OPERATION

PRE-START UP CHECK LIST REVERSE ROTATION

1. Check the alignment of the pipes to the pump. Pipes must
NOTICE:
be supported so that they do not spring away or drop down
when the pump flanges or union joints are disconnected. PUMPS OPERATED IN REVERSE MUST HAVE A
SEPARATE PRESSURE RELIEF VALVE INSTALLED TO
2. Temporarily install vacuum and pressure gauges in the 1/4" PROTECT THE PUMP FROM EXCESSIVE PRESSURE.
NPT ports located on the pump cylinder. These can be
used to check the actual suction and discharge conditions It may be desirable to run the pump in reverse rotation for
after pump start-up. system maintenance. The pump will operate satisfactorily in
reverse rotation to strip lines, at a reduced performance level.
3. Inspect complete piping system to ensure that no piping
When operating the pump in reverse, a separate bypass valve
loads are being placed on the pump.
MUST be installed to protect the pump from excessive
4. Secure appropriate hose connections. pressure.

START UP PROCEDURES FLUSHING THE PUMP

NOTICE:
PUMP OPERATING AGAINST A IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR
CLOSED VALVE CAN CAUSE AN EXTENDED TIME, IT MUST BE A LUBRICATING,
NON-CORROSIVE FLUID. IF A CORROSIVE, NON-
SYSTEM COMPONENT FAILURE,
LUBRICATING FLUID IS USED, IT MUST BE FLUSHED
PERSONAL INJURY AND PROPERTY
Hazardous pressure
FROM THE PUMP IMMEDIATELY.
can cause DAMAGE.
personal injury or
property damage.
To flush the pump, use the following procedure:

1. Allow the pump to evacuate as much fluid as possible.

2. Run cleaning fluid through the pump intake. The cleaning
NOTICE:
fluid must be compatible with the pump O-rings and vane
CONSULT THE "GENERAL PUMP TROUBLESHOOTING" material. When handling "sticky" fluids that solidify within
SECTION OF THIS MANUAL IF DIFFICULTIES DURING the pump (i.e., waxes, adhesives, resins, asphalts, etc.),
START UP ARE EXPERIENCED. use a fluid that will prevent solidification of the fluid being
transferred and facilitate flushing.

1. Start the pump. Priming should occur within one minute. 3. Operate the pump against a closed discharge for 15
seconds to allow the cleaning fluid to recirculate through
2. Check the vacuum and pressure gauges to ensure the
the internal relief valve.
system is operating within expected parameters. Record
the gauge readings in the "Initial Start Up Information"
section of this manual for future reference. RELIEF VALVE
3. Inspect piping, fittings, and associated system equipment NOTICE:
for leaks, noise, vibration and overheating. THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO
4. Check the flow rate to ensure the pump is operating within PROTECT THE PUMP FROM EXCESSIVE PRESSURE
the expected parameters. AND MUST NOT BE USED AS A SYSTEM PRESSURE
CONTROL VALVE.
5. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and Pumping volatile liquids under suction lift may cause
reading the pressure gauge. This pressure should be 15 - cavitation. Partial closing of the discharge valve WILL result in
20 psi (1.0 - 1.4 bar) higher than the maximum system internal relief valve chatter and must not be done. For these
operating pressure, or the external bypass valve setting (if applications, install an external bypass valve, and any
equipped). DO NOT operate the pump against a closed necessary piping, back to the storage tank. This bypass
discharge valve for more than 15 seconds. If system must be used when operating for extended periods
adjustments need to be made, refer to the "Relief Valve (more than 1 minute) against a closed discharge valve.
Setting and Adjustment" section of this manual.

PUMP SPEED RELIEF VALVE SETTING AND ADJUSTMENT

PTO and hydraulically driven units MUST contain speed The relief valve pressure setting is marked on a metal tag
control devices to prevent pump speeds above the maximum attached to the valve cover. Generally, the relief valve should
RPM specifications, regardless of the truck engine unloading be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the
speeds. Should fluid delivery be appreciably less than operating pressure, or the external bypass valve setting (if
expected, see the "General Pump Troubleshooting" section. equipped).

4
 OPERATION
Relief Valve Adjustment Procedure: NOTICE:
1. To INCREASE the pressure setting , remove the relief WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND
valve cap, loosen the locknut, and turn the adjusting screw CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND
inward, or clockwise. Replace the valve cap. MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.
2. To DECREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting screw
outward, or counterclockwise. Replace the valve cap. INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. The pumps are supplied from the CAUSE SYSTEM COMPONENT
factory with the relief valve adjusted to the mid-point of the FAILURE, PERSONAL INJURY AND
spring range. If the pump is equipped with a Blackmer air Hazardous pressure
PROPERTY DAMAGE.
can cause
valve, refer to setting and adjustment procedures covered in personal injury or
property damage.
Blackmer Air Valve Instructions and Parts List No. 201-F00,
286/F or 201-B00.

MAINTENANCE
NOTICE: LUBRICATION
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED Ball bearings and hydraulic motor couplings (if equipped) must
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE be lubricated every three months at a minimum. More frequent
PROCEDURES AND WARNINGS AS PRESENTED IN lubrication may be required, depending on the application and
the operating conditions. TXV pump model bearings MUST
THIS MANUAL.
be replaced after each 1000 hours of service if fluid
temperature is greater than 250oF (120oC).
FAILURE TO SET THE VEHICLE
Recommended Grease:
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -
Mobilith AW-2, or equivalent Lithium grease.
SERVICE CAN CAUSE SEVERE
Hazardous machinery TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly
PERSONAL INJURY OR PROPERTY
can cause severe
personal injury or
372, or equivalent Polyurea grease.
property damage. DAMAGE.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
FAILURE TO RELIEVE SYSTEM covers (27 and 27A) or hydraulic motor adapter (135).
PRESSURE PRIOR TO PERFORMING 2. SLOWLY apply grease with a hand gun until grease begins
PUMP SERVICE OR MAINTENANCE to escape from the grease relief fitting port. Discard
excess grease in accordance with the proper codes and
CAN CAUSE PERSONAL INJURY OR
regulations.
Hazardous pressure PROPERTY DAMAGE.
can cause 3. Replace the grease relief fittings (76A).
personal injury or
property damage.
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
DISCONNECTING FLUID OR lubrication, excessive grease on pumps equipped with
PRESSURE CONTAINMENT mechanical seals can cause seal failure.
COMPONENTS DURING PUMP
OPERATION CAN CAUSE SERIOUS VANE REPLACEMENT
PERSONAL INJURY, DEATH OR MAJOR
Hazardous pressure
can cause
NOTICE:
personal injury or PROPERTY DAMAGE. MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
property damage.
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
IF PUMPING HAZARDOUS FLUIDS THIS MANUAL.
SYSTEM MUST BE FLUSHED PRIOR 1. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 2 - 6 in the
TO PERFORMING SERVICE.
"Pump Disassembly" section of this manual.
2. Turn the shaft by hand until a vane comes to the top (12
Hazardous or toxic
fluids can cause o'clock) position of the rotor. Remove the vane.
serious injury.
3. Install a new vane, ensuring that the rounded edge is UP,

5
 MAINTENANCE
and the relief grooves are facing towards the direction of a. Bend up the engaged lockwasher tang and rotate the
rotation. See Figures 2 and 3. locknut counterclockwise to remove it from the shaft

4. Repeat steps 2 and 3 until all vanes have been replaced. b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
5. Reassemble the pump according to steps 2 - 7 and 12 - 17
of the "Pump Assembly." section of this manual. c. Repeat steps a and b on the opposite shaft end.
5. The TX(S)4-inch pump model is equipped with bearing lock
collars (24A). To remove:
a. Remove the jam nuts (24C) and loosen the two set
screws (24B).
b. Slide the lock collar off the shaft.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21) and carefully pry the
head (20) away from the cylinder (12).
7. Slide the head off the shaft. The head O-ring (72), bearing
(24), and mechanical seal (153) or lip seal (152) will come
off with the head assembly. Remove and discard the head
Figure 2 - Vane Installation - TX(S)(D) Models* O-ring.
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.
a. Pull the bearing (24) from the housing in the head (20).
b.To remove the mechanical seal (153), use two screw
drivers to gently push the backside of the seal jacket to
push the seal from the head (see Figure 4). Use care
when placing the screw drivers to prevent damage to
the seal faces. Remove and discard mechanical seal
O-rings.

Figure 3 - Vane Installation - TXV Models*

Figure 4 - Mechanical Seal Removal
*NOTE: 2-inch pump models have four (4) vanes.

PUMP DISASSEMBLY c. To remove the lip seal assembly (152), use a thin pry
bar against the lip seal retaining ring to gently push the
NOTICE: housing (152B) out of the head (20). Use care not to
FOLLOW ALL HAZARD WARNINGS AND damage the lip seal (152A). To remove the lip seal
INSTRUCTIONS PROVIDED IN THE "MAINTENANCE" (152A), remove the retaining ring (152D) from the
SECTION OF THIS MANUAL. housing, and gently pry the lip seal from the housing.
Remove and discard the housing O-ring(s) (152C and
1. Starting on the inboard (driven) end of the pump, clean the 152E).
pump shaft thoroughly, making sure the shaft is free of
8. Pull the rotor and shaft (13) from the cylinder (12). While
nicks and burrs. This will prevent damage to the
one hand is pulling the shaft, the other hand should be
mechanical seal or lip seal when the inboard head
cupped underneath the rotor to prevent the vanes (14) and
assembly is removed.
push rods (77) from falling out. Carefully set the rotor and
2. Remove the inboard bearing cover capscrews (28) and shaft aside for future vane replacement and reassembly.
slide the inboard bearing cover (27A) and gasket (26) off
9. Remove the remaining components from the outboard side
the shaft. Discard the bearing cover gasket. On the 1.5, 2,
of the pump, as instructed in steps 6 and 7 above.
2.5, and 3-inch pump models, the dirt shield (123A) will
come off with the bearing cover.
PUMP ASSEMBLY
3. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off Before reassembling the pump, inspect all component
the shaft. Discard the bearing cover gasket. parts for wear or damage, and replace as required. Wash
out the bearing /seal recess of the head and remove any
4. If equipped with locknuts and lockwashers (24A and 24B): burrs or nicks from the rotor and shaft.

6
 MAINTENANCE
e. Install new housing O-ring(s) (152C and 152E) in the
1. Reassemble the OUTBOARD side of the pump first:
groove(s) of the housing. Lightly grease the housing O-
a. For a CLOCKWISE rotation pump, position the pump ring(s) and push the lip seal and housing assembly into
cylinder with the INTAKE port to the left. the head recess with the lip seal inward. The lips of the
lip seal will face the rotor when the housing is installed.
b. For a COUNTERCLOCKWISE rotation pump, position
Make sure the housing is bottomed out in the back of
the pump cylinder with the INTAKE port to the right.
the head (20).
2. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 5.

Figure 6 - Lip Seal - TXV “B” Models

Figure 5 - Head O-ring Installation

3. Install the head (20) on the outboard side of the cylinder

(12). Install and uniformly tighten four head capscrews
(21) 90o apart, torquing to 25 lbs ft (34 Nm).

4. MECHANICAL SEAL (If equipped)

Apply a small amount of motor oil in the head recess. Push
the mechanical seal assembly (153) into the recess of the
head with seal jacket drive tangs inward. The pin in the
stationary seat must be between the lugs in the back of the
head recess.

5. LIP SEAL ASSEMBLY (if equipped) Figure 7 - Lip Seal - Discontinued TXV “A” Models
The lip seal assembly (152) consists of a metal housing
with elastomer(s) around its outer diameter(s), and a teflon
6. Hand pack the ball bearing (24) with grease. Refer to the
lip seal in its inner diameter. TXV “A” model pumps are
"Lubrication" section for the recommended grease.
equipped with spacer washers. Refer to Figures 6 and 7.
7. Install the bearing (24) into the head recess. The bearing
a. Apply a small amount of light motor oil on the inner
balls must face outward, with the grease shield inward.
diameter of the lip seal housing (152B) to facilitate lip
Ensure the bearing is fully and squarely seated against the
seal (152A) installation.
lip seal housing (152B) or mechanical seal (153). On TXV
Note: When installing the lip seal, be careful not to pump models, install two 3/8" (10 mm) washers and two
damage the lip seal O-ring. bearing cover capscrews (28) to clamp the bearing and
b. On TXV “B” model pumps, push the lip seal (152A) compress the lip seal housing inner O-ring (152E) for
squarely into the housing (152B) with the pin in the lip proper bearing locknut adjustment (see Figure 8). The
seal aligned with the hole in the back of the housing. washers and capscrews will be removed after the locknuts
The lip seal should seat flush or slightly recessed in the are adjusted.
housing, around its entire diameter.
c. On TXV “A” model pumps, insert the spacer washers
(152F) into the housing, then push the lip seal (152A)
squarely into the housing (152B) with flat side of the lip
seal against the spacer washers. The lip seal should
seat flush or slightly recessed in the housing, around its
entire diameter. Note: If necessary, the spacer
washers can also be located after the lip seal, as shown
in Figure 7, to re-position the lip seal on the pump shaft.
d. Insert the retaining ring (152D) into the groove in the
housing. Figure 8 - Clamping the Bearing

7
 MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on c. Loosen both locknuts (24A) one complete turn.
the opposite, inboard end. d. Tighten one locknut (24A) until a slight rotor drag is felt
9. Remove the vanes (14) and push rods (77) from the rotor when turning the shaft by hand.
and shaft assembly (13). Inspect for wear and damage, e. Back off the nut the width of one lockwasher tang "B".
and replace as follows: Secure the nut by bending the closest aligned
a. Partially install the non-driven end of the rotor and shaft lockwasher tang into the slot in the locknut. The pump
(13) into the open side of the pump cylinder (12). should turn freely when rotated by hand.
b. Leave part of the rotor outside of the cylinder so that the f. Tighten the opposite locknut (24A) by hand until it is
bottom vanes (14) can be installed and held in place as snug against the bearing (24). Then, using a spanner
the push rods (77) are installed in the push rod holes of wrench, tighten the nut the width of one lockwasher
the rotor. Insert the new vanes into the rotor slots with tang. Tighten just past the desired tang, then back off
the rounded edges outward, and the vane relief the nut to align the tang with the locknut slot. Secure
grooves facing TOWARDS the direction of rotation. the nut by bending the aligned lockwasher tang into the
Refer to Figures 2 and 3. slot in the locknut. The pump should continue to turn
freely when rotated by hand.
c. After the bottom vanes (14) and push rods (77) are
installed, insert the rotor and shaft (13) fully into the g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
cylinder (12).
done, one or both locknuts (24A) are too tight and
d. Install the remaining vanes (14) into the top positions of should be alternately loosened one stop at a time
the rotor. If equipped with a mechanical seal (153), (.001") (25 microns). Begin by loosening the locknut
rotate the shaft by hand to engage the drive tangs adjusted last.
of the seal jacket in the rotor slots.
h. On TXV pumps, after adjustment is complete, remove
10. Install the inboard head (20), mechanical seal (153) or lip the bearing cover capscrews (28) and 3/8" washers from
seal (152), and bearing (24) as instructed in steps 2 both ends of the pump.
through 7. Apply a thin coating of motor oil on the inboard
shaft to aid installation. 13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models
a. Slide the lock collar (24A) over the shaft and against the
11. Rotate the shaft by hand to engage the mechanical seal
drive tangs (if equipped), and to test for binding or tight bearing (24), with the counterbored side towards the
spots. If the rotor does not turn freely, lightly tap the rims of bearing.
the heads (20) with a soft faced mallet until the correct b. Push the collar (24A) forcibly against the bearing (24)
position is found. Install all of the remaining head by hand, while tightening the two setscrews (24B).
capscrews (21) for each head (20) and uniformly torque to Install and tighten the two jam nuts (24C) against the
25 lbs ft (34 Nm). collar.

12. LOCKNUT INSTALLATION (if equipped) c. Repeat this procedure on the opposite pump end. After
installing both lock collars, verify the shaft turns freely
It is important that th e bearing locknuts (24A) and when rotated by hand.
lockwashers (24B) be installed and adjusted properly.
14. Inspect the grease seal (104) for wear or damage and
Overtightening locknuts can cause bearing (24) failure or a
replace as required. Grease the outside diameter of the
broken lockwasher tang. Loose locknuts will allow the rotor grease seal and push it into the bearing cover (27 or 27A)
(13) to shift against the heads, causing wear. See Figure 9. with the lip of the seal inward. The lip will face outward
when the bearing cover is installed on the head.
15. Attach a new bearing cover gasket (26) and the bearing
cover (27 or 27A) to the head (20). Install and torque the
bearing cover capscrews (28) to 15 lbs ft (20 Nm).
16. Follow steps 14 and 15 to install the grease seal (104) and
bearing cover (27 or 27A ) on the opposite side of the
pump. On TXV pump models, the outboard bearing cover
(27) is also a shaft protector and must be installed on the
non-driven shaft end.
17. On 1.5, 2 and 2.5-inch pump models, push the dirt shield
(123A) over the inboard shaft and firmly against the
bearing cover (27).
Figure 9 - Locknut Adjustment 18. On TX(S)D pump models, attach the shaft protector (186)
on the non-driven shaft end.
a. On both ends of the pump shaft, Install a lockwasher
(24B) with the tangs facing outward, followed by a OPERATION WITHOUT SHAFT
locknut (24A) with the tapered end inward. Ensure the PROTECTOR CAN CAUSE SERIOUS
inner tang "A" of the lockwasher is located in the slot in
PERSONAL INJURY, MAJOR
the shaft threads, bending it slightly, if necessary.
PROPERTY DAMAGE, OR DEATH.
b. Tighten both locknuts (24A) to ensure that the bearings
(24) are bottomed in the head recess. DO NOT Do not operate
without guard
overtighten and bend or shear the lockwasher inner in place.
tang.
8
 GENERAL PUMP TROUBLESHOOTING

NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS
ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND
WARNINGS AS PRESENTED IN THIS MANUAL.

SYMPTOM PROBABLE CAUSE

Pump Not Priming 1. Pump not wetted.

2. Worn vanes.
3. Suction valve closed.
4. Leaks in the suction line.
5. Strainer clogged.
6. Suction line or valves clogged or too restrictive.
7. Broken drive train.
8. Pump vapor-locked.
9. Pump speed too low for priming.
10. Relief valve partially open, worn or not seating properly.

Reduced Capacity 1. Pump speed too low.

2. Suction valves not fully open.
3. Leaks in the suction line.
4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows
& fittings, clogged strainer, etc.).
5. Damaged or worn parts.
6. Excessive restriction in discharge line causing partial flow through the relief valve.
7. Relief Valve worn, set too low, or not seating properly.
8. Vanes installed incorrectly (see "Vane Replacement").

Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid source.
2. Running the pump with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line (see "Pump Drive").
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Excessively worn rotor.
9. Malfunctioning valve in the system.
10. Relief valve setting too low.
11. Damaged vanes (see following category).

Damaged Vanes 1. Foreign objects entering the pump.

2. Running the pump dry.
3. Cavitation.
4. Viscosity too high for the vanes and /or the pump speed.
5. Incompatibility with the liquids pumped.
6. Excessive heat.
7. Worn or bent push rods, or worn push rod holes.
8. Settled or solidified material in the pump at start-up.
9. Hydraulic hammer - pressure spikes.
10. Vanes installed incorrectly (see"Vane Replacement").

Troubleshooting continued on page 10.

9
 GENERAL PUMP TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE

Broken Shaft 1. Foreign objects entering the pump.
2. Viscosity too high for the pump speed.
3. Relief valve not opening.
4. Hydraulic hammer - pressure spikes.
5. Pump/driver misalignment.
6. Excessively worn vanes or vane slots.
7. Settled or solidified material in the pump at start-up.

Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Lip seal not seated properly.
7. Corrosion on lip seal housing.
8. Mechanical seal faces cracked, scratched, pitted or dirty.

10