BLACKMER AVC Datasheet

BLACKMER PISTON AIR VALVE 960333
Page 1 of 8
INSTRUCTIONS
AND PARTS LIST
NO. 201-G00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS WITH PARTS LIST
For Piston Air Valve Style AVC
and Discontinued Style AVB
Section
Effective
Replaces
201
Sept 2009
July 2009
TABLE OF CONTENTS Page
SAFETY DATA..........................................................1-2
VALVE DATA............................................................... 2
Air Valve Technical Data............................................2
Initial Air Valve Settings .............................................2
INSTALLATION ........................................................... 2
Pre-Installation Cleaning............................................2
Mounting the Air Valve...............................................3
Air Valve Adjustment..................................................3
TANK TRUCK FUEL OIL DELIVERY OPERATION .... 4
Air Systems................................................................4
Electric / Hydraulic Systems.......................................4
MAINTENANCE ........................................................... 5
Maintenance and Inspection Schedules.....................5
Air Valve Removal and Disassembly .........................5
Air Valve Assembly....................................................6
PARTS LIST.........................................................7
NOTICE:
Keep this document with the appropriate Blackmer pump
installation, operation and maintenance instruction
manual.
NOTICE:
Review and follow all hazard warnings provided in the
appropriate Blackmer pump installation, operation and
maintenance instruction manual.
Blackmer pump manuals and parts lists may be obtained from
Blackmer’s website (www.blackmer.com) or by contacting
Blackmer Customer Service
NOTE: Numbers in parentheses after individual parts indicate
reference numbers on Blackmer Parts List
NOTE: A pump with a standard relief valve may be converted
to use the Piston Air Valve with the installation of a Piston Air
Valve Kit. See the Parts List, Table 3 for applicable pump
models.
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 Air Valves 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 Air Valves, and MUST be kept
with the pump.
Blackmer Air Valve service shall be performed by
qualified technicians ONLY. Service shall conform to all
applicable local and national regulations and safety
standards.
Thoroughly review the pump manual and all Air Valve
instructions and hazard warnings, BEFORE performing
any work on the Blackmer Air Valves.
Maintain ALL system and Blackmer air valve pump
operation and hazard warning decals.

201-G00 Page 2/8
SAFETY DATA
Hazardous machinery
can cause serious
personal injury or
property damage.
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
Hazardous
machinery can
cause serious
personal injury.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
serious personal injury or death
Hazardous fluids can
cause fire, serious
personal injury or
property damage.
All fluids pumped must be compatible
with piston material. Incompatibility
can cause fire, serious 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 or toxic
fluids can cause
serious injury.
If pumping hazardous fluids, the system
must be flushed and decontaminated
prior to performing service or
maintenance.
Hazardous pressure
can cause serious
personal injury or
property damage.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
NOTICE:
Installation and maintenance shall be performed by
qualified technicians only, following the appropriate
procedures and warnings as presented in this manual and
the appropriate pump installation, operation, and
maintenance instructions.
VALVE DATA
AIR VALVE TECHNICAL DATA
Maximum Pump Pressure 125 psi (8.6 Bar)
Maximum Air Pressure 125 psi (8.6 Bar)
Minimum Air Pressure 70 psi (4.8 Bar)
Maximum Operational Temperature 240°F (115°C)
Minimum Operational Temperature -20°F (-29°C)
INITIAL AIR VALVE SETTINGS
Pump Operating Pressure:_______________________
Low Pressure Setting: __________________________
High Pressure Setting: __________________________
Peak Pressure Setting: __________________________
INSTALLATION
The Blackmer Air Valve is a piston type actuator (see parts
list drawing on page 7). The air valve is designed to work
with a flow sensing pilot valve (air or electric) which puts
pressure behind the piston when the nozzle is open and fluid
is flowing. This permits high pressure operation of the pump.
When the nozzle is closed and flow is stopped, the flow
sensing pilot valve relieves the actuating pressure from
behind the piston and the pump will automatically go into low
pressure bypass.
Approximately 70 psi (4.8 bar) minimum air pressure is
required to properly operate the air valve control system. Air
pressure MUST NOT exceed 125 psi (8.6 bar).
PRE-INSTALLATION CLEANING
Foreign matter entering the pump WILL cause extensive
damage. The pump and the surrounding area MUST be
cleaned prior to attempting air valve installation.
NOTICE:
A preset, spring loaded air check valve must be installed
in the vehicle air supply line to ensure minimum safe air
pressure for the brake system.

201-G00 Page 3/8
INSTALLATION
MOUNTING THE AIR/RELIEF VALVE
1. Remove the pump relief valve cap (1) and turn the adjusting
screw (2) counterclockwise to relieve spring tension,
reference the pump maintenance manual.
2. Remove and discard the pump’s four relief valve cover bolts
(5 & 5C). Remove the cover assembly (4), spring guide (7),
spring (8), and gasket (10). Clean and inspect the gasket
surfaces, repairing as necessary.
3. Install a new gasket (10).
NOTICE:
The relief valve spring must be confined between the boss
on the relief valve (9) and the boss on the piston (11A).
4. Attach the Air Valve assembly to the pump using the four
new bolts provided (5 & 5C). Ensure the relief valve spring
is seated in the piston boss. Position the valve cover (4) so
that the air inlet pipe hole is accessible to attach the air line.
5. Torque the air valve mounting bolts as indicated in Table 1.
PUMP MODEL TORQUE * - lbs ft (Nm)
TXD2.5, TXD1225, TXH3
TXD3, TXD1230 19 – 25 (25.8 – 33.9)
* Torque bolts in an alternating pattern.
Table 1
AIR/RELIEF VALVE ADJUSTMENT
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in this manual and the appropriate pump
installation, operation, and maintenance instructions.
Hazardous pressure
can cause serious
personal injury or
property damage.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
NOTICE:
If the air valve retaining ring (11F) is removed, and the
jam nuts (11E) turned out beyond the retaining ring, the
piston (11A) will not seal, allowing air to leak to the
atmosphere.
The Blackmer Air Valve low and high pressure settings are
adjustable within a specific range to suit the engine operating
speed and operating conditions. See Table 2. Attach a
suitable pressure gauge at the pump discharge gauge port
(73) to make the required air valve adjustments. Record the
air valve and pump operating pressures in the “Initial Air
Valve Settings” chart.
Discharge Pressure Setting / Range – PSI (bar)
Model TXD2.5, TXD1225,
TXH3 TXD3, TXD1230
Pump Operating 100 (6.9) Maximum
Low 40-80 (2.8-5.5) 55-85 (3.8-5.9)
70-125 (4.8-8.6); 80-125 (5.5-8.6);
High 125 (8.6) Maximum – Do Not Exceed
Peak 15-25 (1.0-1.7) above normal
operating pressure
Table 2 – Blackmer Piston Air Valve Settings
LOW PRESSURE ADJUSTMENT:
The air valve low pressure adjustment MUST be set first.
NOTICE:
The air valve low pressure setting regulates the delivery
hose pressure when the nozzle is closed. Adjust the air
valve only high enough to open the flow sensing valve.
1. Adjustment MUST be made with the pump at normal idle
speed - 200 RPM minimum.
2. SLOWLY close the delivery nozzle, allowing the pressure
to be relieved inside the air valve cap.
3. Remove the air valve cap (1) and O-ring (88).
4. Turn the adjusting bushing (2C) clockwise to increase the
pressure setting, or counterclockwise to decrease the
pressure setting. Refer to Table 2 for setting ranges.
5. Install O-ring and air valve cap, tighten the cap securely.
6. Open and close the delivery nozzle several times to
ensure the correct setting.
Hazardous pressure
can cause serious
personal injury or
property damage.
Incorrect settings of the Blackmer air
valve can cause system component
failure, personal injury and property
damage.
HIGH PRESSURE ADJUSTMENT: Do not exceed
the maximum pressure listed in Table 2.
1. Adjustment MUST be made with the pump at normal
operating speed and with air pressure behind the air
valve piston.
2. Slowly close the delivery nozzle, allowing the pressure to
be relieved inside the air valve.
3. Remove the air valve cap.
NOTICE:
Always use a counter wrench (opposing wrench) when
tightening the jam nuts (11E). Always start with the jam
nuts turned all the way down, clockwise, against the
adjusting bushing.
4. Adjust the jam nuts counterclockwise to increase the
pressure setting or clockwise to decrease the pressure
setting, until the required high pressure setting is
achieved. See Table 2 for setting ranges.
5. Install the air valve cap securely.
6. Open the delivery nozzle and observe the pump’s
discharge gauge. Repeat steps 2-5 until required high
pressure setting is achieved.
7. After the final adjustment is made, ensure that the jam
nuts (11E) are tight. Inspect the air valve cap O-ring (88)
and replace as necessary.
NOTICE:
Where regulations require, holes in R/V cap (1) and
capscrew w/hole (5C) are used by the Weights and
Measures official(s) to apply a security seal or tag.

201-G00 Page 4/8
TANK TRUCK FUEL OIL DELIVERY OPERATION
Air Systems for Automatic Pressure and Speed Control
The pump is equipped with an adjustable spring actuated relief
valve. The spring bears against a piston. With the air pressure
on the piston, the valve controls pressure in the conventional
manner. When air pressure is removed, the relief valve opens
wide, reducing the system pressure.
The pilot valve senses flow. It closes when the nozzle closes
and removes air pressure from the pump air valve and the air
cylinder on the engine speed control.
When the nozzle is opened, the liquid flow actuates the pilot
valve. Air pressure on the air cylinder then speeds up the
engine and pump to a preset value and, by pressurizing the
pump air valve, increases the system pressure to obtain the
desired flow.
Closing the nozzle automatically reduces the engine and pump
speed to an idle, and reduces the system pressure, making the
hose easier to handle. The net effect also reduces wear and
tear on the equipment.
The nozzle may be partially closed to “top off” a tank in the
same manner as when a Blackmer pump with the standard
relief valve is used.
Rigidly mount the engine speed control air cylinder to prevent
variations in the speed control.
Figure 1 - Air System
Electric/Hydraulic Systems For Automatic Pressure And Speed Control
Explosive fluids will
cause severe personal
injury, death or major
property damage.
Failure to provide full flow discharge
piping, a properly grounded system and
system components will cause static
electricity, incendiary sparks and
ignition of explosive liquids. Hazardous fluids can
cause fire, serious
personal injury or
property damage.
Failure to mount the 3-way pneumatic
valve away from heat, flame, sparks or
outside the engine compartment can
cause fire, personal injury or property
damage.
The pump is equipped with an adjustable spring relief valve.
The spring bears against the piston. With pump discharge
pressure on the piston, the valve controls pressure in the
conventional manner. When the pump discharge pressure is
removed, the relief valve opens wide, reducing the system
pressure.
The flow switch “senses” flow. With the pump running and the
nozzle open, liquid causes the electrical switch to close and
energize the solenoids. The solenoid on the carburetor or
injection pump causes the engine and pump to speed up to a
pre-set value. At the same time, the solenoid valve at the
pump uses the pump discharge pressure to change the bypass
setting at the pump, increasing the system pressure to obtain
the desired flow.
Closing the nozzle opens the flow switch, automatically reduces
the engine speed to an idle, and reduces the system pressure,
making the hose easier to handle. The net effect also reduces
wear and tear on the equipment. The nozzle may be partially
closed to “top off” a tank in the same manner as when a
Blackmer pump with the standard relief valve is used.
Rigidly mount the engine speed control solenoid to prevent
variations of the engine speed.
Figure 2 – Electric / Hydraulic System

201-G00 Page 5/8
MAINTENANCE
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in this manual and the appropriate pump
installation, operation, and maintenance instructions.
Hazardous machinery
can cause serious
personal injury or
property damage.
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
Hazardous
machinery can
cause serious
personal injury.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
serious personal injury or death
Hazardous fluids can
cause fire, serious
personal injury or
property damage.
All fluids pumped must be compatible
with piston material. Incompatibility
can cause fire, serious 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 or toxic
fluids can cause
serious injury.
If pumping hazardous fluids, the system
must be flushed and decontaminated
prior to performing service or
maintenance.
Hazardous pressure
can cause serious
personal injury or
property damage.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
AIR VALVE MAINTENANCE
AND INSPECTION SCHEDULES
Valve Assembly
Part Inspection Schedule Action Required
Breather Vent
(6A) Weekly If leakage is present,
IMMEDIATE valve
service is required.
Air Valve
Assembly Annually
Disassemble, inspect
U-cup/ Quad Ring seals
and replace if cracked,
blistered or worn.
Piston Assy. (11) 3 Years
(Or Less) REPLACE
AIR VALVE REMOVAL AND DISASSEMBLY
1. Remove the cap (1) from the air valve assembly.
Remove and discard the cap O-ring (88).
2. Remove the retaining ring (11F) and jam nuts (11E) from
the adjusting rod. Turn the adjusting bushing (2C)
counterclockwise to reduce spring tension.
3. Remove the four capscrews (5 & 5C) and washers
(5A & 5B).
4. Carefully remove the air valve assembly, spring (8), and
if necessary, the valve (9).
5. Remove and discard the gasket (10). Clean gasket
areas.
6. Clean the breather vent (6A) with an air hose to remove
any foreign matter.
7. Remove the piston (11A) with the attached adjusting rod
(11B). Inspect the coating on the piston outer diameter
for scratches, wear and surface damage. Discard the
piston if the coating is worn or damaged.
8. Remove the U-cup (6) and quad ring seals (7), being
careful not to scratch the grooves in the piston cover (4)
and discard.
9. Thread the adjusting bushing (2C), CLOCKWISE
completely into the valve cover (4).

201-G00 Page 6/8
AIR VALVE ASSEMBLY
NOTICE:
Prior to assembly, the piston outer diameter and piston
cover bore & U-cup/Quad Ring grooves must be lightly
coated with a lithium based grease. Remove any grease
in the breather vent hole.
1. Install the U-cup (6) and Quad Ring (7) seals as shown in
Figure 3. Install the U-cup seal with the V-groove feature
facing the air supply. Install the Quad Ring in the cover
groove on the liquid side of the Air Valve. The U-cup and
Quad Ring must be oriented as shown to properly seal
and prevent cross-contamination between the air supply
and pumpage.
2. Insert the piston with the attached adjusting rod (11B)
into the adjustment bushing (2C).
3. Install both jam nuts (11E) all the way down to the
adjusting bushing and replace the retaining ring (11F).
NOTICE:
The relief valve spring must be confined between the
boss on the relief valve (9) and the boss on the piston
(11A).
4. If removed, reinstall the valve (9). Place the spring (8)
between the boss on the piston assembly and the valve.
Mount the air valve assembly to the pump, ensuring that
the gasket is properly seated. Torque the capscrews (5
& 5C) as indicated in Table 1.
5. Install a new gasket (10) and insert the four capscrews (5
& 5C) with washers (5A & 5B) into the air valve
assembly.
6. With a new O-ring (88) installed, attach the air valve cap
(1) securely.
7. Adjust the new valve as provided in the “Air Valve
Adjustment” section of this manual.
Table 3 – PARTS LIST for PISTON AIR VALVE STYLE AVC 1
Ref.
No. Part Name Parts Per
Valve
Pumps
TXD2.5
TXD1225
TXH3
Part No.1
Pumps
TXD3
TXD1230
Part No.
1 Cap 1 411754 411754
2C Adjustment Bushing 1 501703 501703
4 Cover 1 411758 411759
5 Capscrew 3 920448 920425
5A Flat washer 4 909662 909662
5B Lock washer 4 909649 909649
5C Capscrew w/ Hole 1 920465 920430
6 U-cup packing
2FKM 1 495030 495032
7 Quad Ring seal 2FKM 1 495033 495034
6A Breather Vent 1 495029 495029
8 Spring 1 471621 471816
9 Valve
3Standard 451623 451807
Corrosion Resistant 1 451624 451808
10 Gasket
21 531603 531803
11
Piston Assembly – includes:
11A Piston (1)
11B Adjusting Rod (1)
11E Jam Nut (2)
11F Retaining Ring (1)
1 891714 891727
88 O-Ring
2FKM 1 701979 701979
A/V Conversion Kit 3FKM — 891725 891728
Seal Kit FKM — 891713 891726
1Previous style AVB used two U-cup packings (6), no Quad Ring Seal (7) and a different
Piston Assembly (11) construction. All parts as listed above my be used in style AVB Piston Air Valves
2 Parts included in Seal Kit
3A/V Conversion Kit includes all above parts EXCEPT the Valve (ref. 9).

Figure 3 - PARTS ILLUSTRATION

NOTES
1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.
Telephone: [phone] • Fax: [phone]
E-mail: [e-mail] • Internet Address: www .blackmer.com