BLACKMER TXV2.5B Manual

BLACKMER TRUCK PUMPS 960296
INSTRUCTIONS NO. 202-A00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: TXV2.5B, 3B
and Discontinued TXV2(A)(B), 2½(A), 3(A) Models
Section
Effective
Replaces
202
Jan 2014
July 2007
Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts Lists
202-A01, 202-A02 and 202-A03.
Blackmer pump manuals and parts lists may be
obtained from Blackmer’s website (www.blackmer.com)
or by contacting Blackmer Customer Service.
TABLE OF CONTENTS Page
PUMP DATA
Technical Data.......................................................2
Initial Pump Start Up Information...........................2
INSTALLATION
Pre-Installation Cleaning........................................3
Location and Piping...............................................3
Truck Mounting......................................................3
Pump Drive............................................................3
Pump Rotation.......................................................4
To Change Pump Rotation....................................4
OPERATION
Pre-Start Up Check List.........................................5
Start Up Procedures..............................................5
Pump Speed..........................................................5
Reverse Rotation...................................................5
Flushing the Pump.................................................6
Pump Relief Valve .................................................6
Relief Valve Setting and Adjustment......................6
MAINTENANCE
Strainers ................................................................7
Lubrication.............................................................7
Vane Replacement................................................8
Pump Disassembly................................................8
Pump Assembly.....................................................8
TROUBLE SHOOTING......................................10
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 Truck Pumps MUST only be installed in systems,
which have been designed by qualified engineering
personnel. The system MUST conform to all applicable
local and national regulations and safety standards.
This manual is intended to assist in the installation and
operation of the Blackmer truck pumps, and MUST be kept
with the pump.
Pump service shall be performed by qualified technicians
ONLY. Service shall conform to all applicable local and
national regulations and safety standards.
Thoroughly review this manual, all instructions and hazard
warnings, BEFORE performing any work on the pump.
Maintain ALL system and pump operation and hazard
warning decals.

SAFETY DATA
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous pressure
can cause personal
injury or property
damage
Hazardous pressure
can cause personal
injury or property
damage
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
If pumping hazardous or toxic fluids,
system must be flushed prior to
performing service
Hazardous pressure
can cause personal
injury or property
damage
Hazardous or toxic
fluids can cause
serious injury.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Hazardous
machinery can
cause serious
personal injury. Do not operate
without guard
in place
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
TXV Models
Maximum Operating
Temperature * 240 – 375°F (115 – 190°C)
Maximum 640 RPM
Maximum Viscosity * 20,000 – 50,000 SSU
(4,250 – 10,500 cSt)
Maximum Differential
Pressure 125 psi (8.6 Bar)
Maximum Working
Pressure 175 psi (12.1 Bar)
* Maximum operating limits are dependent on the materials of
construction. See Blackmer Material Specs 202-091.
INITIAL PUMP START UP INFORMATION
Model No.: ___________________________________
Serial No.: ___________________________________
Date of Installation: ___________________________
Pressure Gauge Reading: ______________________
Vacuum Gauge Reading: _______________________
Flow Rate: ___________________________________

202-A00 page 3/12
INSTALLATION
NOTICE:
Blackmer truck pumps must only be installed in systems
designed by qualified engineering personnel. System
design must conform with all applicable regulations and
codes and provide warning of all system hazards.
PRE-INSTALLATION CLEANING
NOTICE:
New pumps contain residual test fluid and rust inhibitor.
If necessary, flush pump prior to use.
Foreign matter entering the pump WILL cause extensive
damage. The supply tank and piping MUST be cleaned and
flushed prior to pump installation and operation.
LOCATION AND PIPING
An improperly designed piping system or unit installation
WILL significantly reduce pump performance and life. The
following are piping system guidelines for pump installation.
1. To minimize intake losses, locate the pump as close as
possible to the source of supply.
2. Piping MUST be properly supported to prevent any piping
loads from being placed on the pump.
3. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection.
4. Minimize the number of intake line fittings (valves, elbows,
etc.) and piping turns or bends.
5. Install vacuum and pressure gauges in the ¼" NPT ports
located on the pump cylinder near the intake and
discharge flanges to check pump at start-up
6. Install a strainer in the inlet line to protect the pump from
foreign matter. Place the intake strainer to allow frequent
cleaning.
7. Intake and discharge piping MUST be free of all leaks.
TRUCK MOUNTING
The pump will operate satisfactorily in any position. Consult
Blackmer factory for vertical shaft mounts. The pump can be
bolted to the truck frame or on a saddle hung below the
frame, and MUST be adequately supported. Mounting the
pump with the cylinder feet down, or with the intake port up, is
recommended for thorough draining of the pump.
PUMP DRIVE
The pump may be driven by a power take-off through
universal joints. When using universal joints, a splined slip
joint, properly lubricated, must be used on the connecting
jackshaft to prevent end thrust on the pump shaft.
It is very important to install a proper drive line to avoid
excessive wear, vibration and noise see Fig. 2 and Table 1.
A drive shaft guard between the pto and
pump must be provided to prevent
personal injury, property damage, or
death.
Do not operate
without guard
in place
Note: A Drive Shaft Guard Between the Pump and
PTO Must Be Provided (Not Shown)
Figure 2 Pump Drive
Angle of Drive Shaft
1º through 5º 6º through 10º 11º through 15º
Very Good Good Fair
Table 1
General guidelines to follow for proper pump drive:
1. DO NOT use Square slip joints.
2. Use the least number of jackshafts as is practical.
3. Use an even number of universal joints.
4. The pump shaft and power take-off shaft must be parallel
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
any misalignment. The PTO shaft coming off at the
transmission does not need to be perfectly horizontal as
long as the pump is shimmed to have its shaft parallel in
all respects to the PTO shaft.
5. The yokes of the universals at both ends of the jackshaft
must be parallel and in phase.
6. The maximum angle between the jackshaft and the pump
shaft is 15 degrees. Refer to Table 1.
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.

202-A00 page 4/12
INSTALLATION
Hydraulic Drive
The pump may also be driven hydraulically. Hydraulic motors
need to be well supported with their shafts parallel to the
pump shaft in all respects. Blackmer provides an optional
close-coupled hydraulic motor adapter. The adapter provides
for straight alignment of a hydraulic motor drive through a
solid coupling connected to a straight key shaft. This coupling
connection requires grease lubrication every three months at
minimum. Refer to the "Lubrication" section of this manual.
Figure 3 Hydraulic Drive
PUMP ROTATIONNOTICE:
Confirm correct pump rotation by checking the pump
rotation arrows respective to pump driver rotation.
TO CHANGE PUMP ROTATION
The TXV pump models are equipped with a double ended
rotor and shaft, enabling them to be driven from either shaft
end. To change rotation, rotate the pump 180 degrees so that
the opposite shaft becomes the driven shaft. On TXV pump
models, the outboard bearing cover (27) MUST be mounted
over the non-driven shaft end.
Operation without shaft protector can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place

202-A00 page 5/12
OPERATION
Pumps operating against a closed
valve can cause system failure,
personal injury and property damage
Hazardous pressure
can cause personal
injury or property
damage
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous pressure
can cause personal
injury or property
damage
If pumping hazardous or toxic fluids,
system must be flushed prior to
performing service
Hazardous or toxic
fluids can cause
serious injury.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
Hazardous pressure
can cause personal
injury or property
damage
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes must
be supported so that they do not spring away or drop
down when the pump flanges or union joints are
disconnected.
2. Install vacuum and pressure gauges in the ¼" NPT ports
located on the pump cylinder near the intake and
discharge flanges. These can be used to check the actual
suction and discharge conditions after pump start-up.
3. Inspect complete piping system to ensure that no piping
loads are being placed on the pump.
4. Secure appropriate hose connections.
START UP PROCEDURES
NOTICE:
Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are experienced.
1. Ensure that appropriate valves are open in the inlet and
discharge lines.
2. Start the pump. Priming should occur within one minute.
3. Check the vacuum and pressure gauges to ensure the
system is operating within expected parameters. Record
the gauge readings in the "Initial Start Up Information"
section of this manual for future reference.
4. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
5. Check the flow rate to ensure the pump is operating within
the expected parameters.
6. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and
reading the pressure gauge. This pressure needs to be 15
-20 psi (1.0 - 1.4 Bar) higher than the maximum system
operating pressure or the external bypass valve setting (if
equipped). DO NOT operate the pump against a closed
discharge valve for more than 15 seconds. If
adjustments need to be made, refer to the "Relief Valve
Setting and Adjustment" section of this manual.
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. If fluid delivery is less than expected, see the
"General Pump Troubleshooting" section
REVERSE ROTATION
NOTICE:
When pumps are operated in reverse a separate pressure
relief valve must be installed to protect the pump from
excessive pressure.
It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation for a LIMITED time, at a reduced
performance level. When operating the pump in reverse, a
separate bypass valve MUST be installed to protect the pump
from excessive pressure.