INSTRUCTIONS

BLACKMER AIR VALVE 960331 AND PARTS LIST

Page 1 of 8 NO. 201-F00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS & PARTS LIST Section 201
Effective April 2007
For Pump Models: TXD2A-AVA, TXD2.5A-AVA, TXD3E-AVA, Replaces Dec 2006
TXH3A-AVA

TABLE OF CONTENTS Page

SAFETY DATA......................................................... 1-2
NOTICE:
Review and follow all hazard warnings provided in the
VALVE DATA .............................................................. 2 appropriate Blackmer pump installation, operation and
Air Valve Technical Data ....................................... 2 maintenance instruction manual
Initial Air Valve Settings......................................... 2
NOTE: Blackmer pump manuals & parts lists may be
INSTALLATION .......................................................... 2 obtained from Blackmer’s website
Pre-Installation Cleaning ....................................... 2 (www.blackmer.com) or by contacting Blackmer
Mounting the Air Valve .......................................... 3 Customer Service
Air Valve Adjustment ............................................. 3
PUMP PUMP PARTS LIST
PUMP
TANK TRUCK FUEL OIL DELIVERY OPERATION 4 INSTRUCTION
MODEL 2” 2.5” 3”
Air Systems ........................................................... 4 MANUAL
Electric / Hydraulic Systems .................................. 4 TXD 201-A00 201-A02 201-A03 201-A04
TXH3 201-C00 201-C01
MAINTENANCE .......................................................... 5
Maintenance and Inspection Schedules................ 5
Air Valve Removal and Disassembly..................... 5 NOTE: Numbers in parentheses following individual
Air Valve Assembly................................................ 6 parts indicate reference numbers on Blackmer Parts
List
PARTS LIST........................................................ 7

SAFETY DATA
NOTICE:

Blackmer Air Valves MUST only be installed in systems

This is a SAFETY ALERT SYMBOL. which have been designed by qualified engineering
When you see this symbol on the product, personnel. The system MUST conform to all applicable
or in the manual, look for one of the following signal words local and national regulations and safety standards.
and be alert to the potential for personal injury,
death or major property damage This manual is intended to assist in the installation and
operation of the Blackmer Air Valves, and MUST be kept
with the pump.
Warns of hazards that WILL cause serious personal injury,
death or major property damage. Blackmer Air Valve service shall be performed by
qualified technicians ONLY. Service shall conform to all
applicable local and national regulations and safety
standards.
Warns of hazards that CAN cause serious personal injury,
death or major property damage. Thoroughly review the pump manual and all Air Valve
instructions and hazard warnings, BEFORE performing
any work on the Blackmer Air Valves.
Warns of hazards that CAN cause personal injury
or property damage. Maintain ALL system and Blackmer air valve pump
operation and hazard warning decals.
NOTICE:
Indicates special instructions which are very
important and must be followed.
 SAFETY DATA

Failure to set the vehicle emergency Disconnecting fluid or pressure

brake and chock wheels before containment components during pump
performing service can cause severe operation can cause serious personal
personal injury or property damage. injury, death or major property damage
Hazardous machinery Hazardous pressure
can cause serious can cause personal
personal injury or injury or property
property damage. damage.

Failure to disconnect and lockout If pumping hazardous fluids system

electrical power or engine drive before must be flushed and decontaminated
attempting maintenance can cause prior to performing service or
serious personal injury or death maintenance.
Hazardous
machinery can Hazardous or toxic
cause serious fluids can cause
serious injury.
personal injury.

All fluids pumped must be compatible Failure to relieve system pressure prior
with diaphragm material. to performing pump service or
Incompatibility can cause fire, serious maintenance can cause personal injury
personal injury or property damage. or property damage.
Hazardous fluids can Hazardous pressure
cause fire, serious can cause serious
personal injury or personal injury or
property damage. property damage.

NOTICE:
Installation and maintenance should 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 INITIAL AIR VALVE SETTINGS
Maximum Pump Pressure 125 psi (8.6 Bar) Pump Operating Pressure:_______________________

Maximum Air Pressure 125 psi (8.6 Bar) Low Pressure Setting: __________________________

Minimum Air Pressure 70 psi (4.8 Bar) High Pressure Setting: __________________________

Maximum Operational Temperature 240°F (115°C) Peak Pressure Setting: __________________________

Minimum Operational Temperature -20°F (-29°C)

INSTALLATION
The Blackmer Air Valve is a diaphragm type actuator (see PRE-INSTALLATION CLEANING
parts list drawing on page 6). The air valve is designed to
work with a flow sensing pilot valve (air or electric) which puts Foreign matter entering the pump WILL cause extensive
pressure behind the diaphragm when the nozzle is open and damage. The pump and the surrounding area MUST be
fluid is flowing. This permits high pressure operation of the cleaned prior to attempting air valve installation.
pump. When the nozzle is closed and flow is stopped, the
flow sensing pilot valve relieves the actuating pressure from NOTICE:
behind the diaphragm and the pump will automatically go into The Blackmer air valve is designed for fuel oil service.
low pressure bypass. Contact factory for all other fluids.
NOTICE:
Approximately 70 psi (4.8 bar) minimum air pressure is A preset, spring loaded air check valve must be installed
required to properly operate the air valve control system. Air in the vehicle air supply line to ensure minimum safe air
pressure MUST NOT exceed 125 psi (8.6 bar).
pressure for the brake system.
201-F00 Page 2/8
 INSTALLATION
MOUNTING THE AIR/RELIEF VALVE PRESSURE SETTING / RANGE – PSI (bar)
1. Remove the pump relief valve cap (1) and turn the adjusting Pump Operating 100 (6.9) Maximum
screw (2) counterclockwise to relieve spring tension. Low 10-35 (.69 –2.4)
2. Remove and discard the pump’s four relief valve cover bolts
(5 & 5C). Remove the cover assembly (4), spring guide (7), 70-125 (4.8-8.6);
High
spring (8), and gasket (10). Clean and inspect the gasket 125 (8.6) Maximum – Do Not Exceed
surfaces, repairing as necessary. 15-25 (1.0-1.7) above normal
Peak
3. Install a new gasket (10). operating pressure
NOTICE: Table 2 – Blackmer Diaphragm Air Valve Settings – All Models
The relief valve spring must be confined between the boss
on the air valve (9) and the boss on the diaphragm Low Pressure Adjustment:
assembly (9c). The air valve low pressure adjustment MUST be set first.
4. Attach the Blackmer Air Valve assembly to the pump using
the four new bolts provided (5 & 5C). Ensure the valve NOTICE:
cover (4) is positioned so that the air inlet pipe hole is The air valve low pressure setting regulates the delivery
accessible to attach the air or hydraulic line. hose pressure when the nozzle is closed. Adjust the air
5. Torque the air valve mounting bolts as indicated in Table 1. valve only high enough to open the flow sensing valve.

PUMP MODEL TORQUE * - lbs in (Nm) 1. Adjustment MUST be made with the pump at normal idle
TXD2A-AVA 150(16.9) speed - 200 RPM minimum.
TXD2.5A-AVA, TXH3A-AVA, 2. SLOWLY close the delivery nozzle, allowing the pressure
175 (19.8)
TX200B-AVA to be relieved inside the air valve cap.
TXD3E-AVA 225 (25.4) 3. Remove the air valve cap (1) and O-ring (88).
*Torque specification tolerance is +/- 10 lbs in (1.08 Nm). 4. Turn the adjusting bushing (2C) clockwise to increase the
Table 1 pressure setting, or counterclockwise to decrease the
pressure setting. Refer to Table 2 for setting ranges.
AIR/RELIEF VALVE ADJUSTMENT 5. Install O-ring and air valve cap; tighten the cap securely.
NOTICE: 6. Open and close the delivery nozzle several times to
Maintenance should be performed by qualified ensure the correct setting.
technicians only, following the appropriate procedures
and warnings as presented in this manual and the High Pressure Adjustment: - Do not exceed the
appropriate pump installation, operation, and maximum pressure listed in Table 2.
maintenance instructions.
1. Adjustment MUST be made with the pump at normal
operating speed and with pressure behind the air valve
diaphragm.
Failure to relieve system pressure prior 2. Slowly close the delivery nozzle, allowing the pressure to
to performing pump service or be relieved inside the air valve cap.
maintenance can cause personal injury 3. Remove the air valve cap.
or property damage.
Hazardous pressure
can cause serious
personal injury or
NOTICE:
property damage. To avoid damage to the diaphragm (9c) always use a
counter wrench (opposing wrench) when tightening the
locknuts (2A). Always start with the locknuts turned all
the way down, clockwise, against the adjusting bushing.
Incorrect settings of the Blackmer air
valve can cause system component 4. Adjust the locknuts counterclockwise to increase the
failure, personal injury and property pressure setting or clockwise to decrease the pressure
damage. setting, until the required high pressure setting is
Hazardous pressure achieved. See Table 2 for setting ranges.
can cause serious
personal injury or 5. Install the air valve cap securely.
property damage.
6. Open the delivery nozzle and observe the pump’s
NOTICE: discharge gauge. Repeat steps 2-5 until required high
If the air valve snap ring (83) is removed, and the pressure setting is achieved.
locknuts turned out beyond the snap ring, the diaphragm 7. After the final adjustment is made, ensure that the
(9c) will be damaged allowing pumpage to leak to the locknuts (2A) are tight. Inspect the air valve cap O-ring
atmosphere. (88) and replace as necessary.
The Blackmer Air Valve low and high pressure settings are NOTICE:
adjustable within a specific range to suit the engine operating Where regulations require, holes in R/V Cap (1) and
speed and operating conditions. Refer to Table 2 for the air capscrew with hole (5C) are used by the weights and
valve pressure settings. Attach a suitable pressure gauge at measures official (s) to apply a security seal or tag.
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.

201-F00 Page 3/8

 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 diaphragm. With the air
pressure on the diaphragm, 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. Figure 1 - Air System

The engine speed control air cylinder should be rigidly mounted

to prevent variations in the speed control.

Electric/Hydraulic Systems for Automatic Pressure and Speed Control

Failure to provide full flow discharge Failure to mount the 3-way pneumatic
piping, a properly grounded system and valve away from heat, flame, sparks or
system components will cause static outside the engine compartment can
electricity, incendiary sparks and cause fire, personal injury or property
Explosive fluids will ignition of explosive liquids. Hazardous fluids can damage.
cause severe personal cause fire, serious
injury, death or major personal injury or
property damage. property damage.

The pump is equipped with an adjustable spring relief valve.

The spring bears against the diaphragm. With pump discharge
pressure on the diaphragm, 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.
Figure 2 – Electric / Hydraulic System
The engine speed control solenoid should be rigidly mounted to
prevent variations of the engine speed.

201-F00 Page 4/8

 MAINTENANCE
NOTICE:
Maintenance should 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.

Disconnecting fluid or pressure

Failure to set the vehicle emergency
containment components during pump
brake and chock wheels before
operation can cause serious personal
performing service can cause severe
injury, death or major property damage
personal injury or property damage. Hazardous pressure
Hazardous machinery can cause personal
can cause serious injury or property
personal injury or damage.
property damage.

If pumping hazardous fluids system

Failure to disconnect and lockout
must be flushed and decontaminated
electrical power or engine drive before
prior to performing service or
attempting maintenance can cause
maintenance.
Hazardous
serious personal injury or death Hazardous or toxic
machinery can fluids can cause
cause serious serious injury.
personal injury.

Failure to relieve system pressure prior

All fluids pumped must be compatible
to performing pump service or
with diaphragm material.
maintenance can cause personal injury
Incompatibility can cause fire, serious
or property damage.
personal injury or property damage. Hazardous pressure
Hazardous fluids can can cause serious
cause fire, serious personal injury or
personal injury or property damage.
property damage.

AIR VALVE MAINTENANCE AIR VALVE REMOVAL AND DISASSEMBLY

AND INSPECTION SCHEDULES 1. Remove the cap (1) from the air valve assembly.
Remove and discard the cap O-ring (88).
Valve Inspection 2. Remove the snap ring (83) and locknuts (2A) from the
Action Required
Assembly Part Schedule adjusting rod. Turn the adjusting bushing (2C)
If leakage is present, counterclockwise to reduce spring tension.
IMMEDIATE valve 3. Remove the four capscrews (5 & 5C) and lockwashers
Vent Plate (6A) Weekly service is required. (5B).
DO NOT remove grease 4. Carefully remove the air valve assembly, spring (8), and
from vent hole. if necessary, the valve (9).
Disassemble, inspect
Air Valve 5. Remove and discard the gasket (10). Clean gasket
Annually diaphragms and replace
Assembly areas.
if cracked or blistered.
3 Years 6. Remove the two machine head screws (5A), valve plate
Diaphragm (9C) REPLACE
(or less) (6), diaphragm assembly (9C), and vent plate (6A).
Discard the diaphragm assembly.
7. Thread the adjusting bushing (2C), CLOCKWISE
completely into the valve cover (4).

201-F00 Page 5/8

AIR VALVE ASSEMBLY
NOTICE:
1. Remove the snap ring (83) from the adjusting rod on the The relief valve spring must be confined between the
new diaphragm assembly (9C). boss on the air valve (9) and the boss on the diaphragm
assembly (9c).
NOTICE: 7. If removed, reinstall the valve (9). Place the spring (8)
Prior to assembly, the area around the spacer between between the boss on the diaphragm assembly and the
the diaphragms and the inner diameter of the vent plate valve. Mount the air valve assembly to the pump,
must be greased with a lithium based grease. Remove ensuring that the gasket is properly seated. Torque the
any grease from the outer diameter of the vent plate and capscrews (5 & 5C) to the appropriate value depicted in
diaphragm surfaces. Table 1.
2. Being careful not to damage the diaphragm, place the 8. With a new O-ring (88) installed, attach the air valve cap
vent plate (6A) between the two diaphragms by pulling (1) securely.
the pump side diaphragm corners through the center hole
in the vent plate. 9. Adjust the new valve as provided in the “Air Valve
Adjustment” section of this manual.
3. Insert the new diaphragm assembly into the adjustment
bushing (2C).
4. Install the plate (6) on the air valve with the holes in the
diaphragm, vent plate and plate lined up. Attach the
assembly with the two machine screws (5A), tightening
securely.
5. Install both locknuts (2A) all the way down to the
adjusting bushing and replace the snap ring (83).
6. Install a new gasket (10) and insert the four capscrews (5
& 5C) with lockwashers (5B) into the air valve assembly.

NOTES

201-F00 Page 6/8

 PARTS LIST

PARTS TXD2.5A-AVA,
REF. TXD2A-AVA TXD3E-AVA TXH3A-AVA,
PART NAME PER TX200B-AVA
NO. PART NO. PART NO. PART NO.
VALVE PART NO.
1 Cap 1 411754 411754 411754 411753
2A Locknut 2 922923 922923 922923 922923
2C Adjustment Bushing 1 501701 501701 501701 501701
4 Cover 1 411406 411703 411705 411703
5 Capscrew 3-4 920444 920444 920444 920239
5A Machine Screw 2 922216 922216 922216 922216
5B Lockwasher 4 909649 909649 909649 909693
5C Capscrew w/ Hole 0-1 920433 920433 920433 —
6 Plate 1 701400 701735 701737 701735
6A Vent Plate 1 701418 701618 701818 701618
8 Spring 1 471429 471621 471806 471621
9 Valve ** 1 451417 451623 451807 451623
9C Diaphragm Assembly 1 871175 871180 871185 871180
10 Gasket 1 531403 531603 531803 531603
83 Snap Ring 1 903581 903581 903581 903581
88 O-Ring 1 711917 711917 711917 711917
A/V Conversion Kit ** — 891454 891696 891798 891799
* NOTE: The double diaphragm air valve assembly replaced the single diaphragm assembly in Aug. 1991.
** A/V Conversion Kit includes all above parts EXCEPT the Valve (ref. 9).
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