Overview of Pump Design

The Global Pump TAP series is an automatic self-priming pump driven by a diesel engine or electric motor. Specially designed to handle abrasive fluids such as sewage and sludge containing solids up to 3″ (76.2 mm) in diameter, it provides a dependable, high efficiency solution. The pump has proven itself fully capable in a variety of applications including intermittent flow conditions, open pumping and sewage by-pass pumping where a moderate air handling is required. A characteristic of the priming system is its low impact ecological design, which by using an air/fluid separator called an environmental box assures no release of contaminants during the pump’s operation.

Pump Components

Chassis

The chassis provides a stiff platform upon which the complete pumping unit is mounted. It also doubles as an integral fuel tank capable of holding enough fuel to run the unit at full power for 24 hours. The chassis features a balanced lifting bail designed to support the weight of the fully loaded pump. The lifting bail is the only attachment point suitable to lift the pump. For the users convenience clean-out plugs and d-rings are located on all four corners of the chassis. The clean-out plugs allow for easier rinsing of the fuel tank. The d-rings provide appropriate tie-down points.

Engine

The units come standard with an adequately powered diesel engine or electric motor rigidly mounted to the chassis. To protect the engine, safety cut-off protection is provided against low oil pressure and high coolant temperature. Should either of these situations exist the engine will automatically shut down. Do not restart the engine without first identifying the source of the problem. The control panel also includes a tachometer and hour meter. The tachometer allows the user to define the pump’s power setting. The hour meter permits the user to schedule routine maintenance. The pump also features a belt driven air compressor, which is used to power the priming system. The belt driven compressor maximizes the reliability of the priming system. The belt driven compressor is lubricated and cooled via the engine.

Pump End

The pump end is a centrifugal pump specifically designed for municipal and industrial applications. The impeller is a two-vane enclosed geometry with the ability to handle 3″ diameter solids. To further increase the dependability of the unit, the pump is coupled to the engine through a torsional damper. The damper, designed to isolate vibrations between the pump and engine, minimizes the effects of shock loading.

A distinctive feature of the pump is that it has been designed for ease of use and maintenance. The pump is primed by the Global automatic priming system and is supplied, as standard, with a mechanical seal and positive glycol feed. The mechanical seal and glycol quench allow the pump to be run dry for prolonged periods. The back pull-out design allows the bearing housing and impeller to be removed without disturbing either the suction or discharge piping. Both the impeller and suction cover are fitted with cast iron renewable, axial clearance wear-rings. The drive shaft, which is supported by two sets of grease lubricated bearings, is fitted with a replaceable shaft sleeve.

Priming System

The priming system produces a vacuum which is used to draw fluid up through the suction hose and into the pump, once the pump is fully flooded it is completely primed. The vacuum is created by accelerating compressed air through a venturi. When the compressed air flows through the narrowest portion of the venturi it reaches its highest speed. At this point it also has its lowest pressure. Side drillings positioned at this point in the main duct of the venturi are connected to the pump casing via a ball valve and a series of chambers. The air is evacuated from the pump casing and suction hose by drawing it through the chambers and side drillings of the venturi into the venturi’s main duct where it exhausted to the atmosphere through the environmental box. The environmental box is an air/fluid separator which assures no contaminants are released during the pump’s operation.

Using this method of priming the pump has three main advantages over alternative automatic priming systems. The vacuum is created indirectly and so there is no risk that contaminants in the pumping fluid, which could potentially damage a vacuum pump or any other direct method, will be passed into the air compressor. Secondly, with the exception of the air compressor that utlizes the large reserves of the engine’s lubrication and coolant systems to maximize its reliability, this arrangement has no moving parts. Finally, the components of the priming system are adequately corrosion proofed. The venturi is made from 316 stainless steel. The collars used to mount the venturi and the braided steel air line are made from stainless steel. All the other fittings of the priming system are made with a zinc-chromate finish.

Operation of the Pump

With the pump properly plumbed into the system and fully primed, bring the pump unit up to half speed. Then turn the engine off and allow the unit to coast to a stop. If it stops suddenly or there is any unusual noise, identify the cause of the trouble. Do not restart the engine until the problem is corrected. Repeat this procedure until the unit quietly coasts to a stop when the power is cut-off. Continuously check the bearing housing and stuffing box temperature. If either becomes too hot to hold your hand tightly and indefinitely against the housing, the pump may be binding. Stop the unit and correct the cause of the trouble. If pumping hot liquids this may not apply.

The pump may be throttled by fitting a butterfly valve or similar to the discharge side of the pump. However, the pump must never be throttled on the suction side because this may cause it to cavitate. Throttling can reduce the power consumption of the pump. When the pump is exposed to freezing temperatures, it should be drained immediately after stopping.

Pre-Start Checklist

• Fill the fuel tank, using clean fuel
• Check the fuel supply for contaminants such as water, dirt or algae
• Drain the water from the fuel/water separator
• Check that there is fuel in the fuel line, if necessary prime the fuel line
• Check the engine oil level
• Check coolant level
• Check the indicator button for the battery charge
• Check the glycol level in the pump’s mechanical seal glycol reservoir
• Make sure that the fan/alternator drive belt is tight
• Make sure that the safety guard surrounding the torsional damper is secure and in place
• Check that suction and discharge connections are tight and secure
• Make sure that the pump is level

Starting the Engine

• When starting engine manually turn key to run position. Then press the enter button when instructed, engine will start up.
• Throttle is located below control box.
• Turn the throttle to the desired level. Do not exceed the maximum speed unit.
• Check gauges for proper operating levels

Normal Operating Parameters

Once the pump is running, check the following:

• Engine is running smoothly
• Vacuum gauge is within acceptable limits, 10″- 28″ Hg
• Oil pressure and water temperature are within the pre-set limits
• Water is moving through the pump

Maintenance Safety Instructions

WARNING: Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death.

Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply.

• Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Put a “DO NOT OPERATE” tag on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work.
• Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High-pressure oil or fuel can cause personal injury.
• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel lines in a well-ventilated area.
• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.
• Corrosion inhibitor, a component of SCA and lubrication oil, contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.
• To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments.
• Always use tools that are in good condition. Make sure you understand how to use them before performing any service work.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.
• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

General Maintenance Guidelines

The unit should be checked at regular intervals for any slight increase in noise or heat that may develop in any part of the pump, including the coupling, stuffing box and bearings. See the Troubleshooting section at the end of this manual for help in diagnosing the cause of this problem.

The mechanical seal is primarily designed to prevent air being drawn into the back of the pump through the stuffing box. It also prevents gritty particles in the pumping liquid from entering the stuffing box. When servicing or replacing the seal, it is essential that precautions are taken to assure that the seal chamber is kept free of dirt. Though the mechanical seal is designed to allow the pump to run dry for prolong periods, the seal relies upon a constant supply of glycol for both lubrication and cooling. Never run the pump without first checking the seal’s glycol reserve is full.

The pump end’s bearings are grease lubricated. The bearing housing should be about one-third full of good ball bearing grease. Extreme care must be taken to assure that dirt does not contaminate the bearing grease. Too much grease in the bearing housing causes the bearing to run hot. Add small amount of grease every 3 to 6 months being careful to remove old grease if necessary to maintain the housing not more that 1/3 full.

Maintenance of the correct clearance between the pump end’s suction cover and impeller significantly affects the operating efficiency of the complete unit. The pump end is supplied with replaceable wear rings that are designed to maintain the correct clearance. When the clearance increases by about .020″ the rings should be replaced.