MDE-4096C

Blackmer® Global Dispenser Pump Operation,

Maintenance and Kit Installation Manual
April 2008

Introduction

Purpose
This document provides information regarding the operation and maintenance of Blackmer®
Global Dispenser Pumps (GDPs) as used in Gilbarco® self-contained products.

This document also provides step-by-step instructions for kit installation. It is recommended
that kits be installed by a Gilbarco Authorized Service Contractor (ASC).

IMPORTANT INFORMATION
Blackmer GDP pumps must only be installed in systems that have been designed by
qualified engineering personnel. The system must conform to all applicable local and
national regulations and safety standards. This manual must be kept with the pump.

Intended Users
This document is intended for Gilbarco ASCs.

Table of Contents
Topic Page
Introduction 1
Important Safety Information 4
Installation 6
Operation 7
Maintenance 8
Repair Kits 19
Pump Parts List 21
Troubleshooting 29

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 1
Introduction

Required Tools
The following tools are required for the installation of the kit:
• 5 mm Allen® wrench
• 1/4-inch Allen wrench
• Heavy snap ring pliers
• Ratchet wrench
• 16 mm socket
• 13 mm or 1/2-inch socket
• Rubber mallet
• Torque wrench

Required Reading
Before servicing the pump, the technician must read, understand, and follow this document.
Failure to do so may adversely effect the safe use and operation of the equipment.

Related Documents
Document Number Title GOLD Library
MDE-3802 Encore® and Eclipse® Site Preparation Encore and Eclipse
Manual
MDE-2833 Pumps and Dispensers Site Preparation Site Prep
MDE-2530 Pump and Dispenser Installation Manual Advantage® and Legacy® models
MDE-3985 Encore Installation Manual Encore and Eclipse

Pump Model Identification

The pump model identification plate is located on the rear cover. The pump model number
begins with M00955B. For example, M00955B207 is a complete model number.

Abbreviations and Acronyms

Term Description
ASC Authorized Service Contractor
cmHg centimeter of mercury
CW Clockwise
CCW Counterclockwise
GDP Global Dispenser Pump
gpm gallons per minute
inHg inch of mercury
lbs pound-force
lpm liters per minute
mm millimeter
N/A Not applicable
Nm Newton-meter
OIML International Organization of Legal Metrology*
Opt. Optional

Page 2 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Introduction

Term Description
PCV Pressure Control Valve
psi pounds per square inch
RPM Revolutions Per Minute
Std Standard
UHF Ultra High Flow
* OIML Switch (optional) monitors air to fuel mix and is used primarily in
Europe.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 3
Important Safety Information

Important Safety Information

This section introduces the hazards and safety precautions Read the Manual
associated with installing, inspecting, maintaining or servicing Read, understand and follow this manual and any other
this product. Before performing any task on this product, read labels or related materials supplied with this equipment. If you
this safety information and the applicable sections in this do not understand a procedure, call a Gilbarco Authorized
manual, where additional hazards and safety precautions for Service Contractor or call the Gilbarco Support Center at
your task will be found. Fire, explosion, electrical shock or 1-800-800-7498. It is imperative to your safety and the safety
pressure release could occur and cause death or serious of others to understand the procedures before beginning
injury, if these safe service procedures are not followed. work.

Preliminary Precautions Follow the Regulations

You are working in a potentially dangerous environment of Applicable information is available in National Fire Protection
flammable fuels, vapors, and high voltage or pressures. Only Association (NFPA) 30A; Code for Motor Fuel Dispensing
trained or authorized individuals knowledgeable in the related Facilities and Repair Garages, NFPA 70; National Electrical
procedures should install, inspect, maintain or service this Code (NEC), Occupational Safety and Hazard Association
equipment. (OSHA) regulations and federal, state, and local codes. All
these regulations must be followed. Failure to install, inspect,
Emergency Total Electrical Shut-Off maintain or service this equipment in accordance with these
The first and most important information you must know is codes, regulations and standards may lead to legal citations
how to stop all fuel flow to the pump/dispenser and island. with penalties or affect the safe use and operation of the
Locate the switch or circuit breakers that shut off all power to equipment.
all fueling equipment, dispensing devices, and Submerged
Turbine Pumps (STPs). Replacement Parts
Use only genuine Gilbarco replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
! ! WARNING Gilbarco replacement parts could create a safety hazard and
violate local regulations.
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical power to the pump/ Safety Symbols and Warning Words
dispenser. This means that even if you activate This section provides important information about warning
these stops, fuel may continue to flow symbols and boxes.
uncontrolled. Alert Symbol

You must use the TOTAL ELECTRICAL SHUT-

OFF in the case of an emergency and not the This safety alert symbol is used in this manual and
console’s ALL STOP and PUMP STOP or on warning labels to alert you to a precaution which must be
similar keys. followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible
injury or death.
Signal Words
Total Electrical Shut-Off Before Access These signal words used in this manual and on warning
Any procedure that requires access to electrical components labels tell you the seriousness of particular safety hazards.
or the electronics of the dispenser requires total electrical The precautions below must be followed to prevent death,
shut off of that unit. Understand the function and location of injury or damage to the equipment:
this switch or circuit breaker before inspecting, installing, DANGER: Alerts you to a hazard or unsafe practice
maintaining, or servicing Gilbarco equipment. ! which will result in death or serious injury.
WARNING: Alerts you to a hazard or unsafe practice
Evacuating, Barricading and Shutting Off ! that could result in death or serious injury.
Any procedure that requires access to the pump/dispenser or CAUTION with Alert symbol: Designates a hazard or
STPs requires the following actions: ! unsafe practice which may result in minor injury.
CAUTION without Alert symbol: Designates a hazard
or unsafe practice which may result in property or
equipment damage.
• An evacuation of all unauthorized persons and vehicles
from the work area Working With Fuels and Electrical Energy
• Use of safety tape, cones or barricades at the affected
unit (s) Prevent Explosions and Fires
• A total electrical shut-off of the affected unit (s) Fuels and their vapors will explode or burn, if ignited. Spilled
or leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.

Page 4 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Important Safety Information

No Open Fire In an Emergency

Inform Emergency Personnel
Open flames from matches, lighters, welding Compile the following information and inform emergency
torches or other sources can ignite fuels and their vapors. personnel:
• Location of accident (for example, address, front/back of
building, and so on)
No Sparks - No Smoking • Nature of accident (for example, possible heart attack, run
Sparks from starting vehicles, starting or using power tools, over by car, burns, and so on)
burning cigarettes, cigars or pipes can also ignite fuels and • Age of victim (for example, baby, teenager, middle-age,
their vapors. Static electricity, including an electrostatic elderly)
charge on your body, can cause a spark sufficient to ignite • Whether or not victim has received first aid (for example,
fuel vapors. Every time you get out of a vehicle, touch the stopped bleeding by pressure, and so on)
metal of your vehicle, to discharge any electrostatic charge • Whether or not a victim has vomited (for example, if
before you approach the dispenser island. swallowed or inhaled something, and so on)

Working Alone ! WARNING

It is highly recommended that someone who is capable of Gasoline ingested may cause unconsciousness
rendering first aid be present during servicing. Familiarize and burns to internal organs.
yourself with Cardiopulmonary Resuscitation (CPR) methods, Do not induce vomiting.
if you work with or around high voltages. This information is Keep airway open.
available from the American Red Cross. Always advise the Oxygen may be needed at scene.
station personnel about where you will be working, and Seek medical advice immediately.
caution them not to activate power while you are working on
the equipment. Use the OSHA Lockout/ Tagout procedures. If
you are not familiar with this requirement, refer to this ! WARNING
information in the service manual and OSHA documentation.
Gasoline inhaled may cause unconsciousness
Working With Electricity Safely and burns to lips, mouth and lungs.
Ensure that you use safe and established practices in Keep airway open.
working with electrical devices. Poorly wired devices may Seek medical advice immediately.
cause a fire, explosion or electrical shock. Ensure that
grounding connections are properly made. Take care that
sealing devices and compounds are in place. Ensure that you ! WARNING
do not pinch wires when replacing covers. Follow OSHA Gasoline spilled in eyes may cause burns to eye
Lockout/Tagout requirements. Station employees and service tissue.
contractors need to understand and comply with this program Irrigate eyes with water for approximately 15
completely to ensure safety while the equipment is down. minutes.
Seek medical advice immediately.
Hazardous Materials
Some materials present inside electronic enclosures may !
present a health hazard if not handled correctly. Ensure that ! WARNING
you clean hands after handling equipment. Do not place any Gasoline spilled on skin may cause burns.
equipment in the mouth. Wash area thoroughly with clear water.
Seek medical advice immediately.
! WARNING
The pump/dispenser contains a chemical known to the IMPORTANT: Oxygen may be needed at scene if gasoline
State of California to cause cancer. has been ingested or inhaled. Seek medical advice
immediately.

! WARNING Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of
The pump/dispenser contains a chemical known to the machines and equipment in which the unexpected
State of California to cause birth defects or other energization or start-up of the machine(s) or equipment or
reproductive harm. release of stored energy could cause injury to employees or
personnel. Lockout/Tagout applies to all mechanical,
hydraulic, chemical or other energy, but does not cover
electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical
Hazards, 29 CFR Part 1910.333 contains specific Lockout/
Tagout provision for electrical hazards.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 5
Installation

Installation

Inlet Fittings
The Blackmer GDP is shipped without inlet fittings. Appropriate inlet fittings must be
installed on site.

Configuration Table
The following table lists three possible inlet configurations.
Sl. No Inlet Configuration
1 1-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 150# Union (Gilbarco part
numbers R11493-50 and K12179)
2 1-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 300# Union (Gilbarco part
numbers R11493-50 and Q10846-08)
3 3-Bolt Flange with flexible connector (order Gilbarco kit number K94194)

Installing the Fittings

To install the fittings, proceed as follows:

1 Apply a pipe sealant (that is approved for use with petroleum products) to the threads.

CAUTION
Do not use Teflon® tape. Teflon tape may shred off and get caught within
components.

2 Hand-tighten, and then wrench-tighten approximately by another 3 turns. The pump body is
aluminum.

CAUTION
Do not overtighten inlet fittings. The pump body is made of aluminum.
Overtightening may strip pump threads.

3 Check for leaks (refer to the section “Troubleshooting Table” on page 29).

Page 6 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Operation

Operation

PCV Adjustment
Pressure Control Valves (PCVs) must be set to the desired single hose operation pressure. A
retaining ring must be in place at all times during PCV adjustment.

! WARNING
Not using a retaining ring can release hazardous pressure that can
cause personal injury or property damage.

Always ensure that the retaining ring is in place before making the PCV
adjustment.

Take appropriate safety precautions. Failure to do so may result in

personal injury or property damage.

Note: Numbers within parentheses in the procedural steps in the manual refer to the numbers
mentioned in the referenced figures.

To set the proper PCV operation pressure, proceed as follows:

1 To increase the pressure setting, turn the PCV cover (13) inward or clockwise (CW) using a
16 mm socket wrench (see Figure 3 on page 11).

2 To decrease the pressure setting, turn the PCV cover (13) outward or counterclockwise (CCW)
using a 16 mm socket wrench (see Figure 3 on page 11).

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 7
Maintenance

Maintenance

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

Notes:1) Before removing plugs or covers, ensure that approved container and absorbent
materials are ready to contain any released fuel.

2) Follow all safety procedures for working around fuel and fuel vapors.

Draining Pump

Figure 1: Typical Plug Location

Plug, Left Side

Casing (11)

Plug, Lower Right Face (11) Plug, Upper

Face (11)

Front Head Cap Screw

To drain the bulk of the fluid from the pump, proceed as follows:
Note: Residual fluid may remain in the pump.

1 Put the approved tray in place to collect the fuel.

2 Remove the plug (11) on the upper face of the head, directly to the right of the strainer cover
(19). This port may be used to monitor vacuum (see Figure 1).

Page 8 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Maintenance

3 Remove the plug (11) on the lower right face of the head (9). Fluid will be emptied by
removing this plug. Fluid must be properly contained during draining procedure.
Note: Pump contains up to 0.5 liters of fluid. Do not use this port to monitor system pressure.

4 If sump drainage is desired, remove the plug (11) near the mounting hole on the left side of
pump casing (1).

5 Manually turn the pump pulley counterclockwise (CCW) to aid in fluid removal.

6 Properly dispose of all fluid drained from pump.

7 After pump is drained, replace all plugs (11) using a non-hardening pipe sealant.
Note: Do not use Teflon tape.

Strainer/Check Valve Removal

Check valves (if equipped) should be replaced only if pump is experiencing frequent prime
loss, indicating that the check valve is not functioning. Check valve should be installed when
tank check valve is not available. Always use strainers with or without check valves. Strainer
must be kept clean to ensure proper operation and pump life.

To remove the strainer/check valve, proceed as follows:

1 Lower pump fluid level by removing the plug (11) located at the right of the strainer cover and
rotating the pump shaft counterclockwise (CCW) approximately 10 turns (see Figure 2 on
page 10).
Note: Removing the plug allows air to enter.

2 Remove the three strainer cover screws (21).

3 Remove the strainer cover (19). Inspect cover O-Ring (18) for damage. If damaged, discard
O-Ring and replace with new O-Ring.

4 Carefully pull out strainer (17). Keep strainer in a horizontal position to avoid contaminating
pump with strainer debris. It may be necessary to use a small tool to gently hook the inside of
the metal strainer end cap.

5 If equipped, remove the inlet check valve assembly (16). Inspect for cracked or otherwise
damaged O-Rings. Replace if damaged.

6 Lift dome strainer (25) out from the bore located behind the check valve assembly. Inspect
strainer for damage. Clean and/or replace, if necessary.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 9
Maintenance

Strainer/Check Valve Installation

To install the strainer/check valve, proceed as follows:

1 If equipped with the check valve option, insert the dome strainer (25) into the bore (see
Figure 2).

Figure 2: Strainer/Check Valve

Optional Dome
Strainer (25)

Optional
Check
Valve (16)

Screws (21)

Strainer Cover (19) Strainer (17)

Strainer Support

O-Ring (18)

2 Clean the debris from the check valve, especially at the O-Ring seats.

3 Lubricate O-Ring before installing check valve assembly.

4 Insert the check valve assembly (16) or check cap (30) into corresponding pump bore as
shown (see Figure 2). Press the assembly squarely over receiving cylindrical surface until O-
Ring seats firmly over the surface and holds assembly in position.

5 Insert new or cleaned strainer (17) into bore, over check valve assembly.

6 Clean debris from strainer cover O-Ring groove and install O-Ring (18). If O-Ring does not
stay in place, use a small amount of all purpose grease to hold the O-Ring in groove.

7 Install strainer cover (19) with screws (21). Hand tighten, alternating between each screw to
keep the cover parallel to the casing face. Torque the screws to 150 in. lbs (17 Nm). Do not
overtighten. Overtightening may cause damage to screw or casing.

8 Replace the plug (11) in the hole located to the right of the strainer cover (see Figure 1 on
page 8).

Page 10 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Maintenance

PCV Removal

CAUTION
Excessive wear on the PCV can cause improper pump performance, including
flow loss or excessive or low discharge pressure.

To remove the PCV, proceed as follows:

1 Drain the pump following the procedure provided in the section “Draining Pump” on page 8.

2 Remove the snap ring (15) (see Figure 3).

3 Using a 16 mm socket wrench, turn the valve cover (13) outward or counterclockwise (CCW)
until completely removed.

4 Remove the spring (12) and valve (10).

5 If the valve does not come out with the spring, use needle nose pliers to remove it from the
bore.

PCV Installation

To install the PCV, proceed as follows:

1 Inspect valve (10) for damage or excessive wear. Replace if necessary.

2 Install PCV in the reverse order of removal (see Figure 3).

Figure 3: PCV

Valve Cover (13)

Snap Ring (15)

Valve (10)

Spring (12)

Cover O-Ring (14)

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 11
Maintenance

3 Apply a light application of grease on the cover of the O-Ring (14) to prevent the O-Ring from
being damaged during installation.

IMPORTANT INFORMATION
Modification of PCV or failure to correctly install all components of the PCV will void
any regulating agency recognition applicable to this pump.

4 When the pump is operating at full speed, the discharge pressure must not exceed 50 psi (3.5
bar) with any discharge restriction (fully open to fully close discharge). If the pressure exceeds
50 psi (3.5 bar), refer to “PCV Adjustment” on page 7.

Pump Cartridge Removal

CAUTION
Damage or excessive wear to pump cartridge can cause low suction,
low flow, lock-up or excessive noise.

Note: Avoid introducing contamination into the unit during disassembly or installation of the
cartridge. Keep Parts clean.

To remove the pump cartridge, proceed as follows:

Note: Refer to the appropriate exploded view of pump and see Figure 7 on page 15.

1 Drain the pump following the procedure provided in the section “Draining Pump” on page 8.

2 Remove belt and pulley.

3 Remove strainer, check valve, and PCV. Refer to “Strainer/Check Valve Removal” on page 9
and “PCV Removal” on page 11 for disassembly instructions.

4 Remove the 10 head capscrews (5).

5 Slightly rotate the head (9) counterclockwise (CCW) around pump cartridge to provide
exposed edges to grasp.

6 Remove head (9) from pump casing.

7 If the pump cartridge (7) comes off with head, remove by rotating and pulling the cartridge
from the head bore (see Figure 7 on page 15).

8 If the cartridge remains in the pump casing, grasp the shaft and/or liner and pull while slightly
turning back and forth. If necessary, gently tap around the circumference with a rubber mallet
to loosen the cartridge assembly. Ensure that you keep it coaxial with the bore.

Page 12 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Maintenance

CAUTION
Do not pry the cartridge out against the side walls, as this will damage
the gasket seal surface.

Pump Cartridge Installation

Preliminary Steps

CAUTION
To prevent O-Ring damage, break corner on the pump body and cover
at cartridge insertion point, as shown in Figures 4 through 6. Ensure
that you remove any residual matter after you complete this procedure,
as this may cause the pump to fail or wear prematurely.

Figure 4: Pump Cover

Using a file or sand paper,

break corner as shown
(See Figure 6 on page 14)

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 13
Maintenance

Figure 5: Pump Body

Using a file or
sand paper, break
corner as shown
(See Figure 6)

Figure 6: Breaking Corner

0.060” Max.

35°

Note: This figure represents a rough

approximation.

To install the pump cartridge, proceed as follows:

1 Install the wave spring (6) in the cartridge bore with the dowel pin hole exposed by the gap in
the wave spring (see Figure 7 on page 15).

Page 14 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Maintenance

Figure 7: Pump Cartridge

Head Gasket (8)

Direction of
Wave Spring (6)
Pump Cartridge Pump
Insertion Cartridge (7)

2 Lightly grease the O-Rings and the bore in which they fit using silicone grease.

3 Align the pump cartridge dowel pin with the dowel pin hole and slide in the pump cartridge
(7). If dowel pin is in the hole, you should be able to rotate the cartridge very lightly back and
forth and feel the positive stops. The wave spring deflection will also be felt when the
cartridge is pressed in axially.

4 Insert provided guides into screw holes. The guides will orient gasket as well as hold it in
position.

5 Install the head gasket (8). If needed, apply a thin film of motor oil onto the mating surface to
affix areas of the gasket that do not retain their position.

IMPORTANT INFORMATION
Ensure that you have completed the steps described in the “Preliminary Steps” section
on page 13, before you proceed to step 6.

6 Carefully install the head (9) over the cartridge. Push head in until it comes approximately
1/4-inch from the casing face.

7 Carefully replace guides with head screws, threading each of them in a few turns.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 15
Maintenance

8 Alternating between the four screws closest to the shaft, draw in the head approximately one
turn on the screw at a time in order to keep the head parallel to the casing.

Notes:1) It is recommended that you tighten alternately opposing bolts on the other side of the
cover instead of tightening the adjacent bolts.

2) Screws will become very tight if faces are not kept parallel. If necessary, return to
step 3 and check to ensure that the cartridge pin is still aligned with the hole.

9 Once the head is fully drawn in, torque the four screws to 200 in. lbs (23 Nm).

10 Before tightening the remaining head screws, check that the pump shaft turns freely and
uniformly. If so, tighten the remaining screws to 200 in. lbs (23 Nm) and check that the pump
shaft turns freely and uniformly.

11 Reinstall inlet check valve, strainer, and PCV as per previous instructions.

12 Reinstall belt and pulley (see step 1 on page 32).

13 Purge the unit of air and check for leaks.

Sump Float Removal

Pump will have poor suction or sump overflow if sump float mechanism is worn or damaged.

To remove the sump float, proceed as follows:

1 Drain the pump by following the procedure pertained in the section “Draining Pump” on
page 8.

2 Remove the pump from the dispenser per dispenser installation instructions.

3 Remove the ten sump cover screws (5) (see Figure 8 on page 17).

4 Lift off the sump cover (4) and gasket (3). Inspect the gasket and replace, if worn or damaged.

5 The sump return float mechanism should operate freely. At full down position, the float valve
should center and seat against the rubber seal surface. If it does not seat, or parts are worn or
damaged, remove the sump float assembly and replace.

Notes:1) The sump overflow float mechanism (if present) should operate freely. The float valve
should center and seat against the rubber seal surface when float is lifted straight up.

2) Either the sump float assembly (2) or the sump overflow float mechanism (23) can be
removed by removing the two sump base mounting screws (24).

Page 16 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Maintenance

Sump Float Installation

To install the sump float, proceed as follows:

1 Install the sump return float assembly (2) or sump overflow float assembly (23), holding the
mount to the casing with one finger and inserting the two screws (24) with the other hand.
Ensure that the rubber washer has not fallen out and is properly seated in the recess of the float
assembly mount (see Figure 8).

Figure 8: Sump Float Assembly

Sump Overflow Float Assy. Option (23)

Sump Cover Screws (5)

Sump Cover (4)

Gasket (3)
Sump Return Float Assy. (2)

Mounting Screws (24)

2 Tighten the screws (24) to a torque of 18 in. lbs (2 Nm).

3 Check float mechanism. It should operate freely. At full down position, the sump return float
valve should center and seal against the rubber seal surface. The sump overflow float assembly
should seat when the float is fully elevated.

4 Install the sump cover gasket (3). Correctly position the gasket onto all sealing surfaces.

5 Lower the sump cover (4) gently into place over the gasket with the pins aligned, while
ensuring that you do not move the gasket.

6 Install and tighten the center-most sum cover screw (5) to 200 in. lbs (23 Nm).

7 Install the remaining sump cover screws and tighten to 200 in. lbs (23 Nm), alternating in a
cross pattern.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 17
Maintenance

OIML Switch Removal

To remove OIML switch, proceed as follows:

1 Cut and remove tamper resist wire.

2 Using a wrench, rotate the OIML Switch assembly (22) in a counterclockwise (CCW)
direction and remove it (see Figure 9 on page 21).

CAUTION
Do not allow debris to fall into open port.

OIML Switch Installation

To install the OIML switch, proceed as follows:

1 Apply a very thin film of thread sealing compound onto the thread, beginning at about 3 mm
from the end.

CAUTION
Thread sealing tape is not advised as it may cause contamination.

2 Rotate the OIML switch assembly (22) threads in a clockwise (CW) direction into the sump
vent port by hand and tighten firmly with wrench (see Figure 9 on page 21).

CAUTION
Do not allow debris to fall into open port.

3 Secure new tamper resist wire through appropriate holes in the switch body and pump casing
tab.

Page 18 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Repair Kits

Repair Kits

Table of Kits
The following table lists fourteen repair kits.

Note: Kits listed specifically as Ultra High Flow (UHF) are for Ultra High Flow products
manufactured in Europe only.
Gilbarco Reference
Kit Number Kit Description No. Part Description Quantity Used On

Standard and
High Flow

UHF Only
M00955K001 Inlet Strainer Kit-Std Pump (see note 1) 17 Strainer 1 X
18 O-Ring, Strainer Cover 1
M00955K002 Inlet Strainer Kit-UHF 17 Strainer, UHF 1 X
18 O-Ring, Strainer Cover 1
M00955K003 Check Valve Kit (see note 1) 16 Check Valve Assembly 1 X X
18 O-Ring, Strainer Cover 1
M00955K004 Inlet Strainer/Check Valve Kit-Std. Pump 16 Check Valve Assembly 1 X
(see note 1)
17 Strainer 1
25 Strainer, Dome 1
18 O-Ring, Strainer Cover 1
M00955K005 Inlet Strainer/Check Valve Kit-UHF Pump 16 Check Valve Assembly 1 X
17 Strainer, UHF 1
25 Strainer, Dome 1
18 O-Ring, Strainer Cover 1
M00955K006 PCV Kit-Std Pump (see note 2) 10 (PCV) 1 X
12 Spring, PCV 1
14 O-Ring, PCV Cover 1
15 Retaining Spring 1
M00955K007 PCV Kit (see note 3) 10 (PCV) 1 X
12 Spring, PCV 1
14 O-Ring, PCV Cover 1
15 Retaining Spring 1

Notes:
1. Not available for models M00955B102 and M00955B201.
2. Excludes model M00955B705 and UHF.
3. Includes only model M00955B705.
4. Available when sump vent location discharges from the standard vent location on top of the GDP unit. Not available when the alternate
vent location on the rear cover is used.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 19
Repair Kits

Gilbarco Reference
Kit Number Kit Description No. Part Description Quantity Used On

Standard and
High Flow

UHF Only
M00955K008 PCV Kit-UHF Pump 10 PCV 1 X
12 Spring, PCV 1
14 O-Ring, PCV Cover 1
15 Retaining Spring 1
M00955K009 Pump Cartridge Kit-std. Pump 6 Wave Spring 1 X
7 Pump Cartridge 1
8 Gasket, Head 1
18 O-Ring, Strainer Cover 1
14 O-Ring, PCV Cover 1
20 Key, Shaft 1
15 Retainer Ring 1
- Pin-Gasket Guide 1
M00955K010 Pump Cartridge Kit- UHF Pump 6 Wave Spring 1 X
7 Pump Cartridge 1
8 Gasket, Head 1
18 O-Ring, Strainer Cover 1
14 O-Ring, PCV Cover 1
20 Key, Shaft 1
15 Retainer Ring 1
- Pin-gasket Guide 1
M00955K011 Inspection Kit 8 Gasket, Head 1 X X
18 O-Ring, Strainer Cover 1
14 O-Ring, PCV Cover 1
3 Sump Gasket 1
M00955K012 Sump Overflow Check Valve Kit 23 Float, Sump Overflow 1 X X
(see note 4) Assy
24 Capscrew 2
3 Sump Gasket 1
M00955K013 OIML Switch Kit 22 OIML Switch Assy 1 X X
M00955K014 Sump Return Valve and Float Kit 2 Float, Sump Return Assy. 1 X X
24 Capscrew 2
3 Sump Gasket 1

Notes:
1. Not available for models M00955B102 and M00955B201.
2. Excludes model M00955B705 and UHF.
3. Includes only model M00955B705.
4. Available when sump vent location discharges from the standard vent location on top of the GDP unit. Not available when the alternate
vent location on the rear cover is used.

Page 20 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Pump Parts List

Pump Parts List

Figure 9: Pump Models 102 and 201

Optional
24 23

Optional
5
22

11

Optional
16 11

2
17
19 18 24 4
21 3

1
20
7
8

9
12 11
5
15 14 13 10

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 21
Pump Parts List

Pump Models 102 and 201

The following is a list of parts for pump models M00955B102 and M00955B201 (see Figure 9
on page 21 for the exploded view of the pump assembly). This parts list is for reference only.
Refer to “Repair Kits” on page 19 for replacement parts.
Item Description Part Number Quantity
1 Casing, Pump ** 1
2 Float, Sump Return Assembly (std)* 894876 1
3 Gasket, Sump 384861 1
4 Sump Cover Assembly ** 1
5 Screw, Taptite 924002 20
6 Wave Spring* 903408 1
7 Pump Cartridge* 894805 1
8 Gasket, Head* 384860 1
9 Head ** 1
10 PCV* 454800 1
11 Plug 908200 3
12 Spring, PCV* 474860 1
13 Cover, PCV 414800 1
14 O-Ring, PCV Cover* 702335 1
15 Retaining Ring* 903621 1
16 Check Valve Assembly ** 1
17 Strainer ** 1
18 O-Ring, Strainer Cover* 702332 1
19 Cover, Strainer ** 1
20 Key, Shaft* 909152 1
21 Capscrew 924021 3
22 OIML Switch Assy. (optional) 894830 1
23 Float, Sump Overflow Assy. (optional) 894850 1
24 Capscrew 924018 2-4
* Included in one or more repair parts kits.
** Not a saleable item.

Page 22 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Pump Parts List

Figure 10: Pump Model 206

Optional 23
24
5

Optional
22

Optional
25

Optional 11
11
16

18 24
17 2 4
19 3
21

1
7

8 20

10 9
13 11
15
5
14 12

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 23
Pump Parts List

Pump Model 206

The following is a list of parts for pump model M00955B206 (see Figure 10 on page 23 for the
exploded view of the pump assembly). This parts list is for reference only. Refer to “Repair
Kits” on page 19 for replacement parts.
Item Description Part Number Quantity
1 Casing, Pump ** 1
2 Float, Sump Return Assembly 894876 1
(Std)*
3 Gasket, Sump* 384861 1
4 Sump Cover Assembly ** 1
5 Screw, Taptite 924002 20
6 Wave Spring* 903408 1
7 Pump Cartridge* 894805 1
8 Gasket, Head* 384860 1
9 Head ** 1
10 PCV* 454800 1
11 Plug 908200 3
12 Spring, PCV* 474860 1
13 Cover, PCV 414800 1
14 O-Ring, PCV Cover* 702335 1
15 Retaining Ring* 903621 1
16 Check Valve Assembly* 894840 1
17 Strainer* 724890 1
18 O-Ring, Strainer Cover* 702332 1
19 Cover, Strainer 034863 1
20 Key, Shaft* 909152 1
21 Capscrew 924021 3
22 OIML Switch Assy. (optional) 894830 1
23 Float, Sump Overflow 894850 1
Assembly (Opt)
24 Capscrew 924018 2-4
25 Strainer, Dome* 724893 1
* Included in one or more repair parts kits.
** Not a saleable item.

Page 24 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Pump Parts List

Figure 11: Standard Flow Pump Model

Optional
24 23 Optional
Optional 11
22

29

Optional
25 11
Optional
16 11

5
2 4
24
30 28 27
17
19 18
21 3

26 8 7 6
20
11 9
10
12 5
14 13
15

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 25
Pump Parts List

Standard Flow Pump Models

The following is a list of parts for the standard flow pump models M00955B107,
M00955B207, M00955B705 and M00955B707 (see Figure 11 on page 25 for the exploded
view of the pump assembly). This parts list is for reference only. Refer to “Repair Kits” on
page 19 for replacement parts.
Item Description Part Number Quantity
1 Casing, Pump ** 1
2 Float Assembly 894876 1
3 Gasket, Sump* 384862 1
4 Sump Cover ** 1
Assembly
5 Screw, Taptite 924002 21
6 Wave Spring* 903408 1
7 Pump Cartridge* 894805 1
8 Gasket, Head* 384860 1
9 Head ** 1
10 PCV* 454800 1
11 Plug 908200 3(4)
12 Spring, PCV* 474860 1
Spring, PCV* (705 474865
only)
13 Cover, PCV 414800 1
14 O-Ring, PCV Cover* 702335 1
15 Retaining Ring* 903621 1
16 Check Valve 894840 1
Assembly*
17 Strainer* 724890 1
18 O-Ring, Strainer 702332 1
Cover*
19 Cover, Strainer 034863 1
20 Key, Shaft* 909152 1
21 Capscrew 924021 3
22 OIML Switch 894830 1
Assembly
23 Float, Sump Overflow 894850 1
Assembly
24 Capscrew 924018 4
25 Strainer, Dome* 724893 1
26 Sleeve, PCV ** 1
27 Seal Plug ** 1
28 Tube, Vortex ** 1
29 Plug 908202 1
30 Check Cap 724842 1
* Included in one or more repair parts kits.
** Not a saleable item.

Page 26 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Pump Parts List

Figure 12: UHF Pump Models 602 and 605

23
24 11

22

11
11

5
4
24 2
25
16
28
17 27
18
19 3
21

1
26
6
8 7
20
10 11
12 9
13
5
14
15

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 27
Pump Parts List

UHF Pump
The following is a list of parts for the UHF pump models M00955B602 and M00955B605 (see
Figure 12 on page 27). This parts list is for reference only. Refer to “Repair Kits” on page 19
for replacement parts.
Item Description Part Number Quantity
1 Casing, Pump ** 1
2 Float Assembly 894876 1
3 Gasket, Sump* 384861 1
4 Sump Cover ** 1
Assembly
5 Screw, Taptite 924002 21
6 Wave Spring* 903408 1
7 Pump Cartridge* 894806 1
8 Gasket, Head* 384860 1
9 Head ** 1
10 PCV* 454810 1
11 Plug 908200 4
12 Spring, PCV* 474870 1
13 Cover, PCV 414800 1
14 O-Ring, PCV Cover* 702335 1
15 Retaining Ring* 903621 1
16 Check Valve 894840 1
Assembly*
17 Strainer* 724895 1
18 O-Ring, Strainer 702332 1
Cover*
19 Cover, Strainer 034863 1
20 Key, Shaft* 909152 1
21 Capscrew 924021 3
22 OIML Switch 894830 1
Assembly
23 Float, Sump Overflow 894850 1
Assembly
24 Capscrew 924018 4
25 Strainer, Dome* 724893 1
26 Sleeve, PCV ** 1
27 Seal Plug ** 1
28 Tube, Vortex ** 1
* Included in one or more repair parts kits.
** Not a saleable item.

Page 28 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Troubleshooting

Troubleshooting
This section provides troubleshooting and maintenance information for pumps.

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

Troubleshooting Table
The following table contains a list of troubleshooting symptoms and probable causes.
Symptom Probable Cause
Pump not priming or excessive • Suction line obstruction
time to prime • Air leak in suction line
• Clogged strainer (refer to “Strainer/Check Valve Removal” on
page 9 and “Strainer/Check Valve Installation” on page 10)
• Pump speed too low (check motor, pulleys and belt)
• Damaged or missing strainer cover O-Ring (refer to “Strainer/
Check Valve Removal” on page 9 and “Strainer/Check Valve
Installation” on page 10)
• PCV open, worn or not seated properly (refer to “PCV
Removal” and “PCV Installation” on page 11)

Reduced Capacity (Flow) • Pump speed too low

• Air leak in suction lines
• Restriction in suction lines
• Excessive system pressure (flow loss to PCV)
• PCV open, worn or not seated properly
• Worn or damaged pump cartridge

Noise • Inlet Restriction of:

a. Inlet piping
b. Clogged strainer
• Excessive pump speed
• Pump inadequately fastened to the base plate
• Misaligned pulleys
• Improperly anchored piping
• PCV setting too high
• Excessive time with closed discharge line
• Damaged pump cartridge
• Excessive system pressure
Leakage
1 Port • Loose piping
• Improperly applied pipe thread sealant

2 Weep Hole • Damaged shaft seal O-Ring

• Damaged shaft seal

3 Head or Sump Gasket • Damaged gasket

• Improperly torqued mounting screws

4 Sump Overflow • Excessively foamy fuel

• Failure of sump float mechanism
• Failure of sump overflow check valve*

Motor/Belt Overheating • Pump cartridge locked up

• PCV stuck closed
• Excessive speed
• Improper belt tightening or alignment
• Defective or damaged motor

* This applies only to units equipped with the overflow check valve option.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 29
Troubleshooting

Checking Pump Vacuum

! WARNING
You are working in a potentially dangerous environment of flammable fuels and
vapors.

Fire or explosion could result in severe injury or death if you do not follow safe
procedures.

Read and follow all safety precautions as outlined in the section “Important
Safety Information” on page 4.

CAUTION
Do not use Teflon tape. Teflon tape may shred off and get caught within
components.

CAUTION
Ensure that fittings are properly tightened and check for leaks.

To check pump vacuum, proceed as follows:

1 Remove 1/4-inch NPT plug from the side of the strainer extrusion on pump face (see
Figure 13).

2 Install a long 1/4-inch pipe nipple by screwing into pump in order to extend beyond pump
pulley.

Figure 13: Pump Vacuum

Vacuum Port

Vacuum Gauge

Pipe Nipple

3 Attach the vacuum gauge into the pipe.

Page 30 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Troubleshooting

Checking the Pump Pressure

To check the pump pressure, proceed as follows:

1 Remove the feedline filter from the manifold (see Figure 14).

2 Screw on filter cap (R18896-G1) modified with a 1/4-inch NPT tapped hole.

3 Attach the pressure gauge into the hole on the filter cap.

IMPORTANT INFORMATION
When testing is complete, replace the filter cap with the filter.

Figure 14: Pump Pressure Test Set-up

Manifold

Fuel
Filter
Filter
Cap

Pressure
Gauge

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 31
Troubleshooting

Pump Performance Test

1 Check the belt tension.

! CAUTION
Belts and pulleys can pinch fingers and hands. Injuries may result.

Avoid placing fingers or hands between belts and pulleys.

Never turn power on to fit belt on pulley.

Tighter belt tensions can cause pump and motor bearing wear and premature failure.
Loose belts may result in lower flow or excessive belt wear.

The recommended belt tension is 45-55 lbs. (200-244 Newtons).

Notes: 1) The proper belt tension is the lowest tension at which the belt will not slip.

2) Operate the unit with both pressure and vacuum gauges attached. Use an approved
container to collect fuel. Clean spills promptly.

2 Run pump in by-pass with all nozzles closed and record pressure.

3 Run pump in full flow with all nozzles wide-open and record pressure and vacuum. Use a stop
watch to record flow rate in gpm or lpm.

4 If necessary, check the pump speed with a rpm photo-tachometer. Blackmer GDP nominal
speed should be approximately 1250 rpm.

Acceptable Pump Range Table

By-Pass-
Full Flow - All Nozzles Open Nozzles Closed
Pump Configuration Inlet Vacuum Discharge Flow Rate Discharge Pressure
inHg/cmHg Pressure gpm/lpm psi/bar
psi/bar
One Pumping Unit per Hose
Standard Flow 3-8 / 7.6-20.3 15-30 / 1.0-2.1 10-13 / 37-50 20-35 / 1.3-2.4
High Flow 3-8 / 7.6-20.3 25-40 / 1.7-2.8 18-24 / 68-90 28-45 / 1.9 -3.1
One Pumping Unit per Two Hoses
Standard Flow 3-8 / 7.6-20.3 20-35 / 1.3-2.4 17-20 / 64-76 22-38 / 1.5-2.6
Notes:
1. Pressures, vacuum and flow will vary depending upon installation factors, fuels and hardware configurations.
2. For UHF pump ranges, contact Gilbarco.

Page 32 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008
 Troubleshooting

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MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 33
Troubleshooting

The Advantage® Series, Encore®, Eclipse®, Gilbarco®, and Legacy® are registered trademarks of Gilbarco Inc. Allen® is a registered
trademark of Industrial Fasteners, Inc. Blackmer® is a registered trademark of Dover Corporation. Teflon® is a registered trademark of E.I.
Du Pont de Nemours and Company.

© 2008 Gilbarco Inc.

7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone (336) 547-5000 · [Link] Printed in the U.S.A.
MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008