960439

BLACKMER LIQUEFIED GAS PUMPS INSTRUCTIONS NO. 501-L00

FOR LP-GAS AND NH3 SERVICE, TRUCK AND BASE MOUNTED Section 501
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Effective Jan 2019
Replaces Jun 2016
MODEL: LGL3021A

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,

TABLE OF CONTENTS Page death or major property damage.
SAFETY DATA ..................................................................... 1
PUMP DATA
Pump Identification ..................................................... 2
Technical Data ........................................................... 2 Warns of hazards that CAN cause personal injury
Initial Pump Start Up Information ............................... 2 or property damage.
GENERAL INSTALLATION AND OPERATION
Welded Connections .................................................. 3 NOTICE:
Pre-Installation Cleaning ............................................ 3 Indicates special instructions which are very
Location and Piping .................................................... 3 important and must be followed.
Pump Relief Valve and Bypass Valve ........................ 4
Check Valves ............................................................. 4
Pump Rotation ........................................................... 4
MOTOR DRIVEN PUMPS
Pump Mounting .......................................................... 4
Coupling Alignment .................................................... 5 NOTICE:
V-Belt Drive ................................................................ 5 Blackmer liquefied gas pumps MUST only be installed
V-Belt Disassembly .................................................... 5
in systems which have been designed by qualified
Pre-Start Up Check List ............................................. 6
Start Up Procedures ................................................... 6
engineering personnel. The system MUST conform to
TRUCK MOUNTED PUMPS all applicable local and national regulations and safety
Truck Mounting .......................................................... 6 standards.
Pump Drive ................................................................ 6 This manual is intended to assist in the installation
Hydraulic Drive ........................................................... 7
Pre-Start Up Check List ............................................. 7
and operation of the Blackmer liquefied gas pumps,
Start Up Procedures ................................................... 7 and MUST be kept with the pump.
Pump Speed .............................................................. 8 Blackmer liquefied gas pump service shall be
MAINTENANCE performed by qualified technicians ONLY. Service
Strainers ..................................................................... 8
Lubrication.................................................................. 8
shall conform to all applicable local and national
Vane Replacement ..................................................... 9 regulations and safety standards.
Pump Disassembly .................................................... 9 Thoroughly review this manual, all Instructions and
Pump Assembly ....................................................... 10
hazard warnings, BEFORE performing any work on
TROUBLE SHOOTING ...................................................... 11
the Blackmer liquefied gas pumps.
NOTE: Numbers in parentheses following individual parts Maintain ALL system and Blackmer liquefied gas
indicate reference numbers on Blackmer Parts List 501-L01 pump operation and hazard warning decals.
Blackmer pump manuals and parts lists may be obtained from
Blackmer's website (www.blackmer.com) or by contacting
Blackmer Customer Service.
 SAFETY DATA

Failure to set the vehicle emergency Failure to disconnect and lockout

brake and chock wheels before electrical power before attempting
performing service can cause severe maintenance can cause shock, burns or
Hazardous
personal injury or property damage death
Hazardous voltage.
machinery can
Can shock, burn or
cause serious
cause death.
personal injury.

Failure to disconnect and lockout

Operation without guards in place can
electrical power or engine drive before
cause serious personal injury, major
attempting maintenance can cause
property damage, or death.
Hazardous
severe personal injury or death
Do not operate
machinery can
without guard
cause serious
in place
personal injury.

Failure to relieve system pressure prior

Disconnecting fluid or pressure to performing pump service can cause
containment components during pump serious personal injury or property
operation can cause serious personal damage. Systems with meters will still
injury or property damage. be pressurized even after the hose is
Hazardous pressure Hazardous pressure
can cause serious can cause serious emptied
personal injury or personal injury or
property damage 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.

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 INITIAL PUMP START UP INFORMATION
Models LGL3021A Model No.: ____________________________________

Torque required 89 lbs ft

Serial No.: ____________________________________
@100 psi (6.9 bar) (121 Nm)
Maximum Pump Speed @ Max.
800 RPM ID No.: _______________________________________
Differential Press.
125 psi
Maximum Differential Pressure Date of Installation: _____________________________
(8.62 Bar)
240°F
Maximum Operating Temperature
(115°C) Inlet Gauge Reading: ____________________________
350 PSI
Maximum Working Pressure
(24.1 Bar) Discharge Gauge Reading: _______________________
 Technical Data is for standard materials of construction.
Consult Blackmer Material Specs for optional materials Flow Rate: _____________________________________
of construction.
 These pumps are listed by Underwriters’ Laboratories
for liquefied petroleum gas and NH3 service.

501-L00 Page 2/12

 GENERAL INSTALLATION AND OPERATION
NOTICE: LOCATION AND PIPING
Blackmer pumps must only be installed in systems Pump life and performance will be significantly reduced when
designed by qualified engineering personnel. System installed in an improperly designed system. Before starting
design must conform with all applicable regulations and the layout and installation of the piping system, review the
codes and provide warning of all system hazards. following suggestions:
NOTICE: 1. Locate the pump as near as possible to the source of
This pump shall be installed in accordance with the supply to avoid excessive inlet pipe friction.
requirements of NFPA 58, all applicable local, state and
2. The inlet piping and fittings should be at least as large as
national regulations.
the intake port on the pump. Slope the pipe downward to
the pump, and do not install any upward loops. Minimize
the number of intake line fittings and eliminate
WELDED CONNECTIONS restrictions such as sharp bends; globe valves,
NOTICE: unnecessary elbows, and undersized strainers.
Pumps with welded connections contain three non- 3. A strainer must be installed in the inlet line to protect the
metallic O-ring seals that will be damaged if welding is pump from foreign matter. Locate the strainer at least 24"
done with these O-rings installed. (0.6m) from the pump. Strainers must have a net open
Prior to welding the piping, remove the O-rings from under the area of at least four times the area of the intake piping,
inlet flange, outlet flange and relief valve cover as indicated in and must be cleaned regularly to avoid pump starvation.
Figure 1. 4. The intake and discharge piping system must be free of
Reinstall the inlet and outlet flanges. Weld the piping to the all leaks.
the inlet and outlet flanges. After the welding is complete, 5. Expansion joints, placed at least 36" (0.9m) from the
reinstall the O-rings. 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. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
7. Check alignment of pipes to pump to avoid strains which
might later cause misalignment. See Figure 2. Unbolt
flanges or break union joints. Pipes must not spring away
or drop down. After the pump has been in operation for a
week or two, completely recheck alignment.

Figure 1

PRE-INSTALLATION CLEANING
NOTICE: Figure 2
New pumps contain residual test fluid and rust inhibitor. 8. Install pressure gauges in the NPT ports provided in the
If necessary, flush pump prior to use. pump casing to check pump performance at start up.
Foreign matter entering the pump WILL cause extensive 9. The use of a 1.5” or 2” vapor return line will speed up
damage. The supply tank and intake piping MUST be delivery by preventing pressure build up at the receiving
cleaned and flushed prior to pump installation and operation. tank and pressure reduction in the supply tank.
10. Keeping the liquefied gas systems full of liquid, even
when idle, will keep the O-rings from changing shape,
shrinking or super cooling. Evaporation of liquefied gas
leaves an abrasive powder on the surface which can
cause wear to the pump, meter, and seals.

501-L00 Page 3/12

 GENERAL INSTALLATION AND OPERATION
PUMP RELIEF VALVE AND BYPASS VALVE CHECK VALVES
NOTICE: The use of check valves or foot valves in the supply tank is
The pump internal relief valve is designed to protect the not recommended with self-priming, positive displacement
pump from excessive pressure and must not be used as pumps.
a system pressure control valve. If the possibility of liquid backflow exists when the pump is off,
For ALL liquefied gas applications, install an external bypass a check valve in the pump discharge piping is recommended
valve, and any necessary piping, back to the tank. External because the pump can motor in the reverse rotation and
Bypass Valves are integral to the performance and operation create undue stress on all attached components. Never start
of liquefied gas pumps and are included in the boundary / a pump when it is rotating in the reverse rotation as the added
jurisdiction of the pump (Refer to Form 589). DO NOT pipe starting torque can damage the pump and related equipment.
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 PUMP ROTATION
than the pump internal relief valve setting. The valve and NOTICE:
piping must be of adequate size to accommodate the full flow Confirm correct pump rotation by checking the pump
from the pump when the discharge line is closed. The non- rotation arrows respective to pump driver rotation.
adjustable pump internal relief valve is factory set at
approximately 150 PSI (10.3 bar). Blackmer LGL3021 pump model has a double ended rotor
and shaft, enabling them to be driven from either shaft end.
The 'Alternate Discharge to Storage Tank' line and manual To change rotation, rotate the pump 180 degrees so that the
valve may be used to unload transports without pumps into opposite shaft becomes the driven shaft. The shaft protector
the storage tank. The manual valve in this line must remain (186) MUST be mounted over the non-driven shaft.
closed during all other operations.
Refer to Blackmer Bypass Valve Installation and Maintenance
Instructions for bypass valve settings and adjustments.

Operation without guards in place can

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

Figure 3 – Bypass Valve Mounting

MOTOR DRIVEN PUMPS

will improve pump performance. Refer to ANSI/HI standards
Install, ground and wire to local and or a suitable pump handbook for information on typical pump
National Electrical Code requirements. mounting and foundations. Check coupling alignment after
Install an all-leg disconnect switch near pump and base assembly is secured to the foundation.
the unit motor. BOLT
Disconnect and lockout electrical power
before installation or service BASE
Hazardous voltage.
Can shock, burn or Electrical supply MUST match motor Figure 4
cause death. nameplate specifications.

Motors equipped with thermal protection automatically

disconnect motor electrical circuit when overload exists. STANDARD
Motor can start unexpectedly and without warning. PIPE

NOTICE: WASHER
Consult the "General Installation and Operation" section
of this manual for system information.

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 4). A
solid foundation will reduce system noise and vibration, and
501-L00 Page 4/12
 MOTOR DRIVEN PUMPS
COUPLING ALIGNMENT 5. Measure the span length as shown in Figure 6.
The pump must be directly coupled to a gear reducer and/or 6. Adjust the motor base (183) and apply a specified force
driver with a flexible coupling. Verify coupling alignment after (see Table 1) against the belt, at the center of the span,
installation of new or rebuilt pumps. Both angular and parallel so that the belt is deflected 1/64 inch (0.04 mm) for every
coupling alignment MUST be maintained between the pump, inch (25.4 mm) of span. For example, the deflection of a
gear, motor, etc. in accordance with manufacturer’s 20 inch (508 mm) span would be 20/64 or 5/16 inch (7.9
instructions. See Figure 5. mm). Refer to Table 1 for the deflection force of a
properly tensioned drive. A new set of belts should be
1. Parallel alignment: The use of a laser alignment tool or initially tensioned to the upper limit.
dial indicator is preferred. If a laser alignment tool or dial
indicator is not available, use a straightedge. Turn both
SMALL SHEAVE BELT DEFLECTION FORCE
shafts by hand, checking the reading through one
OUTSIDE DIAMETER Minimum Maximum
complete revolution. Maximum offset must be less than
.0005" (0.127 mm). 2.5” to 4.5” 3.0 lbs 4.75 lbs
(63 mm to 114 mm) (1.4 kgs) (2.2 kgs)
2. Angular alignment: Insert a feeler gauge between the
4.75” to 7.0” 4.0 lbs 6.0 lbs
coupling halves. Check the spacing at 90° increments
(121 mm to 178 mm) (1.8 kgs) (2.7 kgs)
around the coupling (four checkpoints). Maximum
variation must not exceed 0.005" (0.127 mm). Some Table 1 - Deflection Force Per Belt
laser alignment tools will check angular alignment as
well. 7. Check again to ensure the sheaves (152 & 152D) are
parallel, then tighten the sheave capscrews (152C &
3. Replace the coupling guards after setting alignment. 152G), the motor mounting nuts (183B) and the adjusting
screw locknut (183B).
8. Assemble the belt guard (182) and the belt guard brace
(182A) to the unit base (32).

Figure 5 – Coupling Alignment

Operation without guards in place can
V-BELT DRIVE cause serious personal injury, major
For installation of Blackmer V-belt units, first mount the pump property damage, or death.
and the motor base to the unit base. Do not fully tighten the
Do not operate
motor mounting bolts until properly installing and adjusting the without guard
belts as follows: in place

1. Wipe the cone surface of the pump QD hub (152A) and

9. Check the belt tension after 24-48 hours of operating.
the inside of the pump sheave hub with a clean cloth
Recheck the tension periodically and tighten the belts as
moistened with a light grade of machine oil. This will
required. DO NOT overtighten belts. Inspect belts
allow for a more uniform draw and prevent the cone
periodically for signs of excessive wear, and replace as
surfaces from “freezing” before being tightened.
required.
2. With the pump shaft key (35) in place, align the key seat
and slide the QD hub (152A) on the shaft, flange end
first. Slide the large end of the sheave (152) bore over
V-BELT DISASSEMBLY
the taper on the QD hub. Insert the three sheave 1. Remove the belt guard (182) and the guard base (182A).
capscrews (152G) through the clearance holes in the Loosen the adjusting screw locknut (183B) on the motor
sheave, and start them into the tapped holes of the QD base (183) and the motor mounting nuts.
hub (152A). Repeat this procedure to assemble the 2. Ease the tension on the belts (181) by moving the motor
motor QD hub (152E) and sheave (152D). towards the pump to shorten the center distance of the
3. To install the belts (181), shorten the center distance of drive. Remove the belts by sliding them over the sheaves
the drive by moving the motor towards the pump, until the (152 & 152D). DO NOT force the belts over the grooves.
belts can be put on the sheaves (152 & 152D) without 3. To remove the sheave from the hub, first remove the
forcing. three sheave capscrews (152C or 152G). Then screw
4. Align the sheaves so that the faces are parallel, then two of the capscrews into the threaded holes in the
snug up the sheave capscrews (152C & G). sheave hub (152A or E). If the cone grip is hard to break
loose, tap the end of the shaft or the QD hub with soft-
Figure 6 – faced mallet while maintaining pressure on the screw.
V-Belt Adjustment 4. The QD hub should slide smoothly off the shaft. If it is
tight on the shaft, gently pry it loose with a screwdriver or
a small wedge placed in the split part of the flange.
Refer to Blackmer V-Belt Parts List and Instructions for
V-belt drive and guard part numbers.

501-L00 Page 5/12

 MOTOR DRIVEN PUMPS
PRE-START UP CHECK LIST 5. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
1. Inspect complete piping system and supports to ensure “Initial Start Up” section of this manual.
that no piping loads are being placed on the pump.
6. Close the discharge valve and check the differential
2. Verify proper coupling or V-belt alignment. pressure across the pump. Pressure must not exceed the
3. Install pressure gauges in the 1/4" NPT intake and pressure setting of the external bypass valve.
discharge ports located on the pump casing to check 7. With the discharge valve still closed, momentarily close
pump performance after start-up. the manual shut-off valve in the bypass return line to
4. Ensure all valves and fittings in piping system are in the check the pump internal relief valve. The differential
start-up or operating positions. pressure will be approximately 150 and 170 PSI (10.3
5. Jog the pump motor to verify proper pump rotation. and 11.7 bar).
8. The external bypass valve must always be set at least 25
PSI (1.7 bar) lower than the internal pump relief valve.
START UP PROCEDURES NOTE: The normal operating pressure must be at least 5
NOTICE: - 15 PSI (0.3 -1.0 bar) less than the external bypass
valve setting. Pump speeds which result in higher
Consult the "Troubleshooting" sections of this manual if
pressures (nearing the valve setting) forces the liquid to
difficulties during start up are experienced.
recirculate, creating excessive wear on the pump and
1. SLOWLY build pressure in the pump. equipment.
2. Start the motor.
3. Check pressure gauges to ensure the system is
operating within expected parameters. Record the gauge
readings in the "Initial Start Up Information" section of Pumps operating against a closed valve
this manual for future reference. can cause system failure, personal
4. Inspect piping, fittings, and associated system equipment injury and property damage
Hazardous pressure
for leaks, noise, vibration and overheating. can cause personal
injury or property
damage

TRUCK MOUNTED PUMPS

PUMP DRIVE
The pump may be driven by a power take-off through
universal joints. When using universal joints, a splined slip
Failure to set the vehicle emergency joint, properly lubricated, must be used on the connecting jack
brake and chock wheels before shaft to prevent end thrust on the pump shaft. It is very
performing service can cause severe important to install a proper drive line to avoid excessive
personal injury or property damage. wear, vibration and noise (see Fig. 7 and Table 2).
Hazardous pressure
can cause personal
injury or property
General guidelines to follow for proper pump drive:
damage 1. Do not use square slip joints.
2. Use the least number of jack shafts as is practical.
NOTICE: 3. Use an even number of universal joints.
Consult the "General Installation and Operation" section 4. The pump shaft and power take-off shaft must be parallel
of this manual for system information. in all respects. Use an angular level measuring device to
ensure the PTO and pump shaft are parallel to each
other. If necessary, the pump can be shimmed to correct
TRUCK MOUNTING any misalignment. The PTO shaft coming off at the
The pump will operate satisfactorily in any position. When transmission does not need to be perfectly horizontal as
locating the pump on a tank, safety should be the first long as the pump is shimmed to have its shaft parallel in
consideration. The pump can be bolted to the truck frame or all respects to the PTO shaft.
on a saddle hung below the frame, and MUST be adequately 5. The yokes of the universals at both ends of the jack shaft
supported. must be parallel and in phase.
6. The maximum recommended angle between the jack
shaft and the pump shaft is 15 degrees. See 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.

501-L00 Page 6/12

 TRUCK MOUNTED PUMPS
START UP PROCEDURES
NOTICE:
A drive shaft guard between the pto and Consult the "General Pump Troubleshooting" section of
pump must be provided to prevent this manual if difficulties during start up are experienced.
personal injury, property damage, or
death.
Do not operate
without guard
in place
Pumps operating against a closed valve
can cause system failure, personal
injury and property damage
Hazardous pressure
can cause personal
injury or property
damage

1. Open the shut-off valve in the bypass return line.

2. If the tank outlet valve is:
a. Lever Operated - Pull the control knob all the way
out. Manually check the lever under the truck to see
Figure 7 – Pump Drive that it is in the completely OPEN position.
Note: A Drive Shaft Guard between the pump and the b. Discharge Pressure Operated - Keep the discharge
PTO MUST be provided. (Not Shown) line valve closed. When pump is started, it will build up
enough pressure to open the tank outlet valve. NOTE:
Angle of Drive Shaft This type of valve usually requires approximately 20
1° through 5° 6° through 10° 11° through 15° PSI (1.4 bar) differential pressure to open and
Very good Good Fair approximately 15 PSI (1.0 bar) differential pressure to
keep it open. If the piping is quite large, it may be
Table 2
necessary to restrict the discharge line shut-off valve
in order to maintain sufficient pressure to keep the
HYDRAULIC DRIVE tank outlet valve open.
Truck mounted pumps may also be driven hydraulically. 3. Start the pump. Confirm proper pump rotation by checking
Hydraulic motors must be well supported with their shafts the pump rotation arrows.
parallel to the pump shaft in all respects. Blackmer provides 4. Check the pump speed. Pump speed must never exceed
an optional close-coupled hydraulic motor adapter. The the recommended maximum. See “Technical Data” section
adapter provides for straight alignment of a hydraulic motor of this manual.
drive through a solid coupling connected to a straight key
5. Check the pressure gauges to ensure the system is
pump shaft. This coupling connection requires grease
operating within expected parameters. Record the gauge
lubrication every three months at minimum. See the
readings in the "Initial Start Up Information" section of this
"Lubrication" section of this manual.
manual for future reference.
6. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
7. Check the flow rate to ensure the pump is operating within
Operation without shaft protector can the expected parameters. Record the flow rate in the
cause serious personal injury, major “Initial Start Up Information” section of this manual for
property damage, or death. future reference.
Do not operate 8. Close the discharge valve and check the differential
without guard
in place pressure across the pump. It must not exceed the pressure
setting of the external bypass valve.
9. With the discharge valve still closed, momentarily close the
manual shut-off valve in the bypass return line to check the
PRE-START UP CHECK LIST internal pump relief valve. The differential pressure should
1. Check the alignment of the pipes to the pump. Pipes be between 150 and 170 PSI (10.3 and 11.7 bar).
must be supported so that they do not spring away or
10. The external bypass valve must always be set at least 25
drop down when the pump flanges or union joints are
PSI (1.7 bar) lower than the pump internal relief valve.
disconnected.
NOTE: The normal operating pressure must be at least 5 -
2. Install pressure gauges in the 1/4" NPT ports located on
15 PSI (0.3 - 1.0 bar) less than the external bypass valve
the pump casing. These can be used to check the actual
setting. Pump speeds which result in higher pressures
inlet and discharge conditions after pump start-up.
(nearing the valve setting) forces the liquid to recirculate,
3. Inspect complete piping system to ensure that no piping
creating excessive wear on the pump and equipment.
loads are being placed on the pump.
4. Secure appropriate hose connections.

501-L00 Page 7/12

 TRUCK MOUNTED PUMPS
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.

MAINTENANCE

Failure to set the vehicle emergency Failure to disconnect and lockout

brake and chock wheels before electrical power before attempting
performing service can cause severe maintenance can cause shock, burns or
Hazardous
personal injury or property damage death
Hazardous voltage.
machinery can
Can shock, burn or
cause serious
cause death.
personal injury.

Failure to relieve system pressure prior

Failure to disconnect and lockout to performing pump service can cause
electrical power or engine drive before serious personal injury or property
attempting maintenance can cause damage. Systems with meters will still
Hazardous
severe personal injury or death be pressurized even after the hose is
Hazardous pressure
machinery can can cause serious emptied
cause serious personal injury or
personal injury. property damage

Disconnecting fluid or pressure If pumping hazardous or toxic fluids,

containment components during pump system must be flushed and
operation can cause serious personal decontaminated, inside and out, prior to
injury or property damage. performing service or maintenance
Hazardous pressure
can cause personal Hazardous or toxic
injury or property fluids can cause
damage serious injury.

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

STRAINERS
Strainers must be cleaned regularly to avoid pump
starvation. Schedule will depend upon the application and
conditions.
Recommended Grease:
LUBRICATION Mobil® - Mobilgrease XHP222,
NOTICE: Exxon® - Ronnex MP Grease,
To avoid possible entanglement in moving parts do not or equivalent Lithium grease.
lubricate pump bearings, hydraulic adapter coupling or
Greasing Procedure:
any other parts while pump is running 1. Remove the grease relief fittings (76A) from the bearing
NOTICE: covers (27) or hydraulic motor adapter (135).
If pumps are repainted in the field, ensure that the 2. SLOWLY apply grease with a hand gun until grease
grease relief fittings (76A) are functioning properly after begins to escape from the grease relief fitting port. Discard
painting. Do NOT paint them closed. Remove any excess grease in accordance with the proper codes and
excess paint from the fittings. regulations.
3. Replace the grease relief fittings (76A).
Lubricate pump bearings and hydraulic motor couplings (if
equipped) every three months at a minimum. More frequent DO NOT over grease pump bearings. While it is normal for
lubrication may be required, depending on the application some grease to escape from the grease tell-tale hole after
and the operating conditions. 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).

501-L00 Page 8/12

 MAINTENANCE
VANE REPLACEMENT 5. To remove locknuts and lockwashers (24A and 24B):
a. Bend up the engaged lockwasher tang and rotate
NOTICE:
the locknut (24A) counterclockwise to remove it from
Maintenance shall be performed by qualified technicians
the shaft
only, following the appropriate procedures and warnings
as presented in this manual. b. Slide the lockwasher (24B) off the shaft. Inspect the
lockwasher for damage and replace as required.
1. Drain and relieve pressure from the pump and system as
required. c. Repeat steps a and b on the opposite shaft end.
2. Remove the head assembly from the outboard (non- 6. Remove the head capscrews (21) and carefully pry the
driven) side of the pump according to steps 4 - 9 in the head (20) away from the casing (12).
"Pump Disassembly" section of this manual. 7. Slide the head (20) off the shaft. The head O-ring (72),
3. Turn the shaft by hand until a vane (14) comes to the top bearing (24), mechanical seal stationary seat and
(12 o'clock) position of the rotor. Remove the vane. stationary O-ring (153A & 153D) will come off with the
head assembly. Remove and discard the head O-ring.
4. Install a new vane (14), ensuring that the rounded edge
is UP, and the relief grooves are facing towards the a. Pull the bearing (24) from the housing in the head
direction of rotation. See Figure 8. (20).
5. Repeat steps 3 and 4 until all vanes have been replaced. b. To remove the mechanical seal stationary seat
(153A), use the blunt end of a screw driver to gently
6. Reassemble the pump according to the "Pump push the backside of the stationary seat from the
Assembly." section of this manual. head. Place a cloth under the seal to avoid damage.
Be careful not to contact the polished face of the
seal during removal. Remove and discard
mechanical seal stationary O-ring.
8. Carefully pull the rotating seal assembly, consisting of
seal jacket (153C), rotating seal face and rotating O-ring
(153B & 153E) from the shaft. Remove and discard the
rotating O-ring (153E).
9. Carefully remove the disc (71).
10. Carefully pull the rotor and shaft (13) from the casing
(12). While one hand is pulling the shaft, cup the other
hand underneath the rotor to prevent the vanes (14) and
push rods (77) from falling out. Carefully set the rotor and
shaft aside for future vane replacement and reassembly.
NOTICE:
The rotor and shaft weighs approximately 34
Figure 8 – Vane Installation pounds (15 kg). Be careful not to pinch the
hand under the rotor and shaft when removing
from casing.
PUMP DISASSEMBLY 11. Lay the pump flat with the remaining head (20) facing
NOTICE: upward to remove the head assembly mechanical seal
Follow all hazard warnings and instructions provided in (153) and disc (71) from the outboard side of the pump,
the "maintenance" section of this manual. as instructed in steps 6 - 9 above.
1. Drain and relieve pressure from the pump and system as 12. If necessary, remove the liner (41) by tapping around the
required. outside diameter of the liner with a hard wood drift and a
hammer until it is driven from the casing (12).
2. Starting on the inboard (driven) end of the pump, clean
the pump shaft thoroughly, making sure the shaft is free
of nicks and burrs. This will prevent damage to the
mechanical seal when the inboard head assembly is
removed.
3. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket. On the 2-
inch pump models the dirt shield (123) will come off with
the bearing cover.
4. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket. On the 2-
inch pump models the dirt shield (123) will come off with
the bearing cover..

501-L00 Page 9/12

 MAINTENANCE
PUMP ASSEMBLY c. After the bottom vanes and push rods are installed,
Before reassembling the pump, inspect all parts for wear or insert the rotor and shaft (13) fully into the casing
damage, and replace as required. Wash out the bearing/seal (12).
recess of the head and remove any burrs or nicks from the d. Install the remaining vanes (14) into the top positions
rotor and shaft. Remove any burrs from the liner. of the rotor.
Reassemble the OUTBOARD side of the pump first: 6. Install the disc (71) on the inboard side of the pump with
1. On 2-inch pump models, apply grease to the liner key the seal cavity facing outward and the disc relief hole
groove in the pump casing to hold the key (74) in place located as shown in Figure 9.
during liner installation. Install key in groove before 7. Install a new head O-ring (72) in the groove on the inside
starting liner (41) into pump casing (12). On 3-inch pump face of the head (20). Lay the O-ring flat and start in on
models, install the liner key (74) in the groove on top of one side of the groove, stretching ahead with the fingers,
the liner (41). as shown in Figure 10.
2. Align the liner key (74) with the pump casing keyway and
start the liner (41) into the casing (12) with the slots in the
liner towards the INTAKE port, and the hole pattern in the
liner towards the DISCHARGE port. Uniformly tap the
outer edge of the liner with a rubber mallet to fully insert
into the casing. NOTE: If the liner is installed backwards,
it will restrict the port openings and cause cavitation,
noise and loss of capacity.
3. Place the disc (71) against the liner (41) with the seal
cavity outward and disc relief hole located as shown in Figure 10 – Head O-ring Installation
Figure 9. 8. MECHANICAL SEAL INSTALLATION
Rotating Assembly –
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor.
b. Slide the seal jacket assembly (153C) over the shaft
and into the disc cavity with the drive tangs of the
jacket towards the rotor. Rotate the jacket assembly
to engage the drive tangs in the rotor slots.
c. Install a new rotating O-ring (153E) in the rotating
seal face (153B). Align and insert the rotating
assembly into the seal jacket with the polished face
outward. Clean the polished face with a clean tissue
and alcohol.
Stationary Seat -
a. Apply a small amount of motor oil in the seal recess
of the head (20).
b. Install a new stationary O-ring (153D) in the
stationary seat (153A). Align the pin in the stationary
Figure 9 - Disc Relief Hole Location
seat with the slot in the head recess and push the
4. Without installing the head O-ring or mechanical seal seat fully into the seal recess with the polished face
components, temporarily attach the outboard head (20) outward. Clean the polished face with a clean tissue
and bearing (24) to the casing (12). Install and hand and alcohol.
tighten two head capscrews (21), 180 degrees apart. This 9. Carefully install the head assembly (20) over the shaft.
head will be used to hold and align the rotor and shaft Do not contact the end of the shaft with the polished face
(13) while the inboard side of the pump is assembled. of the stationary seat. Rotate the head so that the drain
5. Remove the vanes (14) and push rods (77) from the rotor hole (tell-tale hole), located at the back of the bearing
and shaft assembly (13). Inspect for wear and damage, cavity, faces downward when the pump is mounted for
and replace as follows: operation. Install and uniformly tighten four head
a. Partially install the non-driven end of the rotor and capscrews (21) 90° apart, torquing to 30 lbs ft (40.7 Nm).
shaft (13) into the open side of the pump casing (12). 10. Hand pack the spherical roller bearing (24) with grease.
b. Leave part of the rotor outside of the casing (12) so See the "Lubrication" section for recommended greases.
that the bottom vanes (14) can be installed and held 11. Install the bearing (24) into the head recess. Ensure the
in place as the push rods (77) are installed in the bearing is fully and squarely seated in the head (20).
push rod holes of the rotor. Insert the new vanes into 12. Turn the pump casing around and remove the outboard
the rotor slots with the rounded edges outward, and head previously attached.
the vane relief grooves facing TOWARDS the
13. Install the outboard head (20), mechanical seal (153) and
direction of rotation. See Figure 8.
bearing (24) as instructed in steps 6 through 11.

501-L00 Page 10/12

 MAINTENANCE
14. Rotate the shaft by hand to engage the mechanical seal f. Tighten the opposite locknut (24A) by hand until it is
drive tangs, and to test for binding or tight spots. If the snug against the bearing (24). Then, using a spanner
rotor does not turn freely, lightly tap the rims of the heads wrench, tighten the nut the width of one lockwasher
with a soft faced mallet until the correct position is found. tang. Tighten just past the desired tang, then back off
Install all of the remaining head capscrews (21) for each the nut to align the tang with the locknut slot. Secure the
head (20) and uniformly torque to 30 lbs ft (40.7 Nm). nut by bending the aligned lockwasher tang into the slot
15. LOCKNUT ADJUSTMENT in the locknut. The pump should continue to turn freely
when rotated by hand.
It is important that the bearing locknuts (24A) and lockwashers
(24B) be installed and adjusted properly. Overtightening g. To check adjustment, grasp the nut and washer with
locknuts can cause bearing failure or a broken lockwasher fingers and rotate back and forth. If this cannot be done,
tang. Loose locknuts will allow the rotor to shift against the one or both locknuts are too tight and should be
discs (71), causing wear. See Figure 11. alternately loosened one stop at a time (.001" – 25
microns). Begin by loosening the locknut adjusted last.
16. Inspect the grease seal (104) for wear or damage and
replace as required. Grease the outside diameter of the
grease seal and push it into the inboard bearing cover
(27) with the lip of the seal inward.
17. Attach a new bearing cover gasket (26) and the bearing
cover (27) to the inboard head (20). Make sure the
grease fittings (76) are accessible. Install and torque the
bearing cover capscrews (28) to 30 lbs ft (40.7 Nm).
18. Install the grease seal (104) and bearing cover (27) on
the opposite side of the pump as instructed in steps 16
and 17.
Figure 11 - Locknut Adjustment 19. On 2-inch pump models, push the dirt shield (123A) over
a. On both ends of the pump shaft, Install a lockwasher the inboard and outboard shafts and firmly against the
(24B) with the tangs facing outward, followed by a bearing cover (27).
locknut (24A) with the tapered end inward. Ensure the 20. Attach the shaft protector (186) to the non-driven shaft
inner tang "A" of the lockwasher is located in the slot in end of double ended pumps.
the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts (24A) to ensure that the bearings
(24) are bottomed in the head recess. DO NOT
overtighten and bend or shear the lockwasher inner Operation without guards in place can
tang. cause serious personal injury, major
c. Loosen both locknuts one complete turn. property damage, or death.
d. Tighten one locknut until a slight rotor drag is felt when Do not operate
without guard
turning the shaft by hand. in place
e. Back off the nut the width of one lockwasher tang "B".
Secure the nut by bending the closest aligned 21. See "Pre-Start Up Check List" and "Start Up Procedures"
lockwasher tang into the slot in the locknut. The pump sections of this manual prior to restarting pump operation.
should turn freely when rotated by hand.

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

SYMPTOM PROBABLE CAUSE

Pump Not Priming 1. Pump not wetted.
2. Worn vanes.
3. Internal control valve closed.
4. Strainer clogged.
5. Inlet line or valves clogged or too restrictive.
6. Pump vapor-locked.
7. Pump speed too low for priming.
8. Relief valve partially open, worn or not seating properly.

501-L00 Page 11/12

 TROUBLESHOOTING - continued
SYMPTOM PROBABLE CAUSE
Reduced Capacity 1. Pump speed too low.
2. Internal control valve not fully open.
3. Excessive restriction in the inlet line (i.e.: undersized piping, too many elbows & fittings,
clogged strainer, etc.).
4. Damaged or worn parts (vanes, cylinder, 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 on the pump due to:
a. Undersized or restricted fittings in the inlet line.
b. Pump speed too fast.
c. Pump too far from fluid source.
2. Running the pump for extended periods with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line – truck mounted pumps (See “Pump Drive”).
5. Misalignment of pump, reducer, or motor - base mounted pumps.
6. Bearings worn or damaged.
7. Vibration from improperly anchored piping.
8. Bent shaft, or drive coupling misaligned.
9. Excessively worn rotor.
10. Malfunctioning valve in the system.
11. Relief valve setting too low.
12. Liner installed backwards.
13. Damaged vanes (see following category).
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/drive shaft misalignment.
5. Excessively worn 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. Bearings overgreased.
5. Excessive cavitation.
6. Mechanical seal faces cracked, scratched, pitted or dirty.
Overload on Motor 1. Motor Horsepower not sufficient for application.
2. Improper wiring and/or low voltage to motor.
3. Misalignment
4. Excessive pressure or speed.
5. Bearing locknuts adjusted improperly.
6. Faulty or worn bearings.
7. Rotor rubbing against discs or liner.
8. Dirty mechanical seal faces.

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