BLACKMER POWER PUMPS

961222
INSTRUCTIONS NO. 101-B00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: GX2B, GX2.5B, GX3E, GX4B,
X2B, X2.5B, X3E, X4B
Section
Effective
Replaces
101
J an 2014
J ul 2011


TABLE OF CONTENTS Page
PUMP DATA
Technical Data .................................................... 2
Initial Pump Start Up Information ......................... 2
INSTALLATION
Pre-Installation Cleaning ..................................... 3
Location and Piping ............................................. 3
Mounting ............................................................. 3
Coupling Alignment ............................................. 4
Gear Reducer Alignment GX Models ............... 4
Pump Rotation..................................................... 4
To Change Pump Rotation .................................. 4
Check Valves ...................................................... 4
OPERATION
Pre-Start Up Check List ....................................... 5
Start Up Procedures ............................................ 5
Running the Pump in Reverse Rotation .............. 6
Flushing the Pump .............................................. 6
Pump Relief Valve ............................................... 6
Relief Valve Setting and Adjustment ................... 6
PUMP MAINTENANCE
Lubrication .............................................................. 7
Strainers ................................................................. 7
Vane Replacement ................................................. 8
Pump Disassembly ................................................ 8
Parts Replacement ................................................. 8
Pump Assembly ..................................................... 9
GEAR REDUCER MAINTENANCE
Gear Reducer Lubrication .................................... 11
Oil Seal Replacement .......................................... 12
Gear Reducer Disassembly ................................. 12
Gear Reducer Assembly ...................................... 12
PUMP TROUBLE SHOOTING .................................... 13
GEAR REDUCER TROUBLE SHOOTING .................. 14
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
GX 101-B01 101-B02 101-B03 101-B04
X 101-B05 101-B06 101-B07 101-B08

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 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.
NOTICE:
Indicates special instructions which are very
important and must be followed.

NOTICE:

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 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 pump.

Maintain ALL system and pump operation and hazard
warning decals.


101-B00 page 2/16
SAFETY DATA

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

Hazardous
machinery can
cause serious
personal injury.

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
performing service or maintenance

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

Hazardous or toxic
fluids can cause
serious injury.

Hazardous pressure
can cause personal
injury or property
damage


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

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

Do not operate
without guard
in place

Hazardous pressure
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 pump. It is
recommended that the data from this tag be recorded and filed for future reference. If replacement parts are needed, or if
information pertaining to the pump is required, this data must be furnished to a Blackmer representative.


TECHNICAL DATA
2 , 2.5 3 4
Maximum Pump
Speed
780 RPM 640 RPM 520 RPM
Maximum Viscosity 20,000 SSU (4,250 cP)
Maximum Operating
Temperature *
240 300F (115 149C)
Maximum Differential
Pressure
125 psi (8.6 Bar)
Maximum Working
Pressure
175 psi (12.1 Bar)
* Maximum operating limits are dependent on the materials of
construction. See Blackmer Material Specs 101-095.

INITIAL PUMP START UP INFORMATION
Model No.: ____________________________________
Serial No.: ____________________________________
ID No.: _______________________________________
Date of Installation: _____________________________
Inlet Gauge Reading: ____________________________
Discharge Gauge Reading: _______________________
Flow Rate: _____________________________________

101-B00 page 3/16
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
before installation or service
Electrical supply MUST match motor
nameplate specifications.
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.


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 temperature,
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 100F (37.8C)
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-B00 Page 4/16
COUPLING ALIGNMENT
The pump must be directly coupled to a gear and/or driver
with a flexible coupling. Verify coupling alignment after
installation of new or rebuilt pumps. Both angular and
parallel coupling alignment MUST be maintained between the
pump, gear, motor, etc. in accordance with manufacturers
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

GEAR REDUCER ALIGNMENT GX MODELS
The reducer can be rotated on its mounting to raise or lower
the input shaft to facilitate alignment to the motor shaft. To do
so, first loosen the four clamp capscrews (20C) and the two
setscrews (33) in the gear reducer spool flange. The reducer
is then free to rotate. If necessary, tap it lightly with a soft
faced mallet. When aligning the reducer, verify the alignment
of the coupling halves as indicated in Coupling Alignment
section.
NOTICE:
To determine maximum variation of gear reducer shaft
alignment, refer to Blackmer GX model dimension pages

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 GX models, the gear reducer input shaft will rotate in
the opposite direction of the pump shaft. For example,
on a right-hand GX pump, the gear reducer shaft will
rotate counterclockwise.
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.

101-B00 Page 5/16
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
injury, death or major property damage
Hazardous pressure
can cause 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

Pumps operating against a closed valve
can cause system failure, personal
injury and property damage
Hazardous pressure
can cause personal
injury or 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.
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 at the factory.
Oil MUST be added before initial pump start-up
4. On GX models shipped without the gear reducer
attached, the inboard bearings 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. See Pump Lubrication in the
Maintenance section of this manual.
5. 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.
6. 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.
7. 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.

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."

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

101-B00 Page 6/16
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 residual 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.
X and GX 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
damage.
Hazardous pressure
can cause personal
injury or property
damage

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

101-B00 Page 7/16
MAINTENANCE:


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


Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous voltage.
Can shock, burn or
cause death.


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


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


If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior
to performing service or maintenance
Hazardous or toxic
fluids can cause
serious injury.


Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place

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

SCHEDULED MAINTENANCE

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 GX 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.


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

101-B00 Page 8/16
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.

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. On GX model pumps, disengage the motor shaft
coupling and remove the four clamp capscrews (20C) to
release the clamps (20B). Loosen the two setscrews (33)
in the gear reducer spool flange. The gear reducer can
then be rotated away from the motor shaft and lifted off
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. On X model pumps, remove the inboard bearing cover
capscrews (28) and slide the inboard bearing cover (27A)
and gasket (26) off the shaft. Discard the gasket. On the
X2 and X2.5-inch pump models, the dirt shield will come
off with the bearing cover. Inspect dirt shield and replace
as required.
5. Remove the outboard bearing cover capscrews (28) and
the 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 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.
7. For X4 pump models 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.
8. Remove the head capscrews (21). Gently pry the head
away from the cylinder.
9. 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 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 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 5 Mechanical Seal Removal
10. 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.
11. 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 be replaced with new O-rings.
NOTE: PTFE O-rings should be heated in hot water to aid
installation.
2. Excessive or continuous leakage from the tell-tale hole in
the bearing cover may be an indication of a damaged
mechanical seal. If a mechanical seal has been leaking, it
is recommended the entire seal be replaced. Refer to
"General Pump Troubleshooting" for possible causes of
seal leakage.

101-B00 Page 9/16
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.

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 and 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.
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 9 Locknut Assembly

11. LOCKNUT ADJUSTMENT X2.5, X3 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
9.
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-B00 Page 10/16

12. LOCK COLLAR INSTALLATION X4 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. Repeat this procedure on the opposite pump end.
After installing both lock collars, verify the shaft turns
freely when rotated by hand
13. On X model pumps, inspect the grease seal for wear or
damage and replace as required. Grease the outside
diameter of the grease seal (104) and push it into the
inboard bearing cover (27A) with the lip inward. The lip
will face outward when the bearing cover is installed on
the head. Attach a new bearing cover gasket (26) and the
bearing cover (27A) to the inboard head. Install and
torque the bearing cover capscrews (28) to 15 lbs ft (20
Nm).
14. 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 lbs ft (20
Nm).
15. On X2 and X2.5 models, push the dirt shield (123A) over
the inboard shaft and firmly against the bearing cover.
16. 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 O-
ring (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.
17. Reinstall coupling, shaft key, and coupling guards.
18. Refer to Pre-Start Up Check List and Start Up
Procedures sections of this manual prior to restarting
pump operation.


101-B00 Page 11/16
GEAR REDUCER MAINTENANCE GX MODELS


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


Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous voltage.
Can shock, burn or
cause death.


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


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


If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior
to performing service or maintenance
Hazardous or toxic
fluids can cause
serious injury.


Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place


Failure to allow gear reducer to cool
before attempting maintenance can
cause serious personal injury.
Extreme heat can
cause injury or
property damage.
NOTICE:
Maintenance shall be performed by qualified technicians
only. Following the appropriate procedures and
warnings as presented in this manual.
NOTICE:
Full load operating temperature of the gear reducer can
reach 180F (82C).
GEAR REDUCER 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:
Blackmer gear reducers are not lubricated at the factory.
Oil MUST be added before initial pump start up.
Horsepower calculations for Blackmer reducers are based on
75F (24C) ambient air temperature; 200F (93C) maximum
oil temperature using synthetic oil.
Oil Change Schedule: For normal operation, the gear
reducer oil should be changed every 6 months or 1000 hours,
whichever is shorter. If operating in conditions with wide
ranges in temperature, or in an unusually moist or dusty
atmosphere, the oil should be changed every 3 months or
500 hours, whichever is shorter.
Recommended Oil: Use a synthetic oil with oxidation
inhibitors that is compatible with Buna elastomers. Use
synthetic oil AGMA Viscosity Grade 4 or ISO Viscosity Grade
150 such as Mobil SHC 629, Shell Omala S4 GX 150,
Castrol Isolube EP 150 or equivalent.
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.
Pump
Model
Reducer
Model
Approx. Oil
Capacity *
GX2, GX2.5 HRO-GX 0.5 qt. (0.47 l)
GX3 HRA-GX 0.75 qt. (0.71 l)
GX4 HRB-GX 1.25 qt. (1.18 l)
* Capacity will vary depending on the orientation of the
reducer mounting.
3. Replace the oil level plug and fill & vent plug. Make sure
the vent fitting in the fill plug is kept clean to prevent
expansion from forcing oil leaks at the shaft.
NOTICE:
To maintain proper gear reducer lubrication, the vent
plug must be positioned higher than the oil level plug.
To determine maximum variation of gear reducer shaft
alignment, refer to Blackmer GX model dimension pages.

101-B00 Page 12/16
OIL SEAL REPLACEMENT
NOTICE:
Follow all hazard warnings and instructions provided in
the " Pump Maintenance and Gear Reducer
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 the
gearcase. Press the oil seal (104 or 104A) from the
closure plate. Discard the gasket and oil seal.
3. Grease the outer edge of a new oil seal and press the flat
side of the seal into the inside face of the closure plate.
When the closure plate is reattached to the gearcase
cover, the lips of the oil seal should face the inside of the
gearcase.
4. Place the closure plate and a new gasket on the
gearcase cover. 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
the gearcase. Discard oil seal. Inspect gear reducer
bearings for wear or damage and replace as required
following steps 2 and 3 of the Gear Reducer Assembly
section of this manual.
3. Grease the outer edge of a new oil seal and firmly press
the flat side of the seal into the bore of the gearcase. The
lips of the seal should face the inside of the gearcase.
4. Reinstall the output shaft and gear assembly, the new
closure plate gasket and the closure plate. Install and
torque the closure plate capscrews (116) as indicated in
Table 2.
5. Refill the gear reducer with oil following the procedures
provided in the Gear Reducer Lubrication section of this
manual.
GEAR REDUCER DISASSEMBLY
NOTICE:
Follow all hazard warnings and instructions provided in
the " Pump Maintenance and Gear Reducer
Maintenance" sections of this manual.
1. If the reducer has not been removed from the pump,
disengage the motor shaft coupling and remove the four
clamp capscrews (20C) to release the clamps (20B).
Loosen the two setscrews (33) in the gear reducer spool
flange. The gear reducer can then be rotated away from
the motor shaft and lifted off the pump
2. Drain and properly dispose of oil from gear reducer by
removing the oil level plug (29) and oil drain plugs (29A).
3. Remove the gear case cover capscrews (112). Insert a
wedge between the projecting lugs on the cover and tap
lightly 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
arbor press.
6. To remove the gear (101) and bearings from the splined
output shaft (125A), support the assembly on the gear
and press the shaft out of the gear and bearings.
7. Refer to Oil Seal Replacement to remove and install
new oil seals.
GEAR REDUCER ASSEMBLY
Before reassembling the gear reducer, inspect all
component parts for wear or damage, and replace as
required. Wash out the bearing bores and remove any
burrs or sharp edges with a file.
1. If the shaft and bearing assemblies have not been
disassembled, begin assembly at step 4.
2. The output shaft (125A) is reduced in diameter at one end
of 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 or seizing. Apply a light coating of graphite,
molysulphide or white grease to the shaft.
b. Using an arbor press, press the shaft squarely into the
bearing (24, 24A or 24C). Install the spacer ring (82 or
82B)
c. Align the gear key (124) with the notch in the gear,
and press the gear (101) squarely onto the shaft.
Install the spacer ring (82 or 82A).
d. Press the second bearing (24, 24A or 24B) onto the
shaft. On HRA-GX and HRO-GX models, install the
retaining ring (83A).
3. Prior to installing the bearings on the input shaft, remove
all dirt, burrs or sharp edges from the shaft to prevent
galling or seizing. Apply a light coating of graphite,
molysulphide or 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) of
the input shaft.
b. Using an arbor press, press a bearing (24 or 24A)
onto each end of the shaft.
4. Grease the outer edge of a new oil seal (104 or 104A)
and firmly press the flat side of the seal into the bore of
the gearcase. The lips of the seal should face the inside
of the gearcase.
5. Apply a light coat of oil in the bearing bores of the gear-
case to ease bearing and shaft assembly installation.
6. With the gearcase resting flat on the spool flange (cavity
side 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
are lined up squarely with the bores. Drop the two shaft
assemblies together into their respective bearing bores.
7. Rotate the shafts by hand to verify free movement and
proper 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).
101-B00 Page 13/16
11. Grease the outer edge of a new oil seal (104 or 104A)
and press the flat side of the seal into the inside face of
the closure plate (114).
12. Place the closure plate (114) and a new gasket (115) on
the gearbox assembly cover. Install and torque the
closure plate capscrews (116) as indicated in Table 2.
13. On HRB-GX reducer models, attach the blind closure
plate gasket (119A) and closure plate (119) to the cover.
Install and torque the closure plate capscrews (116) as
indicated in Table 2.
14. On HRO-GX reducer models, install the remaining two
cover capscrews (112A); torque to 30 lbs ft (40.6 Nm)
15. Refill the gear reducer with oil following the procedures
provided in the Gear Reducer Lubrication section.
Ref
No.
Pump
Model
Reducer
Model
Torque
lbs ft (Nm)
GX2, Gx2.5 HRO-GX 30 (40.6)
116 GX3 HRA-GX 5 (6.8)
GX4 HRB-GX 10 (13.6)
Table 2

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. 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 (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").


101-B00 Page 14/16
PUMP 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 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.




GEAR REDUCER TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only,
following the appropriate procedures and warnings as presented in this manual.

SYMPTOM PROBABLE CAUSE
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.


101-B00 Page 15/16
NOTES


Sliding Vane Pumps: 5 to 2200 GPM
Refined Fuels, Liquefied Gases, Solvents,Process

Stainless Steel Sliding Vane Pumps
1 to 265 GPM: Acids, Brines, Sugars, Syrups,
Beer, Beet J uice, Cider, Flavor Extracts, etc.

System One

Centrifugal Pumps
10 to 7500 GPM; Process, Marine

Magnetic Drive Pumps
Stainless Steel: 14 to 215 GPM

HXL 6, 8 & 10
Sliding Vane Pumps

130 to 2,220 GPM

Refineries
Terminals
Barges
Ships

Reciprocating Gas Compressors
Liquefied Gas Transfer, Boosting, Vapor Recovery

Hand Operated Pumps
Dispensing, Transfer, In-line

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: (616) 241-1611 Fax: (616) 241-3752
E-mail: [email protected] Internet Address: www .blackmer.com