BLACKMER TX User Manual

BLACKMER TRUCK PUMPS
960280
INSTRUCTIONS NO. 201-A00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: TX, TXD - 1.5, 2A, 2.5A, 3E, 4A
Section
Effective
Replaces
201
May 2012
Jan 2012
Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts Lists
201-A01, 201-A02, 201-A03, 201-A04 and 201-A05.
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 ..................................................... 9
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.

BLACKMER TX Specifications

General

Brand	BLACKMER
Model	TX
Category	Water Pump
Language	English

Summary

Safety Data and Warnings

Safety Alert Symbol Explanation

Explains the safety alert symbol and signal words used in the manual for hazard communication.

General Safety Precautions

Highlights installation by qualified personnel, manual retention, qualified service, manual review, and decal maintenance.

Pump Data and Identification

Technical Data

Provides key operating specifications like temperature, speed, viscosity, and pressure limits for TX (D) models.

Initial Pump Start Up Information

Fields for recording essential pump data like model, serial, installation date, and initial readings.

Installation Procedures

Installation Guidelines

Emphasizes qualified installation, system design, and adherence to regulations and safety standards.

Pre-Installation Cleaning

Instructions for flushing new pumps and cleaning system components to remove contaminants.

Location and Piping

Guidelines for optimal pump placement, pipe support, line sizing, and instrument installation.

Truck Mounting

Recommendations for mounting the pump on vehicles, considering position for draining.

Pump Drive System

Details on drive shaft alignment, universal joints, slip joints, and avoiding vibration.

Hydraulic Drive and Rotation

Hydraulic Drive System

Explains hydraulic drive options, motor support, and coupling lubrication for specific pump sizes.

Confirming Pump Rotation

Advises checking pump rotation arrows against driver rotation for correct operation.

Changing Pump Rotation (TXD Models)

Procedure for TXD models: rotate pump 180 degrees and use shaft protector on non-driven end.

Changing Pump Rotation (TX1.5, TX4 Models)

Procedure for TX1.5/TX4 models: requires pump disassembly and reassembly.

Pump Operation

Pre-Start Up Checklist

Ensures proper setup including pipe alignment, gauge installation, piping support, and hose connections.

Start Up Procedures

Step-by-step guide for initiating pump operation, checking parameters, and inspecting system.

Pump Speed Management

Stresses the need for speed control devices to prevent exceeding maximum RPMs.

Reverse Rotation Operation

Advises on necessary safety measures, like installing a relief valve, for limited reverse operation.

Pump Flushing and Relief Valve

Flushing Procedure

Detailed steps for evacuating fluid, using cleaning fluid, and recirculating it via closed discharge for cleaning.

Flushing Notices

Important notices regarding residual fluid and proper disposal of waste fluids after flushing.

Relief Valve Usage

Clarifies the internal relief valve's purpose (over-pressure protection) and limitations as a system control.

Adjusting Relief Valve Pressure

Provides instructions for increasing or decreasing the relief valve pressure setting.

Factory Relief Valve Setting

States that pumps are factory set to the mid-point of the spring range unless specified.

Security Seal Requirements

Mentions the use of holes in the relief valve cap for security seals by officials.

Maintenance Procedures

Qualified Technician Requirement

Emphasizes that maintenance must be performed by qualified technicians following manual procedures.

Strainer Maintenance

Highlights regular strainer cleaning to prevent pump starvation, with scheduling based on conditions.

Lubrication Procedures

Guidelines for lubricating bearings and couplings, recommended greases, and frequency.

Manual Greasing Steps

Detailed steps for manual greasing, including removing fittings, applying grease, and replacement.

Auto Greasing Systems

Guidance for auto greasing systems, emphasizing correct adjustment to avoid component failure.

Vane and Pump Component Service

Vane Replacement Procedure

Steps to remove head, position rotor, remove old vanes, install new vanes with rounded edge up, and reassemble.

Pump Disassembly Steps 1-3

Remove bearing covers and gaskets, discard gaskets. Dirt shield may come off with cover.

Pump Disassembly Steps 4-7

Remove head capscrews, pry head away, slide head off shaft, remove O-ring, bearing, and mechanical seal.

Pump Disassembly Steps 8-9

Pull rotor/shaft from cylinder, supporting vanes/push rods. Remove remaining components from outboard side.

Pump Assembly and Seals

Pump Assembly Steps 1-3

Position cylinder, install head O-ring, install head, and tighten capscrews.

Mechanical Seal Installation

Install mechanical seal assembly into head recess, hand pack bearing with grease, install bearing.

Pump Assembly Steps 7-10

Turn cylinder around, install rotor/shaft/vanes/push rods, install remaining vanes, and install inboard head/seal/bearing.

Locknut Installation

Instructions for installing and adjusting bearing locknuts and lockwashers to prevent binding or looseness.

TX4 Lock Collars and Relief Valve

Lock Collar Installation (TX4 Models)

Steps for sliding, tightening, and securing lock collars on TX4 models and verifying shaft rotation.

Relief Valve Assembly Steps

Instructions for inserting valve, spring, guide, gasket, cover, adjusting screw, and cap.

Troubleshooting Notice

Emphasizes that maintenance must be performed by qualified technicians following manual procedures.

Pump Not Priming

Lists probable causes for pump not priming, such as worn vanes, clogged strainer, or air leaks.

Troubleshooting Common Issues

Reduced Capacity Causes

Identifies causes for reduced pump capacity like low speed, suction line restrictions, or worn relief valve.

Pump Noise Causes

Lists causes of pump noise, including excessive vacuum, drive line issues, bearings, or damaged vanes.

Damaged Vanes Causes

Explains causes of vane damage, such as foreign objects, running dry, cavitation, or incorrect installation.

Broken Shaft Causes

Lists causes of broken shafts, including foreign objects, high viscosity, misalignment, or hydraulic hammer.

Mechanical Seal Leakage Causes

Identifies causes of mechanical seal leakage, such as incompatible O-rings, damaged shaft, or overgreased bearings.