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MODEL NUMBER: _4T – DHW – 1D81

1. en 3 LES Ei s U N 7 hs THOMPSON iJ PUMP EXPERIENCE INNOVATION Before starting this pump read this instruction manual carefully This pump has been thoroughly tested before delivery and the performance has been checked and certified within acceptable limits This manual is considered a permanent part of your pump It must be available to all operators of the pump and should remain with the pump if resold If the instructions for use and maintenance are observed the pump will give full performance for a long time This manual also contains information for the prevention and elimination of most common operating problems In event of difficulty contact our service representative who will be able to resolve any particular problems that may arise CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Please note that to receive warranty coverage the pump unit must be registered for warranty upon receipt by the owner Please provide the information requested on the form included at the back of this document To ensure rapid delivery of parts or to resolve difficulty with the pump all requests should be as complete as possible and include the following information as a minimum Model Number 4T DHW 1D81 Unit Serial Number 4T Type of Pump 4 Aluminum Trash
2. Consult Diesel Engine Trouble Shooting Guide Switch 1 position Warning light 2 position Starting Key always in on 1 position when engine is runnin y y 1 Turn the key switch to position 1 Verify all warning lights are lit Page 20 of 60 Effective Date 6 11 2012 THOMPSON iJ PUMP EXPERIENCE INNOVATION 2 Turn key switch to position 2 The engine should start If the engine does not start within 20 seconds return the key switch to the O position OFF and wait at least 1 minute before attempting again 3 When engine starts key switch automatically returns to position 1 NOTE Make sure that all warning lights are off when the engine is running For engines with starting panel equipped with engine protection make sure the OK light only keeps ON 4 Allow the engine to remain at idle speed minimum per the chart below Temperature Time lt 20 C 5 minutes 20 C 10 C 2 minutes 10 C 5 C 1 minute 5 C 20 seconds CAUTION During 1 50 hours do not exceed 70 of maximum rated power WARMING UP After the engine has started run for 1 minute at a low engine speed Full load running while the engine is cold can cause the engine to emit black exhaust smoke and shorten engine life While warming up check the engine for any abnormal noise or vibration RESTARTING AFTER STARTING FAILURE When attempting to restart the engine after starting failure be sure that the engine is
3. thus extend the life of the seal SPRING EE m d 3 S A 4 SPAAN i AS ASDA TE TE E SS SS N A DRIVING BAND DISC PRIMARY RING SEALING FACE The seal housing is lubricated with grease CHECK VALVE A suction flapper style check valve is provided on the suction side of the pump Page 16 of 60 Effective Date 6 11 2012 m THOMPSON id PUMP DESCRIPTION OF OPERATION CENTRIFUGAL PUMP The centrifugal pump is basically a rotating shovel for liquid Each rotation it expels a portion of the liquid The volume of the portion of liquid represents how many gallons per minute the pump delivers The liquid is thrown off the vane tips At the center of the shaft there is no relative motion but the liquid there moves out to replace the liquid thrown off the tip This creates a low pressure area at the shaft center which is also the liquid inlet pump suction External pressure on the liquid supply which is usually atmospheric pressure forces more liquid into the pump suction The amount of velocity of the liquid as it leaves the pump determines how much head or pressure the pump will develop This is determined by the diameter of the vane and how many revolutions per minute it makes shaft speed DIESEL ENGINE INTAKE VALVE BOTH VALVES OPEN FUEL EXHAUST VALVE CLOSED INJECTION OPEN EXHAUST INTAKE COMPRESSION POWER EXHAUST In the Dies
4. Pump Serial Number Reference Number of the spare part Description of the spare part The information and specifications in this publication were in effect at the time of approval for printing The manufacturer reserves the right to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever Page 2 of 60 Effective Date 6 11 2012 THOMPSON mJ PUMP EXPERIENCE INNOVATION TABLE OF CONTENTS PREGAUTIONS neni E A uma cea I LE at esM RE P LU CEU 5 EFFECTS OF COLD WEATHER ON DIESEL ENGINES enm rImrmR rnm rrmnrre rre rii 7 DO S AND DON TS 0 b kb tk bb kat kaa atake aaa aaa aaa aaa aaa aaa teaeaaastassaesoetoesseesoessessoasoeosonsoeosoosonsoonsaneonnoun 9 PUMP SAFETY lili ttl bb kt tk kt kaa kaa atak aaa aaa tea aaa aaa saaa aaa tesesaastasseesoetossseesoessessoasseosoasoeosaasonssenaannonoaun 10 ENGINE SAFE WA eta dada near ace od ae eko kd an E E pe e dak M IM pe kafe pe kata P MTM RUNI DUE MDC QUE EE 11 COMPONENTS IMPELLER kek t tt t kt kat kaka IRI aaa ata aaa aaa stae saa tdassaeseetoeoseessesssesoassesseasouosaosonsonosanaansonnon 15 MECHANICAL SEAL kb tt bb kte kat kk w taa aaa aaa aaa aaa aaa aaa te ssaeseseosoetoessessoessessoesoeosonsonsaanaoneannon 15 GHECK VAVE tt te ct tan a te a nt a et ante e etic gee e he n e a a n e a e ene e 15 DESCRIPTION OF OPERATION CENTRIFUGAL PUMP kb k tk bk kt kaa taa kaa II aaa taa aaa ata eaaasaaseaesaettesssesoesoe
5. distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have spilled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing panels made of porous material are not soaked with fuel or oil and make sure that the ground on which the machine is located has not absorbed fuel or oil To start the engine follow the specific instructions provided in the engine and or machine operating manual Do not use auxiliary starting devices not originally installed on the machine e g Startpilot systems which utilize ether etc Before starting remove any tools that have been used for carrying out maintenance work to the engine and or the machine and check that any guards removed have been replaced In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start The liquids must be mixed in the tank by pouring in first the kerosene and then the diesel fuel Consult your servicing dealer for correct mixture proportions Petrol may not be used because of the risk of it forming flammable vapors During operation the surface of the engine reaches temperatures that may be dangerous Avoid in particular all contact with the exhaust system Before carrying out any work on the engine turn it off and allow it to cool down Do not perform any operati
6. flying particles from grinding drilling or hammering operations or fluids such as fuel solvents lubricants and brake fluids from damaging your eyes Normal glasses do NOT provide adequate protection ALWAYS wear a hard hat and safety shoes FIG 2 ALWAYS wear hearing protectors when exposed to high noise levels for extended periods ALWAYS wear a respirator when painting or exposed to dusty conditions ALWAYS keep your pockets free of loose objects which can fall aut and dran inta machinery FIG 45 Haaw alaves should he warn FIG 5 THOMPSON id PUMP EXPERIENCE INNOVATION EXHAUST FUMES Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension be positive the area is adequately ventilated al FIG 6 HEAVY PARTS Handle tools and heavy parts sensibly with regard for yourself and other persons Lower items don t throw or drop them ALWAYS use proper hoisting equipment for lifting heavy loads ALWAYS Use a back brace when lifting by hand FIRE PREVENTION Whenever possible use a non flammable solvent to clean parts Do not use gasoline or other fluids that give harmful vapors If flammable fluids such as gasoline or diesel fuel must be used extinguish open flames or sparks and DO NOT smoke Store dangerous fluids in a
7. iJ PUMP EXPERIENCE INNOVATION Manually tighten the filler cap Excess tightening may cause to damage the filler cap WARNING Do not overfill the oil pan with engine oil Be sure to keep the specified level between upper and lower limit on the dipstick Warm up the engine by running for approximately 5 minutes while observing for any oil leakage Stop the engine after warming up and leave it stopped for about 10 minutes Recheck the engine oil level with dipstick replenish if necessary If any oil is spilled wipe it away with a clean cloth DRAINING OF THE FUEL TANK 1 Place a suitable container with at least 5 gallon capacity below the tank to catch the fuel NOTE If necessary transfer the contents of the 5 gallon drum to a larger capacity drum and then continue draining The larger capacity drum may be allowed to settle out and recover some of the fuel for future use Recovery of dirty fuel from temporary storage container Sediment Loosen the drain plug from the fuel tank to drain water dirt etc from the fuel tank bottom Please dispose of dirty fuel in a manner that is compatible with the environment We suggest you take the dirty fuel in a sealed container to your local recycling center Do not throw it in the trash pour it on the ground or down a drain as the fuel can be harmful to the environment Page 29 of 60 Effective Date 6 11 2012 N Po hs THOMPSON id PUMP EXPERIENCE IN
8. is SAFETY important to YOU 3 BIG REASONS e Accidents KILL or DISABLE e Accidents COST e Accidents CAN BE AVOIDED NOTICE OF COPYRIGHT PROTECTION AEM Safety Manuals are protected as a copy righted work with ownership duly registered with the Copyright Office Washington D C Any reproduction translation decompiling or other use of an AEM Safety Manual or portion thereof or the creation of derivative works based on an AEM Safety Manual without the prior written approval of AEM is expressly prohibited Copyright infringement can result in civil and criminal sanctions damages and other penalties being imposed Copyright 2004 Association of Equipment Manufacturers Page 51 of 60 Effective Date 6 11 2012 a THOMPSON id PUMP EXPERIENCE INNOVATION FOREWARD This safety manual is intended to point out some of the basic situations which may be encountered during the normal operation and maintenance of your equipment and to suggest possible ways of dealing with these conditions Additional precautions may be necessary depending on application pump type configuration and attachments used conditions at the work site or in the maintenance area The manufacturer has no direct control over pump application operation inspection lubrication or maintenance Therefore it is your responsibility to use good safe practices in these areas The information provided in this manual supplements the specific information about your p
9. on decrease the engine speed to reduce the load on the engine After 5 minutes stop the engine check the cause and take the necessary action Oil or Fuel Leakage or Loose Bolts Occasionally check the engine and its peripheral parts for any symptoms of leakage or loosened bolts Hoses Always keep an eye on the level of the fluid being pumped to ensure that the suction hose does not become uncovered allowing the pump to run dry for an extended period of time Care should be taken to ensure that the discharge hose does not become crimped or allowed to move excessively while the pump is running Low Fuel Level in Tank Always replenish fuel before the level drops too low during operation If level gets too low air will be drawn into the fuel injection pump and the pump will not be able to function properly NOTES Allowable inclined engine operation 35 degree s maximum Excess inclined engine operation may result in white exhaust smoke sudden engine over speed or engine internal damage getting engine oil into the intake port Operate the engine on a surface that is as level as possible Avoid low load running as much as possible Operation at low speeds for long periods of time may result in carbon mixing in with the unburned fuel depositing the piston head injection nozzle and exhaust pipe to cause engine trouble Page 22 of 60 Effective Date 6 11 2012 THOMPSON aJ PUMP EXPERIENCE INNOVATION Do not turn the ke
10. speed of rotation if seals are removed or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel In addition to all other machine specifications ensure that the engine is in a near horizontal position when starting If starting manually ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects Rope starting except for recoil rope starting is not permitted even in emergencies Check that the machine is stable so that there is no risk of it overturning Get to know the engine speed adjustment and machine stop operations Do not start the machine in closed or poorly ventilated environments The internal combustion process generates carbon monoxide an odorless and highly toxic gas so spending too long a Page 12 of 60 Effective Date 6 11 2012 Li ws THOMPSON d PUMP EXPERIENCE INNOVATION time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death The engine may not be used in environments containing flammable materials explosive atmospheres or easily combustible powders unless adequate and specific precautions have been taken and are clearly stated and certified for the machine To prevent the risk of fire keep the machine at a distance of at least one meter from buildings or other machines Children and animals must be kept at a sufficient
11. 6 of 60 Effective Date 6 11 2012 N THOMPSON m PUMP EXPERIENCE INNOVATION Warranty Registration Form IMPORTANT Please note that to receive warranty coverage the pump unit must be registered for warranty upon receipt by the owner Please provide the information requested below Name Title Company Address City State Zip Phone Fax DATE PURCHASED Unit Serial Number Type of Pump Serial Number E mail address Revised documents will be e mailed when available At Thompson Pump s discretion revised documents will be batched and distributed on CD PLEASE FILL IN FORM AND MAIL THIS WARRANTY REGISTRATION FORM UPON RECEIPT MAIL TO THOMPSON PUMP P O BOX 291370 PORT ORANGE FL USA 32129 Page 47 of 60 Effective Date 6 11 2012 N n f hs THOMPSON PUMP EXPERIENCE INNOVATION Parts Order Form IMPORTANT To expedite orders and lessen mistakes it is recommended that a fax be sent with the following information Name Title Company Address City State Zip Phone Fax E mail address Unit Serial Number VERY IMPORTANT List of parts by part number description and quantity If the part numbers s are unknown please give as full a description as possible so that we may expedite your shipment FAX NUMBER 386 761 4498 e mail partssales thompsonpump com Phone Number Toll Free 888 421 7185 Gary Peake Nellie Morris Steve Seymour Parts Sa
12. ATION Warranty Policy Definitions Warranty a warranty is defined as a guarantee written by the manufacturer which assures the integrity of a product in respect to its performance reliability and durability during specified period of time see Limited Warranty Warranty is intended to protect the consumer from a faulty product However it should be clearly understood that the bilateral communication associated with warranty provides the manufacturer with the necessary information required to institute design manufacturing or quality control improvements which are intended to result in an improved product line Material Defect a material defect is an inherent flaw in the material often undetectable until its flaw causes a failure due to the part being unable to perform its normal function Examples of a material defect would include incorrect raw material or casting defects Defective Workmanship relates to the improper assembly of the pump or any of its sub assemblies or to the dimensional incorrectness of any of the components Examples of defective workmanship would include misalignment incorrect bolt tightening incorrect assembly or the absence of a correct or required component Sales Policy or Goodwill Adjustments from time to time the company will issue Sales Policy adjustments as a settlement which Thompson may make as its option which are beyond the scope of the Thompson Limited Warranty policies and which are not ne
13. DO NOT stick fingers into a pump when in operation Check suction strainer and hose regularly for proper submergence and to be sure it is free of obstructions NEVER operate a self priming pump unless the volute is filled with liquid The pump will not prime when dry PUMP only liquids for which the pump has been designed to handle DO NOT pump flammable corrosive or caustic materials unless the pump and piping are explicitly designed for that purpose A pump should not be operated against a closed valve or other no flow conditions Refer to the pump manufacturer s recommended practice for start up operation and shut down procedures DO NOT close down or restrict a discharging hose Be careful of discharge hose whipping under pressure MAKE CERTAIN that whatever is to be connected to the pump is not subjected to pressures greater than those given in the manufacturer s instructions MAKE CERTAIN all connections are securely made and hoses under pressure are secured with appropriate safety devices to prevent whipping BE AWARE OF LIGHTNING Stay clear of the pumping equipment during electrical storms It can attract lightning FIG 10 OVERHEATING PRECAUTIONS Overhead pumps can cause severe damage to the equipment and can cause severe physical burns and injury Operating a pump with the suction and or discharge valve closed is a principal cause of overheating Approach cautiously any pump that has been in operation DO NOT re
14. Drive Pensacola FL 32514 504 South 70 Street Kansas City KS 66111 1481 Dogwood Dr Conyers GA 30012 TOLL FREE 800 767 7313 PHONE 913 788 2583 PHONE 678 382 0151 PHONE 850 478 2833 FAX 913 788 5568 FAX 678 382 0153 FAX 850 479 4349 SARASOTA SERVICE CENTER JACKSON MISSISSIPPI BRANCH BALTIMORE BRANCH 6851 26th Court East Sarasota FL 34243 2110 Hwy 49 S Florence MS 39073 7527 Montevideo Rd Jessup MD 20794 TOLL FREE 800 767 7312 TOLL FREE 800 767 7314 PHONE 410 799 0451 PHONE 941 755 3177 PHONE 601 932 4916 FAX 410 799 0454 FAX 941 753 8618 FAX 601 932 4918 WEST PALM BEACH SERVICE CENTER 15935 Assembly Loop Jupiter FL 33479 GOLDSBORO NORTH CAROLINA BRANCH 2963 U S 13 North Goldsboro NC 27534 TOLL FREE 800 767 7311 TOLLFREE 800 767 7308 PHONE 561 624 7801 PHONE 919 778 2743 FAX 561 624 7803 FAX 919 778 7335 Page 50 of 60 Effective Date 6 11 2012 N e be THOMPSON ad PUMP EXPERIENCE INNOVATION JCIATION OF ary PORTABLE PUMPS m ai www aem org NT A SAFETY MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL SAFETY ALERT SYMBOL This Safety Alert Symbol means ATTENTION is involved The Safety Alert Symbol identifies important safety messages on machines safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message Why
15. EASONAL VISCOSITY OIL AND PROPER COOLANT CONCENTRATION Use seasonal grade viscosity engine oil based on expected air temperature range between oil changes and a proper concentration of low silicate antifreeze as recommended See Diesel Engine Oil and Engine Coolant Requirements Page 7 of 60 Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION DiESEL FUEL FLOW ADDITIVE For IMPORTANT Treat the fuel when outside temperature drops below 0 C 32 F best results use with untreated fuel Follow all instructions recommended on the label Page 8 of 60 Effective Date 6 11 2012 DO oo ee AE at a O U O z j r OS CO Tu SE TOM Pa D THOMPSON mJ PUMP EXPERIENCE INNOVATION Do s AND DON TS Consult the engine amp pump manufacturer s instructions before starting the unit Follow all safety health amp environmental rules and procedures Make sure all guards and shields are in place and secured before starting engine Ensure that the pump is level stable and secure before starting Fill pump with water before starting Ensure wear plate amp impeller are in good condition Impeller to wear plate gap should be between 015 030 Keep suction lift to a minimum and support all hoses amp piping as needed Check fuel supply verify adequate fuel level amp check for contamination Tighten all suction connections properly use pipe compound or Teflon tape Use only goo
16. Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the SAFETY INFORMATION on page 24 and the chapter titled BEFORE OPERATION WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actions that expose you to carbon monoxide SUCTION HOSE CONNECTION The hose must be the same size or larger than the suction port connection A larger suction hose will improve pump efficiency i e using a 3 suction hose on a 2 pump To prevent collapse of the hose use a hose that is reinforced with a non collapsible wall such as braided wire construction Keep the pump as close to the liquid you are pumping Avoid kinks or tight bends in the hose DiscHARGE HOSE CONNECTION The discharge hose must be the same size or larger than the discharge port connection A hose that is too small will result in pump casing damage Use of a larger hose on the discharge connection will improve pump output by lowering the fluid friction caused by the hose After checking the gasket connect the hose to the discharge and tighten it securely STARTING THE PUMP Do not actuate the starter for more than 20 seconds at a time If the engine does not start wait 1 minute before repeating the attempt If the engine does not start after two attempts trace the cause prior to proceeding
17. G ccccccccccccecccececececeeeeceueesueusueuuueeeuueeeuuueeeeeueueueueueuaeueueueueeeneeuaaess 37 COMMON DIESEL PROBEEMS es deowiotoik od kata bk kd ako ed ttnt t kd lk S 1H EUN ke a SUR s AFER AE Vos bd ne 39 TORQUE REFERENCE CHART viw tt wavajf satan aaa a a Ra cna a n E a ond o a a ra c b cu a a 47 LUE SIS IR MTM PP 48 WARRANTY REGISTRATION FORM L 0 cccccececeeceeceseecceeueeceeueseueueeeceueseuaueueueeueueeusueeeeeuensesues 50 a biebEIim ESP TETTE 51 MANUAL REGISTRATION FORM atteeeeeeeorooeooooueooooueoooooeoeoooueeoooeeeoonneeooonevoooneooonneooonneoonnnesonnnen 52 THOMPSON PUMP MANUFACTURING CONTACT LIST cccccccccccceeececeeeceeeueseeeueeeueseeeeuseeeaeseeens 53 Page 4 of 60 Effective Date 6 11 2012 m THOMPSON PUMP EXPERIENCE INNOVATION PRECAUTIONS DO NOT OPERATE the pump without all covers guards in place Never remove any cover plate or drain plug from any overheated pump Allow the pump to cool prior to adding any fluids Prior to starting M Check all fluid levels within normal levels M Ensure all covers guards are in place M Locate pump on a surface which will not cause it to tip roll slide or fall M Exhaust fumes can kill DO NOT OPERATE the engine in a confined or enclosed space without adequate ventilation Operating Problems may affect emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Har
18. L 33905 504 South 70 Street Kansas City KS 66111 21 Arnold Farm Rd W Greenwich RI 02817 TOLL FREE 877 689 7634 PHONE 816 935 5311 PHONE 401 397 4950 PHONE 239 690 0600 FAX 913 788 5568 FAX 401 397 4980 FAX 239 690 0904 JACKSONVILLE SERVICE CENTER SAVANNAH SERVICE CENTER CHARLESTON SERVICE CENTER 6743 Greenland Industrial Blvd 125 Westside Blvd Pooler GA 31322 120 Jed Park Place Summerville SC 29483 Jacksonville FL 32258 TOLL FREE 800 767 8507 TOLL FREE 800 767 7309 TOLL FREE 800 767 7305 PHONE 912 330 0233 PHONE 843 879 0393 PHONE 904 292 4883 FAX 912 330 0280 FAX 843 879 0397 FAX 904 262 5183 ORLANDO SERVICE CENTER BATON ROUGE SERVICE CENTER CHESAPEAKE VIRGINIA BRANCH 706 W Landstreet Road Orlando FL 32824 18394 Tom Dr Hammond LA 70403 1321 Victory Blvd Chesapeake VA 23323 TOLL FREE 800 767 7304 TOLL FREE 800 510 5649 TOLL FREE 800 767 7307 PHONE 407 812 4007 PHONE 985 321 0070 PHONE 757 485 4690 FAX 407 812 4030 FAX 985 321 0074 FAX 757 485 4779 PANAMA CITY SERVICE CENTER MARYLAND SERVICE CENTER MYRTLE BEACH SERVICE CENTER 1619 Florida Ave Lynn Haven FL 32444 38190 Old Stage Rd Unit A Delmar DE 19940 157 Winyah Road Conway SC 29526 PHONE 850 277 0445 PHONE 302 907 0292 PHONE 843 347 5532 FAX 850 277 0120 FAX 302 907 0532 FAX 843 347 5542 PENSACOLA SERVICE CENTER KANSAS CITY BRANCH ATLANTA GEORGIA BRANCH 3310 McLemore
19. LER HAS ANY AUTHORITY TO BIND THE SELLER TO ANY AFFIRMATIONS REPRESENTATION OR WARRANTY CONCERNING THE PRODUCT SOLD UNDER THIS WARRANTY THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF IMPLIED WARRANTIES WHEN APPLICABLE SHALL COMMENCE UPON THE SAME DATE AS THE EXPRESS WARRANTY ABOVE AND SHALL EXCEPT FOR WARRANTIES OF TITLE EXTEND ONLY FOR THE DURATION OF THE WARRANTY Some states do not allow limitations on how long the implied warranty lasts so the above limitations may not apply to you The only remedy provided to you under an applicable implied warranty or the express warranty shall be the remedy provided under the express warranty subject to the terms and conditions contained therein Thompson Pump 8 Mig Co Inc shall not be liable for incidental or consequential loses and damages under the express warranty any applicable implied warranty or claim for negligence except to the extent that this limitation is found to unenforceable under applicable state law Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For more information contact the Thompson Pump Service Department at 800 767 7310 Page 45 of 60 Effective Date 6 11 2012 N Po hs THOMPSON id PUMP EXPERIENCE INNOV
20. NOVATION 3 Drain until fuel with no water or sediment comes out Then tighten the drain plug firmly It is recommended to use Teflon tape on the threads of the drain plug to ensure zero leakage around the threads REPLACE THE FUEL FILTER 1 Place a container under the fuel filter prior to unthreading This will prevent unnecessary fuel spillage 2 Turn the engine fuel filter counter clockwise using a filter wrench customer procured to remove it 3 Clean the engine fuel filter mounting face 4 Moisten the new engine fuel filter gasket with diesel fuel and install the new engine fuel filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 34 of a turn with the filter wrench Tightening torque 15 to 17 ft lbf REPLACING THE AIR CLEANER ELEMENT 1 Remove the cover Remove the air filter 2 Install a new air filter back into the filter housing 3 Replace the cover CHECK TORQUE OF ALL NUTS AND BOLTS Check that all the nuts and bolts on the engine and the pump unit are torqued to the proper value using the supplied torque reference chart CHECKING AND CLEANING COOLING FINS o Whenever using compressed air for cleaning wear protective equipment such as goggles to protect your eyes Dust or flying debris can cause severe eye irritation O Dirt and debris adhering on the engine cooling fins reduce the cooling performance causing overheating Make it a rule t
21. ON Runs ps Black White Rough P Smoke Smoke ower X X X X X X X X X X X X X X X X X X X X X X o Air can cause numerous problems with the diesel engine and is one of the hardest problems to solve The best way to determine that air is the problem is to hook up a clear hose in the return system If air is coming through the return system then it is Page 39 of 60 Effective Date 6 11 2012 A rmm THOMPSON aJ PUMP EXPERIENCE INNOVATION probably getting into the system on the inlet side somewhere and causing problems with the fuel system o Air can enter the system two ways The first is a bleed back where air is evident after the engine sets inoperative for a period of time and the fuel drains back to the tank and the system has to be reprimed The engine may or may not start but if it does start it may only run a few seconds die and refuse to start immediately The lift pump is one of the most common causes of this situation however any opening in the fuel system can allow this situation o Constant air out the return and constant rough running missing and white smoke can also be an indication of air in the system In this situation air is usually entering the system somewhere prior to the pump inlet If a fuel leak is evident this should be checked and repaired first however a fuel leak does not necessarily have to be evident where air is entering Sometimes the fuel system can be pressured up by an external fuel pump If a
22. ON FLAPPER 1 Remove the suction line 2 Remove the three nuts 18 from the suction port 30 Remove the suction port 30 and flapper 29 3 Replace the flapper 29 4 Install the suction port 30 to the pump cover 28 using serviceable thread sealant blue and the three nuts 18 Page 36 of 60 Effective Date 6 11 2012 m l THOMPSON PUMP EXPERIENCE INNOVATION PUMP TROUBLESHOOTING GUIDE Pump fails Air leaks on suction side of system Tighten connections seal leaks to prime low Suction lift too high Check and lower pump if possible 20 volume output max Obstruction in Suction or Discharge Clear obstruction back flush Broken belt on vacuum system Replace with spare belt Clogged vacuum system suction line Clear suction line check eductor clear Overheated liquid in pump casing Check proper discharge path Impeller worn or broken Replace impeller Impeller clogged with debris Disassemble and clean impeller volute Wearing ring worn Replace wearing ring Suction strainer is clogged by debris Clean strainer Discharge head greater than rated capacity Evaluate discharge path contact manufacturer Discharge check valve clogged Clear check valve check operation Engine running to slow See engine troubleshooting guide Pump fails to Viscosity of the liquid is higher than expected Contact servicing dealer provide proper Engine governor high setting incorrect Reset governor under no load conditions pressure En
23. RSELF MAINTENANCE MORE DIFFICULT MAINTENANCE TASKS SHOULD BE PERFORMED BY YOUR AUTHORIZED SERVICING CENTER THEY ARE BEST EQUIPPED AND STAFFED TO PROVIDE THE LEVEL OF SERVICE AND SAFETY YOU AND YOUR PUMP DESERVES MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance practice is essential for safe economical and trouble free operation It will also help reduce pollution To help you properly care for your pump the following pages include routine inspection procedures and simple maintenance procedures using basic hand tools Other procedures are found in your engine manufacturer s service manual Difficult or technically intensive tasks are best handled by your servicing dealer or other qualified mechanic The preventive maintenance schedule applies to normal operating conditions If you operate your pump under severe conditions such as sustained high load or high temperature operation or use in unusually dusty conditions consult your servicing dealer for recommendations applicable to your use To ensure the best quality and reliability use only genuine dealer parts for repair or replacement Use of other manufacturer s parts may void your pump warranty MAINTENANCE SAFETY Some of the most important safety precautions are as follows However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task SAFETY PRECAUTIONS M Make
24. SAE Society of Automotive Engineers Inc 400 Commonwealth Drive Warrendale PA 15096 Publishes a list Operator Precautions SAE J153 May 87 AEM Association of Equipment Manufacturers 111 East Wisconsin Avenue Milwaukee WI 53202 This manual is another in a series on the safe operation of machinery published by AEM For additional publications visit our web site at www aem org Association of Equipment Manufacturers ANT Toll free 1 866 AEM 0442 e mail aem aem org ta WWW Gem OTg ki w PP 130 2 Page 58 of 60 Effective Date 6 11 2012 THOMPSON d PUMP EXPERIENCE INNOVATION Page 59 of 60 Effective Date 6 11 2012 A l THOMPSON aJ PUMP EXPERIENCE NNOVATION Registration Form WARRANTY AND MANUAL REGISTRATION IMPORTANT Please note that to receive warranty coverage the pump unit must be registered for warranty upon receipt by the owner Please provide the information requested below Name Title Company Address City State Zip Phone Fax DATE PURCHASED November 16 2011 Model Number 4T DHW 1D81 Unit Serial Number 4T Type of Pump Serial Number E MAIL ADDRESS Revised documents will be e mailed when available At Thompson Pump s discretion revised documents will be batched and distributed on CD PLEASE FILL IN FORM AND MAIL THIS WARRANTY REGISTRATION FORM UPON RECEIPT MAIL TO THOMPSON PUMP P O BOX 291370 PORT ORANGE FL USA 32129 NOTE To r
25. T OVERFILL Ensure the dipstick is firmly seated to prevent debris from entering the sump INSPECTION AFTER INITIAL 50 HOURS OPERATION CHANGE ENGINE OIL AND OIL FILTER Oo Page 26 of 60 Use caution while the engine oil is still hot being careful not to splash engine oil on your skin which may cause burns Change the dirty oil while the engine is warm This allows the oil to drain quickly and completely The initial wear of internal parts of the engine results in the oil getting dirty rapidly Effective Date 6 11 2012 N a THOMPSON mJ PUMP EXPERIENCE INNOVATION Place a suitable container with at least 1 gallon capacity below the engine to catch the used oil and then remove the dipstick and the oil filler cap from the engine Removing the oil filler cap allows the engine oil to drain quickly Open the oil pan drain plug and allow all of the oil to drain completely Install the drain plug tightened securely Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain as oil can be harmful to the environment Turn the screw on the oil filter counter clockwise using an allen wrench customer procured to remove it Clean the engine oil filler mounting face Moisten the new engine oil f
26. and battery if so equipped Always replace safety devices removed during service or repair before returning pump to operation Battery Servicing e Always wear safety glasses and gloves when servicing or working with batteries e Before servicing battery turn off electrical systems then disconnect ground terminal clamp Before installing a battery turn off electrical equipment then connect the battery ground clamp last e Maintain electrolyte at the recommended level Check level frequently Add distilled water to batteries only when starting up never when shutting down Use a flashlight to check level NEVER use a flame e Donot short across battery terminals the spark could ignite the battery gases Battery acids will burn skin eat holes in clothing and can cause blindness if splashed in eyes If you spill acid on yourself flush skin immediately with lots of water Apply baking soda to help neutralize the acid If acid gets into the eyes flush immediately with large amounts of water and seek proper medical treatment immediately Page 56 of 60 Effective Date 6 11 2012 WORK SAFELY ELECTRIC MOTOR DRIVEN PUMPS Follow motor manufacturer s recommended maintenance and operation instructions If circuit breaker or fuse is stripped examine the system for the problem before restarting pump NEVER use the power cord to aid lifting the pump NEVER operate a pump with a plug in type power cord without a ground fau
27. at a complete stop before turning the key CAUTION Do not turn the key to the 2 position when the engine is not completely stopped or during operation Otherwise the starter motor pinion or ring gear will be damaged Wait at least 1 minute before the second attempt to allow for battery voltage recovery AFTER THE ENGINE HAS STARTED After the engine has started warm up the engine and check the following points If an abnormality is found stop the engine and correct the abnormality If in doubt contact your servicing dealer Alarm lamps Page 21 of 60 Effective Date 6 11 2012 N rmm THOMPSON id PUMP EXPERIENCE INNOVATION Fuel leaks and oil leaks from engine Color of exhaust gas Vibration or noise ADJUSTING THE ENGINE SPEED This engine speed is controlled by the governor lever on the side of the engine A stud with a wing nut is used to lock the governor lever in a constant speed position preventing movement due to pump vibration IMPORTANT CHECKS DURING OPERATION Exhaust Gas Color Avoid engine operation if black smoke continues to come out Black smoke is generated when the engine is overloaded This shortens the engine life Abnormal Noise or Vibration Depending on the machine unit structure resonance may arise at a certain engine speed resulting in sudden violent vibration Avoid engine operation near that speed If this occurs contact your servicing dealer Alarm Lamps If an alarm lamp comes
28. ater water containing solids and non potable liquids It is not designed to pump potable drinking water and should never be used for this application Due to the pump operation the pump assembly and or hoses may move up and down or side to side during operation This may cause the pump to move around while the pump is operating Depending on factors such as hose length and the surface that the pump is installed on this movement may result in injury and consideration should be given to anchor the pump prior to operation Unless the pump is monitored continuously it is advisable to anchor the pump and hoses to ensure no unexpected movement This pump is designed to pump solids up to 1 0 inch While pumping the liquids with the solids entrained it is possible that the solid material will get lodged in the clapet preventing the clapet from closing completely Maximum pump performance can be achieved with the discharge hose angled slightly upwards during pump operation If the discharge hose will be running across a road or in a traffic area provide a means of protecting the hose such as 4 x 4 boards running parallel to the hose or a traffic control ramp specifically designed for this application to prevent collapse of the hose and subsequent pump damage If this pump is used in an area where freezing may result ensure that the pump is completely drained prior to being left idle to prevent pump casing damage Page 19 of 60
29. cessarily related to either a material defect or improper workmanship This type of settlement is generally regarded as a public relations instrument Warranty Approval Rejection In all cases Thompson Pump reserves the right to approve reject or partially approve a warranty claim The Thompson Warranty Department will provide to the best of its ability a failure analysis decision within 30 days of receipt of the completed claim It must be understood that the Thompson Pump Warranty Department will evaluate and assess all warranty claims All warranty approvals will be based upon our standard warranty policy A detailed Warranty Claim Form must be submitted to the Thompson Pump Warranty department within 10 days after the failure occurs The Warranty Claim Form must be complete and accurate when it is submitted to Thompson Pump All damaged parts must be retained and returned to Thompson Pump if and when requested In cases where the full or partial amount of a warranty claim is approved a copy of the approved warranty claim will be returned with an evaluation letter and a credit memo for the appropriate parts labor and mileage Labor will be reimbursed to the distributor for labor hours in accordance with Thompson Pump s established repair policies set by the Warranty Department Thompson Pump will reimburse the distributor at a rate for a single mechanic equal to 7596 of the distributors straight time flat shop rate not to exceed 45 00 per h
30. ct the positive terminal from the battery 3 Connect a DC voltmeter between the and terminals on the battery 4 Connect an ammeter between the positive pole on the battery and the B terminal on the voltage regulator 5 Start and stop the engine until the battery voltage drops below 13 vdc 6 When battery voltage reaches 14 5 volts the ammeter current should suddenly drop down to almost zero Page 31 of 60 Effective Date 6 11 2012 N Q A hs THOMPSON id PUMP EXPERIENCE INNOVATION 7 Replace the regulator if the recharge current is zero with voltage less than 14 0 volts WARNING When the engine is running do not disconnect the battery cables or switch the key to OFF position Keep the voltage regulator away from heat sources greater than 75 C Do not perform electric welds on the engine Page 32 of 60 Effective Date 6 11 2012 4G e THOMPSON d PUMP EXPERIENCE INNOVATION PUMP PREVENTIVE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD Every Perform at every indicated Fach Daily Monthly 9 Months month or operating hour interval 2500Hrs whichever comes first 1 Pump Volute Flush Hoses and Strainer Check Seal Housing Grease x 2 Cil Seal Inspect Mechanical Seal Inspect se Impeller and Wearing Ring Inspect All Critical Fasteners Check se Torque 1 For commercial use log hours of operation to dete
31. currence of most common accidents This pump is designed to pump liquids including muddy water water containing solids and non potable liquids It is not designed to pump potable drinking water and should never be used for this application Pumping flammable liquids such as gasoline can result in a fire or explosion resulting in serious injury or death Pumping chemical solutions such as acids or pumping salt water Such as seawater can result in corrosion to the pump internals resulting in damage to the pump This pump is designed to be operated on level ground to avoid spillage of any oil or fuel from the pump engine All forms of warranty will cease to apply if the safety instructions are not observed The non observance of the safety regulations and operating instructions will also lead to all forms of warranty ceasing to apply WARNING SYMBOLS These are the warning symbols which are used in this manual WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury Page 11 of 60 Effective Date 6 11 2012 A p THOMPSON id PUMP ENGINE SAFETY SAFETY INSTRUCTIONS Hatz engines are built to provide safe and long lasting performances but in order to obtain these results it is essential that the maintenance requirements described in th
32. d Apply heat to the fuel filter to break up the wax DO NOT USE OPEN FLAME TO HEAT THE FUEL FILTER Page 6 of 60 Effective Date 6 11 2012 m f b THOMPSON iJ PUMP EXPERIENCE INNOVATION MINIMIZING THE EFFECT OF COLD WEATHER ON DIESEL ENGINES Diesel engines are designed to operate effectively in cold weather However for effective starting and cold weather operation a little care is necessary The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine Contact your servicing dealer for additional information and local availability of cold weather aids USE GRADE No 1 D FUEL When temperatures fall below 5 C 40 F Grade No 1 D Fuel is best suited for cold weather operation Grade No 1 D fuel has a lower cloud point and a lower pour point CLOUD POINT the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug POUR POINT the temperature at which fuel begins to thicken and becomes more resistant to flow through fuel pumps and lines NOTE On an average Grade No 1 D fuel has a lower BTU heat content rating than Grade No 2 D fuel When using Grade No 1 D fuel you may notice a drop in power and fuel efficiency but should not experience any other engine performance effects Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation S
33. d Starting or Stalling after Starting Rough Idle Misfiring or Back firing under Load Runaway Diesel keeps running after key is turned off White or Black Exhaust Smoke High Fuel Consumption The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen are very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Prior to shutdown M Reduce the RPM to minimum M Allow for the engine to cool M Shutdown the engine per applicable procedure Page 5 of 60 Effective Date 6 11 2012 n f hs THOMPSON m PUMP EXPERIENCE INNOVATION Do not allow the pump to sit idle for long periods with water in the pump casing Below 15 F wax crystals begin to form in diesel fuel These will clog the fuel filter and stop the engine as the temperature drops toward 0 F Any good winter fuel conditioner for diesel fuel will keep the fuel moving to atleast 20 F Follow the instructions on the bottle If the fuel has already gelled due to the cold The time proven remedy is to add a gallon of kerosene for each 10 to 20 gallons of fuel to the tank then allow it to sit long enough for the kerosene to diffuse into the fuel In weather below 20 F one gallon of kerosene for 10 gallons of fuel will keep things moving but fuel economy will be reduce
34. d hose gaskets and good quality reinforced suction hose Use a trash strainer or foot valve when open pumping and keep it clean and free from obstructions Avoid air traps in the suction amp discharge lines and make sure that suction line is designed with a slight slope to the pump Follow the maintenance schedule as specified in the manual Drain the pump and all hoses amp piping during extended periods of non usage or during freezing weather Allow inexperienced personnel to operate equipment unless they are supervised Forget safety health amp environmental precautions Attempt suction lifts over twenty five feet Allow impeller amp wear plate to wear excessively creating a large gap Allow the suction line to become clogged or mired in mud Forget to grease mechanical seal as prescribed in manual Lift the pump with suction or discharge hoses attached Operate the pump at an excessive angle of inclination Allow the unit to run out of fuel Run the engine faster or slower than the recommended operating speed range By pass or disconnect any safety shutdown switches or gauges Neglect periodic service and maintenance Perform any service or repairs while the engine or the pump end is running or is hot Operate the unit while a discharge valve is closed or the discharge line is obstructed Page 9 of 60 Effective Date 6 11 2012 c E em THOMPSON id PUMP EXPERIENCE INNOVATION RULE OF THUMB Diesel fuel
35. e manual are observed along with the following safety recommendations The engine has been built to the specifications of a machine manufacturer and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by Hatz which therefore declines all responsibility for accidents caused by such operations The following instructions are intended for the user of the machine in order to reduce or eliminate risks especially those concerning the operation and standard maintenance of the engine The user should read these instructions carefully and get to know the operations described By not doing so he may place at risk his own heath and safety and that of anyone else in the vicinity of the machine The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of the dangers involved This is particularly true for standard and above all special maintenance work For special maintenance contact personnel trained specifically by Hatz This work should be carried out in accordance with existing literature Hatz declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine s functional parameters or to the fuel flow rate adjustments and
36. eceecaeeaeeseeeaeeceeeaees 22 STOPPING THE ENGINE 0ccceccecececcecceeececcueececceceaeecuecuecaeecuecaeececceeaeeceeeeeseceueeaeeseeeaes 23 SERVICING THE PUMP MAINTENANCE tt kt tk kt kaa kaa kaa taa aaa aaa aaa aaa saaa aaa ea saaeseasaesoesoessesstesoeosousoaosonsonssanaaneannon 24 THE IMPORTANCE OF MAINTENANCE 0ccceccecececceeeceececcecececcueeeeeceeeaeececceeeaeeceeeaeeeeeeass 24 MAINTENANCE SAFETY 2 0cccecceeccecceccecececcaecaeccuecaeeceecaeeceecuecaeeceeeeeseecueeaeeteesteeaeeeaees 24 SAFETY PRECAUTIONS 0ccceccecececcecceeececceeceecueeateceecuecauecuecaeeceeceeaeeceeceeseecueeaueseeeaes 24 Page 3 of 60 Effective Date 6 11 2012 A p THOMPSON id PUMP EXPERIENCE INNOVATION DIESEL ENGINE PREVENTIVE MAINTENANCE ccccccceccsccecseeucceeeueesceueeseeueeeueeueueueeeueeeeeuaess 25 AIR CLEANER ELEMENT id d da atitid aka d ol ak kl al kk kk a bd kk a kk ka dak e kb kk ke kek kb km bd ka 26 ENGINE OIL CHECK TT 26 INSPECTION AFTER INITIAL 50 HOURS OF OPERATION cccceceeeseeeeceseeeseeeueeeeueeseeeeeeeeans 26 ENGINE OIL CHANGE a si ri s z rca klas sens blie sons te de oue pous kons asie Ja FrRpat Fete puxrS9dabbesdeap Ee dd 26 INSPECTION EVERY 150 HOURS OF OPERATION veeeeteeoeooeeoeouooorouoooeouonoooonsooonoooounoeooonn 28 ENGINE Oll CHANGE inniti need nda cen onec dea 28 DRAIN FUEL ANK eR m 29 REPLACE FUEL FILTER aoi qisict ula uiua adi Dax Mud tM as
37. eceive warranty coverage for parts that are not manufactured by Thompson Pump the individual warranty cards provided must be returned for warranty within 30 days of receipt by the owner Order No Page 60 of 60 Effective Date 6 11 2012
38. ection Back Supports Other job related specific items Do not wear loose clothing or any accessory flopping cuffs untied show laces dangling neckties and scarves rings wrist watches or other jewelry that can catch on protruding or moving parts or controls Long hair should be securely bound to prevent entanglement with moving parts FIG 3 BE ALERT Know where to get assistance Know how to use a first aid kit and fire extinguisher or fire suppression system FIG 4 BE AWARE Take advantage of training programs offered Safety programs should require that one person at each jobsite be assigned the overall responsibility and authority for safety Know who the person it and COMMUNICATE with the Know what the jobsite rules are and FOLLOW THE RULES Be safety conscious responsible and reliable Think about safety BEFORE something happens BE CAREFUL Human error is caused by many factors carelessness fatigue overload preoccupation incompatibility between operator and the equipment drugs and alcohol to name a few Damage to the equipment can be fixed in a short period of time but injury or death has a lasting effect For your safety and safety of others encourage your fellow workers to act within safety rules PERFORM MAINTENANCE SAFELY CLOTHING AND PERSONAL PROTECTIVE ITEMS ALWAYS wear appropriate safety glasses goggles or face shield when working FIG 2 Proper eye protection can keep
39. efore beginning your pre operation checks be sure the pump is level and the engine switch is in the OFF position CHECK THE GENERAL CONDITION OF THE PUMP Look around and underneath the engine for signs of oil or diesel fuel leaks Remove any excessive dirt or debris especially around the muffler and recoil starter Look for signs of damage Check that all shields and covers are in place and all nuts bolts and screws are tightened CHECK THE ENGINE Check the engine oil level Running the engine with a low oil level can cause damage Check the air filter A dirty air filter will restrict air flow to the engine reducing engine performance Check the fuel level Starting with a full tank will help to eliminate or reduce operating interruptions for refueling CHECK THE PUMP SUCTION AND DISCHARGE HOSES Check the general condition of the hoses prior to connecting them to the pump The suction hose must be made of a reinforced material to prevent collapse during operation Page 18 of 60 Effective Date 6 11 2012 THOMPSON iJ PUMP EXPERIENCE INNOVATION The gasket on the suction hose must be in good condition and properly installed All hose connectors and clamps must be in good condition and properly installed If installed ensure the strainer is clean and in good condition Ensure that the discharge hose is secured to prevent movement and possible injury This pump is designed to pump liquids including muddy w
40. el the fuel is not mixed with the air entering the cylinder during the intake stroke Air alone is compressed during the compression stroke The Diesel fuel oil is injected or sprayed into the cylinder at the end of the compression stroke In Diesel engines compression ratios are as high as 22 5 to 1 and provide pressures of 500psi at the end of the compression stroke Through the compression process the air can be heated up 1000 degrees F This temperature is high enough to spontaneously ignite the fuel as it is injected into the cylinder The high pressure of the explosion forces the piston down on the power stroke then as the piston moves upward the exhaust stroke the exhaust valve opens clearing the gases out of the cylinder making the cylinder ready to repeat the process Page 17 of 60 Effective Date 6 11 2012 A oo THOMPSON iJ PUMP BEFORE OPERATION IS YOUR PUMP READY For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the engine and or the pump to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the engine WARNING Improperly maintaining this pump or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a pre operation inspection before each operation and correct any problems B
41. ents Do not smoke or use naked flames while filling Take care when removing the oil filter as it may be hot The operations of checking filling up and replacing the cooling liquid must be carried out with the engine turned off and cold Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard The cooling liquid is polluting so dispose of itin a manner that does not damage the environment During operations which involve access to moving parts of the engine and or removal of the rotary guards disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor Check belt tension only when the engine is turned off In order to move the engine use exclusively the eyebolts fitted for this purpose by Hatz These lifting points are however not suitable for the entire machine so in this case use the eyebolts fitted by the manufacturer SAFETY INSTRUCTIONS FOR INSPECTION MAINTENANCE AND INSTALLATION WORK Work may only be carried out on a pump unit that is shutdown The pump unit may not be under pressure and both the pump unit and the diesel engine must be completely cooled down The procedures for shutting down the pump unit are described in the Operating Instructions and must be observed at all times Pumps used to process hazardous substanc
42. es must first be cleaned and or decontaminated As soon as the work is complete all safety provisions and guards must be re installed prior to continued pump operation When shutting down a pump unit for maintenance the ground wire on the diesel engine must be disconnected prior to performing any work on the pump unit Page 14 of 60 Effective Date 6 11 2012 N pe THOMPSON d PUMP EXPERIENCE INNOVATION UNAUTHORIZED MODIFICATION Modifications and or changes to the pump unit are only permitted with Thompson Pump Mfg approval The use of original spare parts and accessories will contribute to safety In the case of other parts being used Thompson Pump Mfg shall be discharged from any form of responsibility for the consequences ensuing therefrom Page 15 of 60 Effective Date 6 11 2012 THOMPSON sd PUMP EXPERIENCE INNOVATION COMPONENTS CENTRIFUGAL PUMP IMPELLER Non Clogging with tangential volute A 4 inch 2 vane impeller with a single wall volute Capable of pumping up to 675 gallons of water per minute depending on suction hose size and suction lift height MECHANICAL SEAL The seal is composed of tungsten carbide seats nitrile rubber elastomers grease lubrication and a back up lip seal The carbide seats have a low resistance to dry running and if the pump takes a long time to prime this could damage the seal Grease surrounds the seal housing to provide continuous lubrication
43. essure Relief Devices e Lifting Devices NEVER START OR OPERATE A PUMP KNOWN OR SUSPECTED TO BE DEFECTIVE OR MALFUNCTIONING FIG 9 If your daily check uncovers any items that need attention repair replacement or adjustment report them promptly The most minor malfunction could be the result of more serious trouble or can cause it if pump is operated When in doubt attach an OSHA Lockout Tagout device tag to the control panel to disconnected electrical power supply at breaker on electrically driven pumps and disconnect the battery and or spark plug wire on engine driven pumps Page 54 of 60 Effective Date 6 11 2012 WORK SAFELY PUMPS IN GENERAL SAFE WORKING PROCEDURES USE COMMON SENSE Most accidents can be avoided by using common sense and concentrating on the job to be done ONLY EXPERIENCED AND QUALIFIED personnel should install and operate pump equipment KNOW THE PROPER starting procedure for your equipment Follow the manufacturer s operation manual to the letter DO NOT operate a pump without all guards and shields in place If OSHA required guards are damaged or misplaced contact the manufacturer for replacement When lifting pump use only lifting equipment in good repair and with adequate capacity Follow manufacturer s lifting recommendation Check all lubricant levels before pump installation in accordance with manufacturer s maintenance programs Keep hands and feet clear of moving parts
44. f LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up ALWAYS replace safety devices removed during the service or repair before returning pump to operation NEVER use the power cord to aid in lifting the pump Sizing Extension Cords Use the following chart to select the correct size extension cord to prevent excessive amperage draw or voltage drop which would cause the motor to overheat Cables that are too long or coiled can cause a voltage drop Be aware that strong sunlight can cause a voltage drop Wire Gauge and Cord Length in feet Amperes 50 100 150 6 16 16 14 8 16 14 12 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 SAFE WORKING PROCEDURES ALLOW only qualifies personnel to INSTALL WIRE and OPERATE submersible pumps Whenever electricity is present there is the possibility of electrocution NEVER use a pump motor in an explosive atmosphere if it is not exclusively designed for that application ALWAYS ground the pump Make certain to connect the pump to the right phase and voltage DO NOT run the pump if voltage is not within limits Make all electrical installations in accordance with National Electric Code State and Local electric codes Mount electrical control box in a vertical position p
45. fuel leak then becomes evident this could be the source of the air leak Visual inspection of rubber hoses line fittings and steel lines where they have been rubbed should also be made to isolate the source of the air BLACK SMOKE o Black smoke can be caused when there is an improper air to fuel ratio The fuel does not burn completely and the partially burned particles are expelled in the exhaust One of the most common causes of black smoke is an air inlet restriction This can be anything from a plugged air cleaner an intake hose collapsing or anything else causing an air flow problem even plugged exhaust o Injector malfunction is also a common cause for black smoke as is incorrect engine timing Over fueling can also cause black smoke and is one of the reasons setting a fuel system above factory specifications is strongly discouraged Internal injection pump problems can also result in black smoke WHITE SMOKE o White smoke usually occurs when there is not enough temperature to burn the fuel The unburned fuel particles are then exhausted usually by a rich fuel smell In cold weather itis not uncommon to get white smoke until engine temperature builds up One cause of white smoke on engine start up could be faulty glow plugs or glow plug system Low engine cranking speed can also create an excessive amount of white smoke o Ifthe problem persists after the engine is up to operating temperature several other things should be checked A faul
46. gine internal problem Consult engine troubleshooting guide Mechanical problem with pump Check for broken shaft bad coupling etc Foreign material inside casing Disassemble and clean impeller Bearing failure Replace bearings Driver Speed higher than planned Reduce speed overloaded Liquid specific gravity too high Contact servicing dealer Liquid handled of greater viscosity than water Contact servicing dealer Too large an impeller diameter Trim impeller Low voltage Consult power company Stress in pipe connection to pump Support piping properly Pump vibrates Pump capacity is too low Check vacuum gauge for proper suction or is noisy Pump is not mounted correctly Check mounting bolts tight Piping not mounted fixed Check for proper piping run Pump is cavitating Check Pump does not Prime section Suction strainer clogged with debris Clean strainer Obstruction in suction or discharge Clear obstruction back flush Misalignment Align all rotating parts Excessive suction lift Contact servicing dealer Clogged suction strainer Clean strainer Impeller clogged with debris Disassemble and clean impeller volute Worn bearings Replace bearings Impeller screw loose or broken Replace lockscrew Cavitation improper suction design Correct suction piping Wrong direction of rotation See start up instructions Premature Worn wearing ring Replace ring bearing failure Misalignment Align all rotating parts Suction or discharge pipe not properly Correct supports suppo
47. ials flames or spark producing devices at a safe distance while refueling e Keep fuel nozzle in contact with tank being filled or provide a ground to prevent static sparks from igniting fuel Page 55 of 60 Effective Date 6 11 2012 jT THOMPSON id PUMP EXPERIENCE INNOVATION Do not spill fuel on hot surfaces Clean up spillage immediately Do not start engine until fuel cap is secured to the fuel tank Always make sure that fuel is being put in the fuel tank motor oil in the proper location and hydraulic oil into hydraulic oil reservoirs Maintenance and Repair All installations operations and maintenance should be in accordance with pump and engine manufacturer s recommended operation and maintenance program These manuals should be kept available with the equipment Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up see Section 3 Page 5 FIG 11 BEFORE doing any major work disconnect the ignition
48. ilter gasket with the engine oil and install the new engine oil filter Cover screw tightening torque 15 to 17 ft Ibf Fill with engine oil up to the upper limit on the dipstick To check the oil level insert the dipstick in fully When checking the engine oil level with the dipstick wait for about 3 minutes and then check the level as it takes a little while for the engine oil supplied from the filler port to fill the oil pan NOTE sump capacity is 1 3 quarts Manually tighten the filler cap Excess tightening may cause to damage the filler cap WARNING Do not overfill the oil pan with engine oil Be sure to keep the specified level between upper and lower limit on the dipstick Warm up the engine by running for approximately 5 minutes while observing for any oil leakage Stop the engine after warming up and leave it stopped for about 10 minutes Recheck the engine oil level with dipstick replenish if necessary If any oil is spilled wipe it away with a clean cloth Page 27 of 60 Effective Date 6 11 2012 N Q Po hs THOMPSON id PUMP EXPERIENCE INNOVATION INSPECTION EVERY 150 HOURS OPERATION CHANGE THE ENGINE OIL AND OIL FILTER O Page 28 of 60 Use caution while the engine oil is still hot being careful not to splash engine oil on your skin which may cause burns Change the dirty oil while the engine is warm This allows the oil to drain quickly and completely The initial wear of in
49. ject to change without notice eo In the event of any breach of the warranty the original Consumer must deliver or ship the defective unit or parts freight prepaid to the factory or any of the Thompson authorized parts and service centers providing prior permission is obtained from the factory Thompson agrees that it will replace or repair at our option any such unit or parts where the defect results from a breach of its warranty without charge to the original Consumer provided said defect occurred within the warranty period Thompson or the authorized service repair centers will not be responsible for the cost of the units or parts and the shipment of said unit or parts to or from Thompson s plant or service centers Thompson s warranty obligation with regard to equipment not of its own manufacture is limited to the warranty actually extended to Thompson by its suppliers Should a failure of such motor or engine occur during the warranty period the original Consumer must notify Thompson Pump amp Mig Co Inc Port Orange Florida and follow the instructions given THIS WARRANTY DOES NOT COVER REPAIRS OR REPLACEMENT MADE WITHOUT NOTIFICATION TO THOMPSON PUMP amp MFG CO INC THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND OF ANY OTHER OBLIGATION ON THE PART OF THE SELLER NO AGENT EMPLOYEE OR REPRESENTATIVE OF THE SEL
50. leaner Element Replace Oil Cooling Fins Clean A Fuel Tank Clean S Injectors Clean Check Crankcase Oil Replace Oil Filter Replace X Fuel Filter Replace X UNDER VERY DUSTY CONDITIONS CLEAN FREQUENTLY A UNDER EXTREMELY DUSTY CONDITIONS CLEAN EVERY 8 HOURS GOOD MAINTENANCE PRACTICES DICTATES CHECKING FOR COOLANT FUEL AND OIL LEAKS AT EACH SERVICING INTERVAL CHECK TIGHT ANY SUSPECT NUT BOLT OR SCREW Page 25 of 60 Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION EACH USE AND DAILY INSPECTION AIR CLEANER ELEMENT In extremely dusty conditions the air filter may require more frequent cleaning 1 4 Remove the cover Remove the air filter Thoroughly clean the air filter in a soapy water solution Be careful not to cause any rips or tears in the filter element If the air filter is damaged replace it with a new one Thoroughly rinse and dry the air filter replace it back into the filter housing Replace the cover CHECK ENGINE OIL LEVEL 1 2 4 5 Remove the dipstick clean and replace the dipstick fully Remove the dipstick Verify that the oil level is between the min and max as marked on the dipstick If the level is below min fill the sump using the oil fill connection on the rocker arm cover or if this is not available use the hole on the drain side or the air filter side Re check oil level after filling DO NO
51. les Parts Sales Parts Sales Ext 4161 Ext 4172 Ext 4160 4620 City Center Dr Port Orange FI 32129 1370 Phone 800 767 7310 20 00 MINIMUM ORDER Page 48 of 60 Effective Date 6 11 2012 m a e THOMPSON mJ PUMP EXPERIENCE INNOVATION Manual Registration Form IMPORTANT Please provide the information requested below so that we can automatically update manual information as revisions occur Name Title Company Address City State Zip Phone Fax Unit Serial Number Type of Pump Serial Number E mail address Revised documents will be e mailed when available At Thompson Pump s discretion revised documents will be batched and distributed on CD Please return to Thompson Pump Attention Engineering Department Page 49 of 60 Effective Date 6 11 2012 N nmm THOMPSON id PUMP EXPERIENCE INNOVATION Thompson Pump amp Manufacturing Co Inc 4620 CITY CENTER DRIVE P O BOX 291370 PORT ORANGE FLORIDA USA 32129 www thompsonpump com MAIN OFFICE PARTS DEPARTMENT Jerry Tarnow Parts Sales Mgr SERVICE DEPARTMENT Bill Crooms National Service Mgr PHONE 800 767 7310 PHONE 888 421 7185 386 944 4110 386 944 4139 PHONE 800 761 7310 FAX 386 767 4753 FAX 386 761 4498 jtarnow thompsonpump com FAX 386 767 4753 bcrooms thompsonpump com FT MYERS SERVICE CENTER WEST COAST OFFICE NEW ENGLAND BRANCH 5491 Division Drive Ft Myers F
52. lt circuit interrupter NEVER use cords with frayed cut or brittle insulation Check the cord on the pump for nicks in the insulation and for sound connections to the ground fault interrupter plug and motor NEVER let extension cords or the plug connections lay in water Locate the pump so that the cord cannot fall into any water or be submerged by rising water unless the pump is designated for such use NEVER handle energized power cords with wet hands MOTOR OVERLOAD do not exceed the manufacturer s recommendation for maximum lift or discharge head See manufacturer s published curve for proper sizing of motors A misapplied motor can overheat Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the pump Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so FIG 11 Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures Pumps with float switches or other automatic devices can start without warning if not properly locked out BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal o
53. move hoses from a pump until the system is properly cooled to ambient temperature DO NOT remove the cover plate or drain plugs from any overheated pump Allow the pump to cool Check pump temperature before opening fill port or drain plug If overheating of the pump casing occurs e STOP the pump immediately e Allow the equipment to cool completely e Slowly and cautiously vent the pump e Refer to the manufacturer s instruction manual before restarting the unit e Remove hoses carefully Heated water can be in hoses and static head produces pressure FIG 10 BEFORE STARTING Check the pump thoroughly at delivery for any shipping damage Locate the pump in an accessible location as close to the liquid as possible Secure the pump after it is placed in its intended operating position so it does not tip roll slide or fall IMMEDIATELY ON STARTING THE PUMP Observe gauges instruments and warning lights to ensure that they are functioning and their readings are within the normal operating range Be sure the immediate work area is safe for operation e Operate control make certain all operate properly and feel right Accustom yourself to the feel of the equipment e Listen for any unusual noises smell for any unusual odors look for any signs of trouble e Be sure to open all manual valves slowly to prevent WATER HAMMER Check all warning and safety devices and indicators If safety related defects or malfuncti
54. nc hereinafter referred to as Thompson warrants the products it manufactures to be free of defects in materials and workmanship The warranty extends only to the original consumer purchaser hereinafter referred to as Consumer and commences on the date of sale to said Consumer and remains in effect for a period of twelve 12 months THIS WARRANTY DOES NOT COVER a Adjustment or replacement of maintenance items and wear parts such as but not limited to seals bearings lubrication and filters b Any work performed to correct malfunction caused by misuse negligence or disregard of Thompson s written instructions concerning installation operation and maintenance of its products Additional service work performed above that which is required to satisfy warranty requirements Transportation charges haul out travel time loss of use or other consequential charge or damage e Any damage caused by sand or abrasive materials chemical deposits corrosion hazardous waste or material acts of God or other outside forces beyond the control of Thompson f Engines electric motors and other items not of our manufacture Warranty on those items if any is the warranty of the manufacturer of such items g Repairs or replacement made without authorization from Thompson or repairs made other than at a service facility designated by Thompson h Delivery schedules are not covered by any warranty terms and all dates given are approximate and sub
55. o check the engine cooling fins daily and clean as needed e Blow off dirt and dust from fins and periphery with compressed air 28 psi 0 19MPa 2kgf cm or less so you do not damage the fins Page 30 of 60 Effective Date 6 11 2012 THOMPSON iJ PUMP EXPERIENCE INNOVATION e f contaminated heavily apply detergent thoroughly clean and rinse with light water spray INSPECTION EVERY 1000 HOURS OF OPERATION CHECKING AND ADJUSTING THE FUEL INJECTION VALVE Oo This adjustment requires specialized knowledge and skill consult your servicing dealer This adjustment is needed to obtain the optimum injection pattern for full engine performance ADJUSTING INTAKE EXHAUST VALVE CLEARANCE o This adjustment requires specialized knowledge and skill consult your servicing dealer The adjustment is necessary to maintain the correct timing for the opening and closing of valves Neglecting the adjustment will cause the engine to run noisily and result in poor engine performance and other damage LAPPING THE INTAKE AND EXHAUST VALVES o This maintenance requires specialized knowledge and skill consult your servicing dealer The adjustment is necessary to maintain proper contact of the valves and seats CHECKING AND ADJUSTING THE FUEL INJECTION TIMING O This maintenance requires specialized knowledge and skill consult your servicing dealer TESTING THE VOLTAGE REGULATOR 1 Check that all connections correspond to the drawing 2 Disconne
56. on while the engine is running The liquid cooling circuit is under pressure Do not carry out any checks before the engine has cooled down and even then open the radiator cap or the expansion tank cautiously Wear protective clothing and glasses If there is an electric fan do not approach the engine while it is still hot as the fan may come on even when the engine is not running Clean the cooling system with the engine turned off While cleaning the oil bath air filter check that the oil is disposed of in such a way as not to harm the environment Any filtering sponges in the oil bath air filter should not be soaked with oil The cyclone pre filter cup must not be filled with oil Page 13 of 60 Effective Date 6 11 2012 N rmm THOMPSON aJ PUMP EXPERIENCE INNOVATION Since the oil must be emptied out while the engine is still hot approximately 80 C particular care should be taken in order to avoid burns In any case make sure that oil does not come into contact with your skin because of the health hazards involved Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each filling operation Do not fill the tank right up to the top but leave sufficient space to allow for any expansion of the fuel Fuel vapors are highly toxic so fill up only in the open air or in well ventilated environm
57. ons are detected SHUT DOWN the equipment Correct the problem or notify your supervisor DO NOT OPERATE EQUIPMENT WITH DEFECTS THOMPSON sd PUMP EXPERIENCE INNOVATION e Ian unsafe condition cannot be remedies immediately notify your supervisor and tagout lockout the pump on the start switch and or appropriate prominent location FIG 11 WORK SAFELY ENGINE DRIVEN PUMPS Do not jump start engine battery When operating internal combustion engines in an enclosed area always make provisions to pipe exhaust fumes to the outside EXHAUST FUMES CAN KILL Do not operate engine driven pump equipment in a confined or enclosed space without adequate ventilation Exhaust gases are odorless and deadly poison DO NOT TOUCH The exhaust system components get very hot and stay hot for some time after shutting the engine off Follow engine manufacturer s instructions explicitly on hand cranking Do not shut down high head pumps quickly 1 Throttle back slowly 2 Open by pass line 3 Should have a check valve 4 Slowly close gate valve on discharge if so equipped Check for fuel oil and hydraulic fluid leaks worn and damaged hoses lines or power cables Refueling When refueling the following precautions must be followed e Add fuel of proper type and grade only when the pump is not running and engine is cool e Fuel in well ventilated area e Turn off all electrical switches e Keep lighted smoking mater
58. our Should a warranty repair take place in the field Thompson Pump will reimburse the distributor for labor costs as noted above and mileage The distributor must notify Thompson Pump prior to repairing the equipment at which time the Thompson Warranty Department will authorize in writing the field repair Thompson Pump will reimburse the distributor at a rate of 1 00 per round trip mile which includes the labor costs of the driver mechanic Thompson Pump will provide replacement parts to affect a warranty repair at no charge to the Distributor or the Consumer If the parts used for a warranty repair are supplied from the Distributor s stock Thompson Pump will provide the replacement parts at no charge or a credit will be issued to the Distributor for the Distributor s normal cost plus an additional 1096 discount allowed Thompson Pump does not warrant equipment or parts that are not of its manufacture but which are required in the production of a complete pump unit or accessory and any such claims must be filed with the appropriate manufacturer Examples of equipment or parts not of Thompson Pump s manufacture are but are not limited to engines air compressors vacuum pumps drive couplings wheels and tires and axles All parts for rejected warranty claims will be invoiced at standard list price less any applicable discount For more information contact the Thompson Pump Service Department at 800 767 7310 Effective 11 15 02 jjf Page 4
59. per RPM a lubrication fuel additive might be used In some cases a slight amount of water has passed through the system or an extra dry fuel has been used This causes the metering valve or plungers amp barrels to stick slightly A lubrication additive in the fuel could solve this problem o In severe cases where an additive does not work the pump needs to be torn down and cleaned In extremely severe cases the metering valve or plungers amp barrels may need to be replaced to solve the problem Page 41 of 60 Effective Date 6 11 2012 N rmm THOMPSON id PUMP EXPERIENCE INNOVATION Low POWER O In most cases low power accompanies other systems such as smoke or a miss In these cases the other symptoms should be researched first and when fixed the low power is usually fixed also If low power is the only complaint then quantity of the fuel supply should be checked On engines that have primary supply pumps the supply pump has been found to put out the proper pressure without pumping the proper quantity of fuel A fuel restriction should also be researched partially plugged fuel filters blocked fuel lines and filters in the tank on some applications If the tank is not vented properly it could build a vacuum which could act like a fuel restriction Poor fuel quality can also result in low power If the fuel system is getting air mixed with the fuel low power is often the result Air intake restrictions exhaust restrictions tran
60. rer s spec in order to assure peak engine performance o Asecond problem injectors develop is poor fuel atomization The main purpose of a nozzle holder assembly is to break the diesel fuel into small enough particles that it will burn properly An injection nozzle is lubricated by the diesel fuel and any lubrication problems such as water or poor lubricating fuel quality can cause the nozzle to stick This will hamper its ability to atomize the fuel properly Another problem causing poor atomization is an improper valve seat Sometimes due to contamination or wear the valve seat will become damaged This also stops the injector from atomizing properly In some cases a diesel injector cleaner in the fuel will help in these situations In more severe cases the nozzle will need to be removed from the assembly cleaned and reset to the manufacturers spec In most cases the nozzle tolerances are so close that once the nozzle is damaged it is not repairable and the nozzle must be replaced in the nozzle holder assembly New nozzles must then be checked and set to manufacturer s specs on a pop tester ENGINE STALLS o When the engine stalls on deceleration it is usually an indication of lubrication problems in the pump The first thing that should be checked is the idle RPM If it is too low it could put the pump governor in a position where it cannot recover from the deceleration quick enough to keep the engine from stalling o Ifthe idle is set to the pro
61. rmine proper maintenance intervals 2 For continuous operation grease seal weekly PUMP FLUSHING Proper pump care requires that the pump volute chamber be flushed with fresh water to ensure that no corrosive liquids or potentially damaging particles are left inside the pump during idle periods 1 Remove all plugs from the pump casing 2 Flush the pump from the discharge side using a high velocity stream of fresh water Continue flushing until clear water comes out of the suction side plug 3 Reinstall the plugs using new O Rings GREASE THE MECHANICAL SEAL Once per week during 24 hour per day operation apply 2 strokes of grease to the fitting on the back of the pump casing REPLACING THE MECHANICAL SEAL 1 Disconnect the suction and discharge piping 2 Remove the two bronze wrench nuts 14 and swing the tye rods 12 out of the way Page 33 of 60 Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION Remove the pump cover 28 from the pump casing 4 Remove and discard the pump cover O Ring 27 4 Remove the impeller locknut 11 and washer 10 5 Using a gear puller remove the impeller If a gear puller is not available use 3 wooden wedges equally spaced around the impeller and wedge the impeller off evenly Extreme care using wedges is important to minimize the potential of bending the shaft which could cause abnormal wear to the bearings and the mechanical seal NOTE Using a me
62. rotected from the elements NEVER attempt to use the power cord or hydraulic hoses as a lifting or lowering device for submersibles Attach a lifting cable to the manufacturer s recommended attachment point on the pump for lowering and lifting the pump FIG 12 NEVER position the pump directly on a soft loose bottom To attain maximum capacity and prevent excessive wear position the pump so it will not burrow itself into sand or clay Stand the pump in a plank a bed of coarse gravel within a perforated container on a suitable flotation device or retain it hanging freely by a lifting cable FIG 13 N THOMPSON aud PUMP EXPERIENCE INNOVATION FIG 13 Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the unit Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for E
63. rted Page 37 of 60 Effective Date 6 11 2012 A THOMPSON iJ PUMP EXPERIENCE INNOVATION Bent shaft Water or contaminates entering bearings Lubrication to bearings not adequate Wrong type of lubrication Pump Clogged suction strainer overheating Suction line clogged Worn wearing ring Premature Misalignment of coupling coupling Bent shaft failure Page 38 of 60 Effective Date 6 11 2012 Replace shaft Protect pump from environment See lubrication instructions See lubrication instructions Clean strainer Clear debris Replace ring Align coupling Replace shaft COMMON DIESEL ENGINE PROBLEMS Complaint Probable Cause Low Cranking Speed Incorrect Starting Procedure Some or All Glow Plugs Bad No Fuel to Cylinders Plugged or Restricted Return Insufficient Fuel Supply No Voltage to Shutoff Solenoid Shutoff Solenoid Bad Poor Fuel Quality Some or All Injectors Bad Incorrect Pump to Engine Timing Low Compression Bad Injection Pump Idle Speed Too Low Fast Idle Solenoid Bad Air In Fuel Governor Binding Metering Valve Sticking In Injection Pump Fuel Leaks at Injection Lines Air Inlet Restricted Incorrect Engine Timing Internal Engine Problems AIR IN THE SYSTEM Will Not To X X X X X X X X X X X X X X X X X X X X X X X X X X X X Hard Starts Dies And On Start Start Stalls Deceleration XX xXx P THOMPSON iJ PUMP EXPERIENCE INNOVATI
64. rules LIVE by them FIG 1 When starting work at a new site check with the designated safety coordinator for specific safety instructions DON T LEARN SAFETY THE HARD WAY Page 52 of 60 Effective Date 6 11 2012 Know the meaning of all hand signals signal flags signs and markings Know the traffic rules used at the work site Know who the signal man is watch and obey his signals Know where the fire extinguishers and first aid kits are kept and how to use them Know where to get proper aid and assistance when needed Use common sense to avoid accidents If an accident does occur be prepared to react to it quickly and effectively NEVER PANIC Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you Study this manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is writt for only this type of equipment Practice all other usual and customary safe working preca and above all FIG 1 REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH FOLLOW A SAFETY PROGF KNOW WHAT IT IS Consult your supervisor for sp ri 1 Instructions and personal safety equipment required For instance you may need e Hard Hat e Safety Shoes Eye Protection Respirators e Heavy Gloves e Reflector Vests e Hearing Protection e Face Prot
65. smission problems and internal engine problems have also been known to cause power problems Page 42 of 60 Effective Date 6 11 2012 N THOMPSON aJ PUMP EXPERIENCE INNOVATION Pump performance Curve Pump End 4T Pump Speed Ratings Continuous Duty 3 600 rpm Test Conditions Fluid Water S G 1 0 Temperature 68 F 20 C Altitude Sea Level 1 Atmosphere Viscosity 31 5 SSU ILL Epi L Lal md a AN A 200 300 400 00 6 2000 CAPACITY y A LLILLLLUELL LA a m AV m 9 7 00 800 USGPM NOTES Referto Thompson Unit Specification Sheets for maximum and minimum operating speeds for the particular driver Tests were conducted according to Hydraulic Institute ANSI HI 1 6 1994 Standards Hydraulic LIIGQUVOG Lau uU rI cui ce P THOMPSON mJ PUMP EXPERIENCE INNOVATION TORQUE REFERENCE CHART O B668 Qe GA EZ N y A J Inches 0 1 2 Grade 5 Grade 8 38 16 UNC 20 ft Ibf 50 13 UNC AO ft Ibf 62 11 UNC 90 ft Ibf 75 10 UNC 135 ft lbf 1 00 8 UNC 265 ft Ibf Page 44 of 60 Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION CONDITIONS OF SALE This LIMITED WARRANTY is extended only to the original consumer purchaser of products manufactured by Thompson Pump amp Mfg Co Inc P O Box 291370 Port Orange Florida 32129 1370 Telephone number 386 767 7310 Thompson Pump 8 Mfg Co I
66. ssoesoessoosousoeosansoneoann 16 DIESEL ENGINE eene aaa taa aaa aaaateaasaattatsaesoessessoesoesseosoesseosoesoaosoosonoaananeannon 16 BEFORE OPERATION IS YOUR PUMP READY ceeennn IRI aaa taa aaa aaa aaa aaa teaesaesoessessoesoesseosoesseosonsoeosansonsannon 17 CHECK THE GENERAL CONDITION OF THE PUMP 02 ccccecececcecceeececceceeeececcsececceceaeeeeeeaes 17 CHECK THE ENGINE kitte tb kt tt kte kaa aaa t aaa aaa aaa taa aaa ttaeeaastetaaesaestesseosoasoeosoesoessoosonsoeoaansoneounn 17 CHECK THE PUMP SUCTION AND DISCHARGE HOSES 0 ccccecceeececcececeececceececcuceaeeeeeeaes 17 OPERATION SAFE OPERATING PRECAUTIONS cccceececcecececceceaeececceeeceeceecaeeceeceeaeeceecaeeceecaeeaeeseeeaes 19 SUCTION HOSE CONNECTION bb bb kt katkat aa aaa ata aaa aaa seat aaa toesaesoesoeosoesoessoosonsoeosansnneounn 19 DISCHARGE HOSE CONECTION kb tt bb kte kaa tat tea aaa ata aaa aaa eeaeaaatoessaesoesosoooesoeosonsoesoanaonsannon 19 STARTING THE PUMP bk tt bb kt katkat aaa aa aaa aaa aaa ata eaaa ata seaeaaesoesssesoesseosoosoessoosousoeosansoneoann 19 SET IDLE LOW SPEED STOP or ka e a a e e ki ai ki e n kak e 21 SET HIGH SPEED STOP bl bbl bb kb tate tea a aaa aaa aaa aaa ata aaaa ata teaesaatoessaesoesoeosoesoessaosousouosansoneounn 21 ADJUSTING ENGINE SPEED kitte bbl kt tk at kaa kaa aaa aa aaa ata aaaaaaasaaesaesosesaesoesssesousoeosoesonosanauneounn 22 IMPORTANT CHECKS DURING OPERATION cccecceeececceeceeccecceeececceeeae
67. suitable place in approved containers which are clearly marked NEVER smoke in areas where flammable fluids are used or stored FIG 7 Use proper non flammable cleaning solvents Follow solvent manufacturer s instructions for use FIG 7 Page 53 of 60 Effective Date 6 11 2012 N pan A THOMPSON sd PUMP EXPERIENCE INNOVATION PREPARE FOR SAFE OPERATION LEARN TO BE SAFE NEVER operate a pump which is new to you without first being instructed in its proper operation READ the operator s manual If one has not been provided GET ONE AND STUDY IT BEFORE OPERATING THE PUMP Know the meaning of all identification symbols on your control and gauges FIG 8 Know the location of the emergency shut down control if the machine is so equipped Before attempting to operate the pump know the capabilities and limitations of the pump Familiarize yourself with controls and instruments their locations and functions Keep hands levers and knobs clean of oil or grease to prevent slipping Carefully read and follow the instructions on all safety signs and decals FIG 8 CHECK IT OUT Know what safety devices your machine is equipped with and see that each item is securely in place and in operating condition FIG 9 For example Drawbar Coupling Chains and Pins E e Alarms and Warning Lamps Reflectors Guards and Shields Drain Covers Plugs and Caps e Shut Down Devices Leveling Jacks Pr
68. sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards M Carbon monoxide poisoning from engine exhaust o Be sure there is adequate ventilation whenever you operate the engine M Burns from hot parts o Letthe engine and exhaust system cool before touching I Injury from moving parts Page 24 of 60 Effective Date 6 11 2012 m THOMPSON iJ PUMP EXPERIENCE INNOVATION o Do not run the pump unless instructed to do so M Read the instructions before you begin and make sure you have the tools and skills required M To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new manufacturer s genuine parts or their equivalents for repair and replacement KEEP GOOD RECORDS OF OPERATION Keep a record of daily operation and the results of any maintenance performed DIESEL ENGINE PREVENTIVE MAINTENANCE Every Every Every Component 8 150 1000 Hours Hours Hours Crankcase Oil Level Inspect X Nuts and Bolts for Torque Inspect X Gauges and Safety Shutdowns Inspect Clean 4 Air C
69. tal tool for removing the impeller instead of wooden wedges can cause damage to the back blades of the impeller and should be avoided a 6 Remove the mechanical seal assembly 7 from the A shaft T Remove the four screws 6 and washers 5 from the pump casing 4 8 Remove the pump casing 4 from the engine 9 Carefully remove the stationary portion of the mechanical seal 7 and the oil seal and replace with a new seal 10 Using serviceable thread sealant blue assemble the pump casing 4 on to the engine using the four screws 6 and washers 5 11 Lubricate the new mechanical seal 7 with a light film of clean oil and assemble the seal on the shaft 12 Place the spacer over the shaft and insert the key 8 on the shaft 13 Install the impeller 9 to the shaft using the old locknut 11 and washer 10 14 Measure the clearance from the impeller blade facing and the pump casing 4 O Ring seating surface 15 Measure the clearance from the top of the rubber wear plate 25 and the O Ring seating surface of the pump cover 28 Page 34 of 60 Effective Date 6 11 2012 20 B E p gt THOMPSON aJ PUMP EXPERIENCE INNOVATION If the clearance difference measured in step 14 minus the clearance measured in step 15 is greater than 0 5 mm then shims must be added between the impeller and the mechanical seal Remove the impeller and add or remove shims as necessary
70. ternal parts of the engine results in the oil getting dirty rapidly Place a suitable container with at least 1 gallon capacity below the engine to catch the used oil and then remove the dipstick and the oil filler cap from the engine Removing the oil filler cap allows the engine oil to drain quickly Open the oil pan drain plug and allow all of the oil to drain completely Install the drain plug tightened securely Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain as oil can be harmful to the environment Turn the screw on the oil filter cover counter clockwise using an allen wrench customer procured to remove it Clean the engine oil filter mounting face Moisten the new engine oil filter gasket with the engine oil and install the new engine oil filter Cover screw tightening torque 15 to 17 ft lbf Fill with engine oil up to the upper limit on the dipstick To check the oil level insert the dipstick in fully When checking the engine oil level with the dipstick wait for about 3 minutes and then check the level as it takes a little while for the engine oil supplied from the filler port to fill the oil pan NOTE sump capacity is 1 3 quarts Effective Date 6 11 2012 10 Li ws THOMPSON
71. tiranin UE VL SECUN US LU E ka rU UU VM 30 REPLACE AIR CLEANER ELEMENT ettveeeoeeeoroooooooooooeouonooouooooooooooooeooonoooonnoeooonn 30 CHECK TORQUE OF ALL NUTS AND BOLTS ceccccceeeseeeeceeeeeeesueeesueceesuaeeeeuaeeees 30 CHECK AND CLEAN COOLING FINSG eeeeeeeneeeeee enne nnne nnne h ener nennen 30 INSPECTION EVERY 1000 HOURS OF OPERATION rtveeroeeeorouoooeooooooouooooouoneooonoooaonoooooun 31 CHECKING AND ADJUSTING FUEL INJECTION VALVE eene 31 ADJUSTING INTAKE EXHAUSE VALVE CLEARANCES ccccceccsseeeeeseeeeeseeesesueeeesees 31 LAPPING INTAKE EXHAUST VALVES eeeennee eene nnnnnn nnn nnn nnne nnns nns 31 CHECK AND ADJUST FUEL INJECTION TIMING 0ccccccccceeeeeseeeeceseeeeesueeseeueeseeuaeeees 31 TESTING THE VOLTAGE REGULATOR 002trteeooeoeoooooeoooooeoeoooeoeoooneeoooneoaoonoooonooooooneoonnneoounn 31 ue sd T ak a ek kk a l 32 PUMP CHAMBER FLUSHING 2 naria EYE ER EY EE pat dada k na s kaadu asa s a E Urso Fe kr y adas s so v sdvirisouos yk 33 GREASE THE MECHANICAL SEAL ccccccceecscececececceceeeseeueseueueueeeueueueeeseuceueuaueeeaeeeees 33 REPLACING THE MECHANICAL SEAL wi otis a UE E DATUM EDAM EFE DEN a RENE DEFINE ko a DEM nrnna E OK 33 REPLACING THE WEAR PLATE asini istis aa a pev eti iia HOD aa da ka eke DA D T ADAN 35 REPLACING THE SUCTION FLAPPER 0veeroveooooeeoooooeooooonooouoooeouonooooonooonneooonnoooonnoooonneooonn 36 PUMP TROUBLE SHOOTIN
72. ty injector can cause white smoke Timing is often a factor when white smoke is excessive Low engine compression can cause the problem and the injection pump can also have problems that result in white smoke Air in the fuel system can also result in white smoke GLow PLUG o One of the main reasons an electric start engine can be hard to start is faulty glow plugs Not all the glow plugs have to be bad before the engine gets hard to start Glow Page 40 of 60 Effective Date 6 11 2012 THOMPSON aJ PUMP EXPERIENCE INNOVATION plugs can be checked several ways One of the easiest ways is with a continuity meter If the meter does not read when connected the glow plug is bad Weak glow plugs can also be detected by the actual meter reading however each application has its own specification that must be known before the test can be accurate If no reading is achieved the glow plug must be replaced INJECTOR PROBLEMS o Several symptoms relate to possible injector problems These symptoms include but are not limited to oil dilution engine running rough a dead miss smoke white or black a drop in fuel economy and starting problems o Injectors can suffer from a drop in opening pressure This usually occurs after several thousand hours in use A drop of 200 300 psi is normal and usually does not have a noticeable affect on the performance of the engine If a pressure drop is more than 300 psi the injector should be reset to manufactu
73. ump that is contained in the manufacturer s manual s Other information which may affect the safe operation of your pump may be contained on safety signs decals markings insurance requirements employer s safety programs safety codes local state provincial and federal laws rules and regulations contracts agreements and warranties It is your responsibility to read and understand this safety manual and the manufacturer s manual s before operating your pump This safety manual takes you step by step through your working day If you do not understand any of this information or if errors or contradictions seem to exist consult with your supervisor before operating your pump IMPORTANT If you do not have the manufacturer s manual s for your particular pump get a replacement manual from your employer equipment dealer or manufacturer of your pump Keep this safety manual and the manufacturer s manual s with your pump Unauthorized modifications of pumps create hazards Pumps must not be modified or altered unless prior approval is obtained from the manufacturer DO NOT PUMP VOLATILE FLAMMABLE OR CAUSTIC CORROSIVE LIQUIDS REFER TO THE OWNER S MANUAL OR CONSULT WITH THE MANUFACTURER FOR THE PROPER PUMP MATERIALS IF YOU ARE TO PUMP HAZARDOUS CAUSTIC CORROSIVE LIQUIDS FOLLOW A SAFETY PROGRAM KNOW THE RULES Each employer is concerned about safety Safe operation and proper maintenance of your pump can prevent accidents KNOW the
74. until the clearance is as close to 0 5 mm as possible Install the impeller 9 to the shaft using a new locknut 11 and washer 10 and thread sealant red Torque the locknut to 20 ft lbf Inspect the rubber wear plate surface for damage If damage is found the wear plate must be replaced and the measurements in steps 14 15 and 16 must be re done Clean the O Ring seating surface on the pump cover 28 and the pump casing 4 Install a new O Ring 27 Fit the pump cover 28 to the pump casing 4 Install the bronze wrench nuts on the tye rods and tighten firmly REPLACING THE WEAR PLATE 1 2 Remove the suction line Remove the two bronze wrench nuts 14 and swing the tye rods 12 out of the way Remove the pump cover 28 from the pump casing 4 Remove and discard the pump cover O Ring 27 Remove the three screws 26 that hold the wear plate 25 to the pump cover 28 Remove the wear plate 25 Remove and replace the volute O Ring 23 Using serviceable thread sealant blue replace the wear plate 25 to the pump cover 28 using the three screws 26 Clean the O Ring seating surface on the pump cover 28 and the pump casing 4 Replace the pump cover O Ring 27 Install the pump cover 28 to the pump casing 4 using the two bronze wrench nuts 14 tightened firmly Page 35 of 60 Effective Date 6 11 2012 THOMPSON id PUMP EXPERIENCE INNOVATION REPLACING THE SUCTI
75. will expand if left unattended in the hot sunlight This expansion of fuel is approximately 0 5 gallons for a 100 gallon tank that the temperature has risen 10 degree s Fahrenheit The standard fuel neck will hold approximately 0 25 gallons from the top of the screen to the top of the filler neck It is therefore not recommended to fill the tank above the screen in the filler neck and in areas where the temperature change is high over the course of the day it is recommended to leave enough room in the tank for the corresponding expansion Page 10 of 60 Effective Date 6 11 2012 Li ws THOMPSON mJ PUMP EXPERIENCE INNOVATION PUMP SAFETY It is the operator s responsibility to provide the necessary safeguards to protect people or property in the vicinity of this pump The operator must be familiar with the controls in order to be able to stop the pump in event of an emergency This pump contains safety devices to help ensure the safe operation and these devices should only be removed by a qualified servicing mechanic Personnel assigned for operating inspecting maintaining and installing the pump should have the correct qualifications to carry out the work in question If a member lacks the necessary knowledge he she should be trained or given a refresher course If necessary this can be arranged by Thompson Pump Mig at the request of the owner of the equipment Following the instructions contained in this manual will prevent oc
76. xcept in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up Check oil level ONLY when pump is cool USE ONLY recommended oil per manufacturer s recommendation INSPECT ELECTRICAL WIRING for worn or damaged insulation INSTALL new wiring if wires are damaged After repairs are made clean the equipment before putting the pump back into position FINAL WORD TO USER Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you You have read this safety manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is written for this type of equipment Practice all other usual and customary safe working precautions and above all REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH Page 57 of 60 Effective Date 6 11 2012 THOMPSON mJ PUMP REFERENCES The following is a partial list of referenced material on safe operating practices U S Department of Labor publishes safety and health regulations and standards under the authority of the Occupational Safety and Health Act for the general construction and mining industries U S Department of Labor Washington DC 20210 NFPA National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 0101
77. y to the 2 position while the engine running Otherwise the starter motor pinion or ring gear will be damaged STOPPING THE ENGINE o Pay sufficient attention not to bring part of your hand and body or clothes in contact with the silencer exhaust pipe and engine body during operation or shortly after stopping the engine The whole engine is hot and may cause scalding serious burns Before stopping engine reduce speed if practicable to minimum Remain at minimum speed for 2 to 5 minutes to allow for engine Cooldown NOTES If the engine is stopped immediately without the cool down period the temperature of engine parts will rise suddenly and could cause engine failure Always cool down the engine at low speed for a few minutes when securing When leaving the engine pump unit in open air after operating place on a level surface keep away from flammable material such as straws withered grass as this could result in ignition After cooling the engine pump unit thoroughly cover it to protect the air cleaner silencer and electrical parts alternator starter motor switches etc from water and dust Ensure the cap for the fuel fill connection is installed and tight to prevent any water or dust from entering the fuel tank Page 23 of 60 Effective Date 6 11 2012 A p THOMPSON iJ PUMP SERVICING THE PUMP THIS SECTION EXPLAINS WHEN AND HOW TO PERFORM ROUTINE INSPECTION SERVICE AND ADJUSTMENTS FOR THE DO IT YOU

MODEL NUMBER: _4T – DHW – 1D81

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MODEL NUMBER: _4T &ndash; DHW &ndash; 1D81

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MODEL NUMBER: _4T – DHW – 1D81