shield and replace asrequired.

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

6. The X2.5 and X3 pump models only are equipped withlocknuts (24A) and lockwashers (24B). To remove:

a. Bend up the engaged lockwasher tang and rotate thelocknut counterclockwise to remove it from the shaft

Figure 2 - Vane Installation

2. Remove the head assembly from the outboard (non-driven) 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 (14) 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 ofrotation. See Figure 2.

5. Repeat steps 2 and 3 until all vanes have been replaced.

6. Reassemble the pump according to steps 2 - 6 and 10 - 13of the "Pump Assembly" section of this manual.

PUMP MAINTENANCE

7

Figure 5 - Locknut Adjustment

a. On both ends of the pump shaft, Install a lockwasher(24B) with the tangs facing outward. Install a locknut(24A) with the tapered end inward. Ensure the innertang "A" of the lockwasher is located in the slot in theshaft threads by bending it slightly, if necessary.

b. With the bearings fully and squarely seated, tightenboth locknuts to ensure the bearings are bottomed inthe head recess. DO NOT overtighten, bend or shearthe 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 al ignedlockwasher tang into the slot in the locknut. The pumpshould turn freely when rotated by hand.

f. Tighten the opposite locknut by hand until it is snugagainst the bearing. Then, using a spanner wrench,tighten the nut the width of one lockwasher tang.Tighten just past the desired tang, then back off the nutto align the tang with the slot in the nut. Secure the nutby bending the aligned lockwasher tang into the slot inthe locknut. The pump should continue to turn freelywhen rotated by hand.

g. To check adjustment, grasp the nut and washer withfingers and rotate back and forth. If this cannot bedone, one or both locknuts are too tight and should bealternately loosened one stop at a time (.001"). Beginby loosening the locknut adjusted last.

12.On X model pumps, inspect the grease seal for wear ordamage and replace as required. Grease the outsidediameter of the grease seal (104) and push it into theinboard bearing cover (27A) with the lip inward. The lip willface outward when the bearing cover is installed on thehead. Attach a new bearing cover gasket (26) and thebearing cover (27A) to the inboard head. Install and torquethe bearing cover capscrews (28) to 15 lbs ft (20 Nm).

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

14.On X2 and X2.5 pump models, push the dirt shield(123A) over the inboard shaft and firmly against thebearing cover.

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

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

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

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

8. Remove the vanes (14) and push rods (77) from the rotorand shaft assembly. Inspect for wear and damage, andreplace 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 thebottom vanes can be installed and held in place as thepush rods are installed in the push rod holes of therotor. Insert the new vanes into the rotor slots with therounded edges outward, and the vane relief groovesfacing TOWARDS the direction of rotation. Refer toFigure 2 in “Vane Replacement.”

c. After the bottom vanes and push rods are installed,insert the rotor and shaft fully into the cylinder.

d. Install the remaining vanes into the top positions of therotor. Rotate the shaft by hand to engage the drivetangs of the mechanical seal jacket in the rotorslots.

9. Apply a thin coating of quality O-ring lubricant on theinboard shaft to aid installation. Install the inboard head,mechanical seal, and bearing as instructed in steps 2through 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 notturn freely, lightly tap the rims of the heads with a soft facedmallet until the correct position is found. Install all of theremaining head capscrews for each head and uniformlytighten, torquing to 25 lbs ft (34 Nm).

11. LOCKNUT INSTALLATION - X2.5, X3 Pump Models OnlyIt is important that the bearing locknuts (24A) andlockwashers (24B) be installed and adjusted properly.Overtightening locknuts can cause bearing failure or a

Figure 4 - Head O-Ring Installation

broken lockwasher tang. Loose locknuts will allow the rotorto shift against the heads, causing wear. See Figure 5.

GEAR REDUCER MAINTENANCE - GX MODELS

GEAR REDUCER LUBRICATION

NOTICE:BLACKMER GEAR REDUCERS ARE NOT LUBRICATED AT THEFACTORY. OIL MUST BE ADDED BEFORE INITIAL PUMP START-UP.

For normal operation, the gear reducer oil should be changedevery 6 months or 1000 hours, whichever is shorter. Ifoperating in conditions with wide ranges in temperature, or inan unusually moist or dusty atmosphere, the oil should bechanged every 3 months or 500 hours, whichever is shorter.



NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIEDTECHNICIANS ONLY, FOLLOWING THE APPROPRIATEPROCEDURES AND WARNINGS AS PRESENTED IN THISMANUAL.

NOTICE:FOLLOW ALL HAZARD WARNINGS PROVIDED IN THE “PUMPMAINTENANCE” SECTION OF THIS MANUAL.

NOTICE:FULL LOAD OPERATING TEMPERATURE OF THE GEARREDUCER CAN REACH 180oF (82oC).

AIR TEMPERATURE OIL VISCOSITY

0oF to 40oF 300 SSU at 100oF (SAE 20)(-180C to 40C) (63 cSt at 38oC)

41oF to 140oF 1000 SSU at 100oF (SAE 40)(5oC to 60oC) (220 cSt at 38oC)

To add oil to the gear reducer:1. Remove the oil level plug (29) and the fill & vent plug

(76C).2. Add oil through the fill hole until oil runs out of the oil level

plug hole.3. Replace the oil level plug and fill & vent plug. Make sure

the vent fitting in the fill plug is kept clean to preventexpansion from forcing oil leaks at the shaft.

NOTICE:TO MAINTAIN PROPER GEAR REDUCER LUBRICATION, THEVENT PLUG MUST BE POSITIONED HIGHER THAN THE OILLEVEL PLUG. TO DETERMINE MAXIMUM VARIATION OF GEARREDUCER SHAFT ALIGNMENT, REFER TO BLACKMER GXMODEL DIMENSIONS 101/105 - 101/108

OIL SEAL REPLACEMENTNOTICE:

FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONSPROVIDED IN THE "PUMP MAINTENANCE” AND “GEARREDUCER MAINTENANCE" SECTIONS OF THIS MANUAL.

To replace the oil seal on the INPUT SHAFT (102):1. Drain and properly dispose of oil from gear reducer by

removing the oil level plug (29) and drain plugs (29A).2. Remove the closure plate capscrews (116), the closure

plate (114), and the closure plate gasket (115) from thegearcase. Press the oil seal (104 or 104A) from theclosure plate. Discard the gasket and oil seal.

3. Grease the outer edge of a new oil seal and press the flatside of the seal into the inside face of the closure plate.When the closure plate is reattached to the gearcasecover, the lips of the oil seal should face the inside of thegearcase.

4. Place the closure plate and a new gasket on the gearcasecover. Install and torque the closure plate capscrews (116)as indicated in Table 2.

To replace the oil seal on the OUTPUT SHAFT (125A):1. Follow steps 1 - 5 of the “Gear Reducer Disassembly.”2. Remove the output shaft (125A) and gear assembly, and

press the oil seal (104 or 104A) from the inside bore of thegearcase. Discard oil seal. Inspect gear reducer bearingsfor wear or damage and replace as required followingsteps 2 and 3 of the “Gear Reducer Assembly” section ofthis manual.

8

Table 1



Extreme heat cancause injury or

property damage.

FAILURE TO ALLOW GEAR REDUCERTO COOL BEFORE ATTEMPTINGMAINTENANCE CAN CAUSE SERIOUSPERSONAL INJURY.




Recommended Oil:Use the grade of oil stamped on the instruction plate attachedto the gearcase. In general, use a lube oil with oxidationinhibitors following the specifications as indicated in Table 1.

GEAR REDUCER MAINTENANCE - GX MODELS3. Grease the outer edge of a new oil seal and firmly press

the flat side of the seal into the bore of the gearcase. Thelips of the seal should face the inside of the gearcase.

4. Reinstall the output shaft and gear assembly, the newclosure plate gasket and the closure plate. Install andtorque the closure plate capscrews (116) as indicated inTable 2.

5. Refill the gear reducer with oil following the proceduresprovided in the “Gear Reducer Lubrication” section of thismanual.

GEAR REDUCER DISASSEMBLYNOTICE:

FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONSPROVIDED IN THE "PUMP MAINTENANCE” AND “GEARREDUCER MAINTENANCE" SECTIONS OF THIS MANUAL.

1. If the reducer has not been removed from the pump,disengage the motor shaft coupling and remove the fourclamp capscrews (20C) to release the clamps (20B).Loosen the two setscrews (33) in the gear reducer spoolflange. The gear reducer can then be rotated away fromthe motor shaft and lifted off the pump.

2. Drain and properly dispose of oil from gear reducer byremoving the oil level plug (29) and oil drain plugs (29A).

3. Remove the gear case cover capscrews (112). Insert awedge between the projecting lugs on the cover and taplightly until the cover is loosened and can be removed.The gear case cover is positioned with two (2) dowel pins(38), which remain in the gearcase.

4. Remove the cover gasket (111) and discard.5. The pinion and input shaft (102) is a one-piece assembly

and does not come apart. If required, remove the bearings(24, 24A) from the shaft with a bearing puller or arborpress.

6. To remove the gear (101) and bearings from the splinedoutput shaft (125A), support the assembly on the gear andpress the shaft out of the gear and bearings.

7. Refer to “Oil Seal Replacement” to remove and install newoil seals.

GEAR REDUCER ASSEMBLYBefore reassembling the gear reducer, inspect allcomponent parts for wear or damage, and replace asrequired. Wash out the bearing bores and remove anyburrs or sharp edges with a file.

1. If the shaft and bearing assemblies have not beendisassembled, begin assembly at step 4.

2. The output shaft (125A) is reduced in diameter at one endof the gear area to facilitate gear and bearing installation.a. Before installing the gear and bearings, remove all dirt,

burrs or sharp edges from the shaft to prevent galling orseizing. Apply a light coating of graphite, molysulphideor white grease to the shaft.

b. Using an arbor press, press the shaft squarely into thebearing (24, 24A or 24C). Install the spacer ring (82 or82B)

c. Align the gear key (124) with the notch in the gear, andpress the gear (101) squarely onto the shaft. Install thespacer ring (82 or 82A).

d. Press the second bearing (24, 24A or 24B) onto theshaft. On HRA and HRO models, install the retainingring (83A).

3. Prior to installing the bearings on the input shaft, remove alldirt, burrs or sharp edges from the shaft to prevent gallingor seizing. Apply a light coating of graphite, molysulphideor white grease to the shaft.a. For HRA gear ratios 5.06, 6.27 and 7.65 install the

retaining ring (83B) on the non-driven (shorter end) ofthe input shaft.

b. Using an arbor press, press a bearing (24 or 24A) ontoeach end of the shaft.

4. Grease the outer edge of a new oil seal (104 or 104A) andfirmly press the flat side of the seal into the bore of thegearcase. The lips of the seal should face the inside of thegearcase.

5. Apply a light coating of oil in the bearing bores of thegearcase to facil i tate bearing and shaft assemblyinstallation.

6. With the gearcase resting flat on the spool flange (cavityside up), start the output shaft (125A) into the bearing bore.Align the bearings and gear teeth of the input shaft (102)with the output shaft, and ensure that the bearings arelined up squarely with the bores. Drop the two shaftassemblies together into their respective bearing bores.

7. Rotate the shafts by hand to verify free movement andproper bearing position.

8. Set the new cover gasket (111) on the gearcase.9. Install the cover (110) on the gearcase, using the dowel

pins for proper positioning. Install the cover capscrews(112), torquing to 30 lbs ft (40.6 Nm).

10.On HRA reducer models, install the spacer rings (82C &82D) into the gearbox cover assembly (110).

11. Grease the outer edge of a new oil seal (104 or 104A) andpress the flat side of the seal into the inside face of theclosure plate (114).

12.Place the closure plate (114) and a new gasket (115) onthe gearbox assembly cover. Install and torque the closureplate capscrews (116) as indicated in Table 2.

13.On HRB reducer models, attach the blind closure plategasket (119A) and closure plate (119) to the cover. Installand torque the closure plate capscrews (116) as indicatedin Table 2.

14.On HRO reducer models, install the remaining two covercapscrews (112A), torquing to 30 lbs ft (40.6 Nm)

15.Refill the gear reducer with oil following the proceduresprovided in the “Gear Reducer Lubrication” section.

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Table 2

REF PUMP REDUCER TORQUENO. MODEL MODEL lbs ft (Nm)

GX2, GX2.5 HRO 30 (40.6)116 GX3 HRA 5 (6.8)

GX4 HRB 10 (13.6)

NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWINGTHE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.

PUMP TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE

Pump Not Priming 1. Pump not wetted.2. Worn vanes3. 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.

Reduced Capacity 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 (i.e.: 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").

Noise 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 source.

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").

Damaged Vanes 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").

10

continued on following page

NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWINGTHE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.

PUMP TROUBLESHOOTING

GEAR REDUCER TROUBLESHOOTING


Broken Shaft 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.

Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.2. O-rings nicked, cut or twisted3. Shaft at seal area damaged, worn or dirty.4. Ball bearings overgreased.5. Excessive cavitation.6. Mechanical seal faces cracked, scratched, pitted or dirty.


Noise and Vibration 1. Worn or damaged bearings. Replace as required.2. Inadequate lubrication or incorrect lubricant (see “Gear Reducer Lubrication”).3. Impurities in the lubricant, such as abrasive particles.4. Excessive overloading. Check horsepower requirements.5. Worn or damaged gear teeth.6. Misalignment of pump or motor. Refer to “Gear Reducer Alignment” section of

this manual, and Blackmer GX model Dimensions 101/105 - 101/108 for maximum variation of shaft alignment.

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