A Preface diesel

PRIVATE

Table of contents0. Preface

a. Declaration of Conformity

b. Test certificate pump(s)

1. General

2. Transport

2.1. General

2.1.1. Special hoisting instruction

2.2. Driver skid

3. Inspection

3.1. Inspection of the pump-unit

4. Storage

4.1. General

4.2. Pump

4.3. Fire pump controllers

4.4. Diesel engine

5. Installation

5.1. Skid foundation with anchor bolts

5.1.1. General

5.1.2. Guidelines for constructing a concrete foundation

5.1.3. Erection

6. Customers connections

6.1. Connection piping

6.1.1. General

6.1.2. Suction piping for horizontal pumps

6.1.3. Discharge piping acc NFPA

6.2. Connecting pressure sensing line

6.2.1. General

6.3. Electrical supply

6.3.1. General

6.3.2. Main (AC) power supply

6.3.3. Jacked water heater connection

6.4. Connecting cooling water system

6.4.1. General

6.5. Connecting fuel system (single and double walled fueltank)

6.5.1. General

6.5.2. Fuel level indicating instruments

6.6. Connecting exhaustsystem

6.6.1. General

6.7. Connecting lead-acid batteries

6.7.1. General

6.7.2. Filling / charging batteries

7. Aligning horizontal pump units

7.1. Aligning the pump-unit

7.1.1. General

7.1.2. Deviations

7.1.3. Coupling data

7.1.4. Pump adjustment with adjustingbolts

7.1.4.1. General

7.2. Driver alignment with adjusting jacks

8. System description

8.1. General

8.2. Controller

8.3. Cooling water system

8.4. Diesel engine

9. Putting the pump-unit into operation for the first time

9.1. Before putting into operation for the first time

9.2. First starting (on site)

9.3. After first operation

10. Maintenance General

10.1. Preventive maintenance programme

10.2. Gland packing directions

11. (Dis) assembling the pump

11.1. Disassembling the pump

11.2. After disassembling the pump

11.3. Assembling the pump

12. Appendix

13. Documents & Drawings

PRIVATE

PREFACE :This is a manual with installation and operation-instructions for your pump-unit and it therefore isn't a repair-manual. Application of the information given in this manual should increase the performance of your pump-unit, extend the service-life and decrease maintenance- and repair costs during the entire service-life. The key to a long service-life of your pump-unit will always be found in executing a careful planned and regularly performed maintenance program. You will understand that a pump which has to operate under rough and dirty conditions will need more attention than a similar pump that operates under the most ideal conditions. The design of your 'Nijhuis'-pump will make it possible to perform quick and simple checks as well as quick and simple replacement of parts so that down-time and repair costs will be minimized during the entire service-life of your pump-unit.

Whenever a question arises regarding your 'Nijhuis'product please contact our service-department. For questions about your pump or spare parts as well as for ordering spare parts please always quote the pump type and serial-number with all your enquiries. This will help us to deal with them better and faster.

Guarantee :Our responsibility goes only as far as indicated in our sales conditions. We are not responsible for damages resulting from ignoring the allowed operating-range of your pump-unit, careless treatment of the installation and/or acting contrary to the instructions mentioned in this manual. If you dismantle the pump during the guarantee-period without our written agreement the guarantee may be invalidated !Manufacturers address :NIJHUIS FIRE PROTECTION

P.O. box 102

7100 AC Winterswijk - Holland

E-mail : nijhuis@nijhuispompen.nl

Telex : 44185

Phone : *31-543-547474

Telefax : *31-543-547476

Shipping address :Freule van Dorthstraat 12

7102 DC Winterswijk - HollandPRIVATE 1 GENERALTC " 1 GENERAL"PRIVATE 1.1 Locating the pump-unit :TC " 1.1 Locating the pump-unit \:"A careful chosen location for the pump-unit is of the utmost importance for maintenance as well as for operation of the pump-unit. When choosing a location for your pump-unit the following factors should be taken into consideration:

Locate the pump as close as possible to the source of the water-supply.

If possible, locate the pump's centre-line under the level of the water-supply source so that gravitation will help to push the water into the pump.

Take care that both suction and discharge lines are kept as short and straight as possible to keep friction-losses as small as possible. Bends in suction as well as in discharge line should have the largest (practicable) possible radius.

Place the pump-unit in such a way that the unit is easily accessible for maintenance, inspection and possible repair activities. Therefore take care of good illumination and ventilation in the pumproom to simplify these activities.

Make sure there is enough space above and round the pump for a hoisting device such as a crane or a winch with enough capacity to hoist the complete unit.

Locate the unit, where possible, in a dry, dustfree and well ventilated space.

Whenever possible, do not locate the pump-unit on locations with a high damage risk. Therefore do not place the unit on locations with extensive traffic (human as well as vehicles). When the unit is placed on a location with extensive traffic however, make sure there is ample space for human as well as for vehicle traffic.

PRIVATE 1.2 Pre installation:TC " 1.2 Pre installation \:"One of the most important factors to successful operation and maintenance of your pump-unit is a correctly performed installation of the unit. A pump-unit that has been installed correctly will remain aligned better in the long run, will show less leakages of casing as well as flanges, will show less vibrations and will demand less servicing. Another aspect that will be influenced by the installation of your pump-unit is it's service-life. A correctly performed installation will prolong the pump's service-life and diminish the risk of failures in emergency situations. A badly performed installation may damage a new pump-unit severely within a relatively short time!

PRIVATE 2 TRANSPORTTC " 2 TRANSPORT"PRIVATE 2.1 General:TC " 2.1 General \:"Note: Pump unit and/or components may only be hoisted at the suitable hoisting supports. Use all hoist supports when hoisting!

Hoisting of each component should always be performed in accordance with the following general instructions and/or the local rules regarding hoisting and transporting.

The capacity of the hoisting-device and all other auxiliary components should be enough to carry the component safely.

Hoisting of each component has to be performed in accordance with all applicable local laws / directions .

Hoisting and transporting should be performed by authorized personnel with the utmost care.

2.1.1 Special hoisting instructions: Apart from the above mentioned general instructions it is necessary to pay extra attention to hoisting

instructions given for auxiliary components.

APRIVATE 2.2 Driver skid TC " 2.2 Driver skid \:"The driver is assembled on a skid, as shown in above figure. On the first place the unit is designed to transport with a forklift. Therefore is the baseplate foreseen with two saving.

A second facilities is to use a hoisting chain with hoisting hook. Fix these correctly behind the 60 mm hole in the baseplate. During lifting of the unit it is important to check that these will stay on there place.

Some baseplate are execute only with hollow pipes, see picture below. These must lift as follow:

The unit is to be hoisted by attaching the hoisting-hooks around 2 pipes or bars. These pipes/bars are not part of Nijhuis' delivery. The pipes/bars should be stuck through the hollow pipes that are welded in the skid for this purpose. The pipes/bars are to be considerably longer than the skid's width in order to prevent the hooks slipping of the pipes/bars and/or to prevent damage to the driver. Naturally, the pipes/bars should have sufficient capacity to carry the weight of the unit.

Note: When the driver is not assembled on a skid it must be hoisted by putting a chain through the available eyebolts. It's not allowed to hoist the driver anywere else because if may damage the driver

PRIVATE 3 INSPECTIONTC " 3 INSPECTION"PRIVATE 3.1 Inspection of the pump-unit:TC " 3.1 Inspection of the pump-unit \:"Generally horizontal fire fighting pump units will be delivered in an almost complete assembled condition

with smaller components such as connecting materials gauges etc. separately packed.

A pump-set generally contains the following components :

Complete dieselengine mounted on skid Horizontal pump

At receipt of the material it has to be inspected accurately for damages and/or the presence of all components. Also check the packing-list. Any damaged or missing parts should be reported immediately to the local agent of the company that is responsible for the transport of the unit. Damages / missing parts should also be marked on the freight bill.

PRIVATE 4 STORAGETC " 4 STORAGE"PRIVATE 4.1 General:TC " 4.1 General \:"Pumpunits are usually delivered and packed in condition for immediate installation. The way of packing in which the pump-units are shipped depends on the method of transport, distance and duration. Units that are to be shipped within Europe are usually delivered without special storage provisions. For units to be shipped out of Europe generally special storage provisions have been made for the duration of the transport. If, for whatever reason, the pump is not to be installed for a considerable time special storage provisions should be made. Nijhuis Fire Protection provides this, on special request only.

Following general directions shall be met:

-All components should be stored in the proper position. Engine and all other non - Nijhuis manufactured components should be stored in accordance with the directions given by the respective manufacturers ; these are generally mentioned in the appendices of the operating and maintenance manuals of the components.

-Do not store components in a place with a high damage risk (places with intensive trafic (human as well as vehicle)).

-Store the components in a dry, dust- and frostfree and well ventilated room.

-In order to avoid bearing damage owing to vibration during storage, e.g. due to machines operated in close vicinity, components should only be stored in rooms free of vibration.

-If components are packed in undamaged seaworthy packagings and provisions have already been taken for long term storage, these packagings should not be removed until installation. Components packed in seaworthy packagings that have not been protected for long term storage, should be removed and protected for long term storage at the moment of arrival. If possible packagings should be applied again after having protected the components.

-If components are not suitably, packed they should be covered entirely. If the room in which the components are stored isn't waterproof the components should be covered with a waterproof protectant.

-Inspect and clean the components regularly (only if not thoroughly packaged in dust- and waterproof closed packagings). If packaged, check the packagings regularly for damage and general condition.

-If components are to be stored for a long term (more than 3 months) before installation and provisions for this storage have not been made (provisions for long term storage are only being made on your special request) these should be made at the time of arrival. The most important provision to be made for this purpose is the protecting of corrodible parts of all components. Protection can be made by greasing these parts so far as possible or, better by applying a special preservation oil. Depending on the provisions taken, storage circumstances and the component, it can be necessary to regrease or re-apply preservation-oil periodically.

-For auxiliary components always consult the directions given by the manufacturers. These directions should always be applied in addition to or instead of the directions that are mentioned in this manual !PRIVATE 4.2 Pump :TC " 4.2 Pump \:"

-All applicable general directions mentioned should be met with.

-All pump components are to be stored in horizontal position.

-Protection of the corrodible pump-parts can be made by greasing these parts (shorter periods) or, better, by applying a special preservation-oil. If storage is going to last longer than 6 months, or will take place under severe environmental circumstances the corrodible pump-parts should always be treated with preservation oil. Greasing will not satisfy in these cases. For extended storage periods the preservation-oil must be changed periodically. The period after which re-application of the preservation-liquid becomes necessary depends on the storage circumstances; when stored indoors the preservation-oil should be re-applied every 18 months, when stored outdoors under a cover the preservation-oil should be re-applied every 12 months.

-When the pump is to be stored for more than 6 months the soft shaft seal packing-rings should be removed.

PRIVATE 4.3 Fire pump controllers : TC " 4.3 Fire pump controllers \: "

-All applicable general directions mentioned should be met with.

-Fire Pump controllers should always be stored under cover in a dry, temperature regulated non-corrosive atmosphere, with each enclosure protected against the effects of condensation by either one of both the following precautions being observed :

*Introduction of dessicant substance such as Silica-Gel, contained within a suitable receptacle, into each enclosure. It is recommended that such a dessicant is replaced on a regular basis (e.g. every 6 - 8 weeks), since it's effectiveness is known to deteriorate with time.

*The connection of auxiliary AC power feeds to the panel anticondensation heaters (when fitted) to maintain the interior of each enclosure at a constant temperature (Note : the auxiliary AC power feed must correspond to the rated voltage of each item of equipment, otherwise damage may occur).

-It is recommended that a suitable polythene covering is employed with protective packaging as necessary to prevent damage to paintwork and exterior mounted components.

-For protracted storage periods it is advisable to utilise hermetically sealed polythene wrapping (evacuated) and then enclose each unit in an export quality packing case lined with tar-paper or equivalent.

PRIVATE 4.4 Diesel engines :TC " 4.4 Diesel engines \:"

-All applicable general directions mentioned should be met with.

-If your pump unit is driven by a diesel engine with turbocharger, the turbocharger or the exhaust flange must be covered so that no dust or other objects will get into the turbocharger (only if not already packaged in a through dust- and waterproof closed packagings).

4.4.1 Diesel engines storage :

-When the engine is to be taken out of service for lengthy periods (> 1 year or storage under severe environmental circumstances), it must be protected according a specific procedure. Nijhuis can give you on request more information.

PRIVATE 5 INSTALLATION :TC " 5 INSTALLATION \:"PRIVATE 5.1 Skid Foundation with anchor bolts :TC " 5.1 Skid Foundation with anchor bolts \:" 5.1.1 General :To achieve a proper long-term functioning of the pump-unit, the pump-unit should be placed on a solid foundation of sufficient capacity made out of, for instance, concrete. The foundation's sizes should be chosen so that it will be able to carry the weight of the entire pump-unit, as well as absorbing vibration, generated by the pump-unit, sufficiently. A solid foundation will guarantee a better unit-alignment in the long-term, which will result in a longer service-life and less wear.

5.1.2 Guidelines for constructing a concrete foundation :Constructing a foundation should be done in accordance with the guidelines that are mentioned hereafter. However, it should be pointed out that these guidelines should only be seen as being guidelines, and no more than that. Therefore, if directions from e.g. concrete-manufacturer are available (for instance regarding hardening-times, mix-compositions) these should be read and applied carefully. Nijhuis Fire Protection is not responsible for the pump-unit foundation !

NOTE :For foundations, out of a material other than concrete, contact Nijhuis' Service

Department. 5.1.3 Erection : When placing the skid onto the foundation, the skid should be hoisted according to the directions given in "Transport".

Place the skid on a number (at least 4) of wedges or stacks of shims, thus that the space between floor and pump-skid is about 20 - 40 millimeters.

Take care that the floor on which the skid is to be placed, is sufficiently strong to carry the weight of the unit and is sufficiently rough so that the concrete that is poured afterwards will be able to obtain a proper bond with the floor.

Adjust the unit to level by adjusting the wedges, or , in case the unit was placed on stacks of shims, by adding / removing shims at the several places. Adjusting the unit to waterlevel should be done with respect to the worked up planes of driver-supports on the skid (these are the highest flat planes from the skid), and not with respect to the skid itself, as the skid isn't necessarily 100 % straight at all places.

Before pouring concrete to fill the space between skid and floor, the floor should be kept moist during a considerable period, in order to saturate the floor with water so that it will soak as less water as possible from the concrete that is to be poured, which would affect the final result. The period during which the floor is to be kept wet varies, depending on the age of the floor, between 12 - 24 hours. As a guideline it can be taken that a floor that is less than one month old should be kept wet for about 12 hours ; a floor that is older than one month should be kept wet for about 24 hours.

Before the concrete can be poured, the anchor-bolts have to be placed. When placing the anchor-bolts make sure the bolts are placed far enough under the frame (into the concrete that is to be poured) so that a sufficiently thick layer of concrete will be able to fill the space above the hook of the anchor-bolts. Further there has to be taken care that the nuts can be tightened far enough after the concrete has hardenened. Therefore take care that the nuts (and possible inclined plates) are tightened just that far that the screw-thread rises just a couple of threads above the nut.

B When pouring concrete special care has to be taken that the concrete can spread itself well around the anchor-bolts so that a good hole-less connection between bolts and concrete can arise and the bolts will be clamped firmly in the concrete.

After the concrete has been poured it should harden out. Hardening time depends on environmental circumstances and the exact composition of the concrete and will vary from days to over a month. Further information concerning the hardening time should be obtained from the concrete manufacturer.

After the hardening-process has been accomplished the anchor-bolts can be tightened and suction / discharge lines and other connections to the unit can be made. Tightening should be accomplished crosswise and in equal steps.

The tightening torques the anchor bolts are to be tightened with, depend on bolt-quality as well as on the quality of the concrete. If required Nijhuis can deliver complete sets of foundation bolts including, if necessary, inclined plates that fulfill DIN 529.

PRIVATE 6 CUSTOMERS CONNECTIONSTC " 6 CUSTOMERS CONNECTIONS"PRIVATE 6.1 Connecting piping :TC " 6.1 Connecting piping \:" 6.1.1 General :Suction as well as discharge piping may not be connected until concrete has hardened entirely and anchor-bolts have been tightened. When connecting suction- and discharge piping the following guidelines should be applied to increase pump efficiency and to prevent future trouble. Read and apply the following advice carefully.

Before connecting suction and discharge piping make sure that both lines are free of debris and other foreign objects that might damage pump and line system.

Inside diameters of suction and discharge piping are to be selected in accordance with the applicable standard (e.g. NFPA-20 and/or Hydraulic Institute) and should be at least as large as the inside-diameters of the respective pump flanges. The minimum straight line of the suction pipe must be 10xD

Packing between all flanges and other connections should, in order to prevent reducing the piping's culvert, have an inside diameter that is about 5 - 10 mm larger than the inside diameter of the respective flanges.

Selection of the materials that are to be applied for the piping (and all other piping-properties) should to be in accordance with the applicable standard (e.g. NFPA-20).

Suction and discharge lines should both be equipped with a suction-gauge respective a pressure gauge. Both gauges should fulfill the applicable conditions of the applicable standards.

Suction as well as discharge piping should be supported as close to the pump flanges as possible in order to reduce/minimize the forces on the pump flanges (see figure ).

Pump- and piping flanges should lay perfectly parallel and centre on centre. NEVER use the bolts of the flange-connections to achieve this. Doing so will cause high tension on pump and flanges.

Tighten the bolts of the flange-connections crosswise and in more equal steps. Tightening torques with which this is to be performed can be found in appendix 1.

6.1.2 Suction piping for horizontal pumps: Suction-piping acc. NFPA shall be equipped with a listed O.S. & Y. gate-valve. A butterfly valve shall not be installed in the suction pipe.

When the suction pipe and pump suction flange are not of the same size (suction pipe > suction flange), suction pipe and flange shall be connected with an eccentric tapered reducer in such a way to avoid air pockets (see figure suction piping). More than one pipe diameter reduction in a single reducer can result in excessive turbulence and noise and should be avoided whenever possible. The reducers should be limited to one pipe diameter to avoid excessive turbulence and noise.

Avoid the use of bends in the suction pipe which rise (partially) above the pump-centerline. Doing thus will diminish the risk of air in the piping-system considerably.

Suction pipes must be hydrostatically tested for tightness according to the applicable test procedure mentioned in the applicable standard (e.g. NFPA-20).

When the water supply can be expected to contain foreign materials, the suction pipe should be equipped with suction screening. Execution of the screening should be according to the applicable standard.

6.1.3 Discharge piping acc NFPA : When the inside diameter of the discharge piping is larger than the inside diameter of the discharge flange, pipe and flange should be connected with a concentric reducer (see figure discharge piping).

Discharge piping should be equipped with a check-valve which should protect the pump against damages caused by back-flowing water and should also maintain the pressure in the discharge system during the time the pump isn't operating. (see figure discharge piping).

Discharge piping should be equipped with a butterflyvalve which is to be used by the weekly performed tests. This buttervly valve should be mounted after the check valve.(see figure discharge piping).

In between check valve and butterfly valve a Tee should be mounted for connection with the measuring pipe line which the generate flow can be measured. The butterfly valve to the system (discharge) should be closed when measuring.

Discharge pipe may be equipped (only for pump-units driven by a diesel-engine and see note) with a pressure relief valve which is to be located directly after the pump (before the check valve). When a concentric reducer between pumpflange and pipe is mounted the pressure relief valve should be mounted directly after this reducer. Aim of the pressure relief valve is to protect the discharge piping, and all components that are connected to it, against damages caused by too high a pressure.

Note: Pressure relief valve, in diesel driven system, are only required if

(Rated shutoff pressure x 1,21) + static suction pressure > the pressure for which the system components are rated.

Sizes, construction and materials of pressure relief valve, check valve, tee and control valve should be in accordance with the demands of the applicable standard (e.g. NFPA-20).

Discharge pipe should be equipped with a branch-pipe before the check valve for the diesel engine cooling system. Execution and location of this branch should comply with the demands according to the applicable standard (e.g. NFPA-20) and are discussed further in 'Connecting cooling water system'.

The discharge pipe should also be equipped with necessary branches for connecting the pressure switches (between check valve and butterfly valve) for both the main fire pump. Execution and location of these pressure switches should comply with the demands to this according to the applicable standard and are discussed further in a seperate .

Pump-units, driven by an aircooled electromotor, a discharge pipe is to be equipped with a circulation relief valve (delivered with pumpset). This valve should be mounted before the check valve and it shall provide sufficient water to prevent the pump from overheating when operating with no discharge. Provision shall be made for a discharge to a drain.

PRIVATE 6.2 Connecting pressure sensing line :TC " 6.2 Connecting sensingline pressure switch \:" 6.2.1 General :The pressure switch to initiate automatic starting in case of pressure drop in the system, is mounted on the side of the controller and already electrically connected. The only connection to be made is the sensing line to the pump discharge. This connection should be in accordance with the applicable standard. The NFPA 20 requirements are given as follow

D The pressure sensing line shall be brass, copper or series 300 stainless steel pipe or tube, and the fittings shall be of nominal size.

The pressure sensing line should be connected to the pump discharge pipe, between the check-valve and butterfly valve.

Each pump (main pump and/or jockeypump) must have its own pressure sensing line.

All connections, and piping should be leak-tight, thoroughly constructed, and resistant to the maximum system pressure.

The pressure switch should be adjusted to your individual sprinkler system. The pressure at which the pressure switch, causing a Pump On Demand (P.O.D.)-signal, has to be adjusted by turning the adjustment knob (5) that is placed on top of the pressure switch. After this pressure is installed replace this knob for a cover knob.

The pressure setting of the switch is indicated by position of the pointer in the display (9).

EThe differential pressure, at which the pressure switch resets (and the P.O.D.-signal is cancelled) has also to be adjusted when installing the controller. The differential pressure is to be set by adjusting the differential dial (19). For adjusting the differential pressure the front cover plate has to be removed. After the front cover plate is removed, the dial can be set between the min (1) and max (10) position. The differential pressure with which these values correspond are stated on the pressure switch

(generally : min 1,2 bar / max. 4 bar differential pressure).

PRIVATE 6.3 Electrical supply :TC " 6.3 Electrical supply \:"NOTE: To avoid injury to an operator or service technician the safety precautions given below and local rules -codes, must be strictly adhered to whenever the equipment is operated, service or repaired. Only well-informed and trained people are allowed to work on this controller or system.

6.3.1 General :

The controller can be delivered mounted on skid or seperately with the pump-unit, in this case it should be connected at the moment of installation. Therefore all sensors, like oil pressure, temperature switch etc, are already connected to a central junction box. A multi-wired cable (standardlength 10 m) with a special connector plug on one side is connected to this box. This plug can connect to the controller which is mounted separately.

NOTE: Connect the multi-core cable only when the main power and the batteries A and B are disconnected or switch of.

When this multi-wired cable has been connected to the controller, all controller / pump-unit connections that are to be made, have been accomplished. Yet, the controller should further also be connected to:

1) Mains ( A.C. ) power supply

2) Jacked water heater connection

6.3.2. Main (A.C.) power supply : Connecting the controller to the mains should be done in accordance with the controller's connecting-schedule, that is delivered with(in) the controller (usually within the controller-casing). The controller's operating voltage, depending on the execution and the country the controller has to operate in, generally is the normal mains-voltage (110 V to 240 V, depending on the country). Connecting should be done in accordance with the applicable legal safety-regulations as well as with respect to the maximum mains-power needed by the controller.( 1 KW for batt.charger + control system and additional power needed for jacked water heater 3000 (or 6000) WATT).

6.3.3 Jacked water heater connection :

Separate cable has to be connection to the jacked water heater to associated terminals in the controller.

WARNING: Do not switch on jacked water heater if engine is not filled with coolant

PRIVATE 6.4 Connecting cooling water system TC " 6.4 Connecting cooling water system " 6.4.1 General :

Water cooled fire engines are execute with a heat exchanger. The raw water supply for this heat exchanger can be taken from the pump discharge through the already installed cooling water line on the skid. Normally Nijhuis connect the supply to the cooling water train, if not, is should be done by the client. The discharge line from the heatexchanger out to a open drain must always done by the client.The cooling water train for a NFPA 20 diesel driven unit shows as follow

Connection from discharge to cooling water train.The supply of water to the cooling system generally can be made by applying a branch-pipe to the pump's discharge piping. This branch to the pump's discharge line should met the following conditions :

The branch should be applied between the pumpdischarge flange and the checkvalve in the discharge line. A steel flexible must be foreseen

The connection from this branch to the cooling water line should be made out of rigid threaded piping. Dimensions of thread and piping should fullfill the applicable standard.

The inside diameter of the complete branch piping, including all connections and possible reducers, should be at least the size of the already mounted cooling water line.

Discharge from the cooling water system to a open drain:The discharge from the cooling water system should be made by installing a discharge pipe from the outlet of the (last) heat exchanger to a drain pit. This discharge pipe should meet the following conditions :

The inside diameter of the discharge pipe should be at least one full size larger than the size of the already mounted cooling water line.

The discharge line should end in an open, clearly visible waste cone (drain) into which the flow should be easily visible. Further, the waste cone should have sufficient capacity .

No valves at all may be placed in this discharge line.

The discharge line should be as short and straight as possible.

The connection between discharge pipe and heat-exchanger should be made out of a flexible material. Generally, a flexible connecting piece is part of Nijhuis' delivery

It shall be permitted to take the discharge back to the suction reservoir when it is provided with visual flow indicator.

The discharge must be protected against frost.

PRIVATE 6.5 Connecting fuel system (single and double walled fueltank)TC " 6.5 Connecting fuel system (double walled fueltank) \:" 6.5.1 General :

If it necessary to work on the fuel system, it must be done with the most care as possible. Wear protection clothing and safety glasses and avoid open fire and or sparks.

The fuel tank, can be execute in single or double walled and for wall or floor mounting. In some case the fueltank is installed on the skid, then Nijhuis has done all the required connection between the engine and the fueltank. When the tank is deliver separately the following connections has to be made by the client with the most care as possible.

Fuel-supply from tank to engine fuel-system

Fuel-return from engine fuel-system to tank

Tank ventilation

Fuel-level indicating instrument(s)

Fuel supply from tank to fuel system :The fuel supply piping from tank to the engine's fuel injection pump should meet the following directions :

The fuel supply line should be manufactured out of a mechanically strong, leak-tight, heat- and fireproof material which should also be resistant to deterioration due to age or environmental conditions. Galvanised fuellines are not acceptable. The dimensions of the fuel supply piping should be selected so that friction-losses are reduced to a minimum. The inside diameter of the fuel supply line(s) may in no case be smaller than the diameter of the fuel-lines that are already assembled to the engine.

For the same reason (reducing friction-losses) the fuel supply lines should be kept as short and straight as possible. Further it is recommended that the number of connections (for a.o. also the mentioned reason) is kept as small as possible. This will also diminish the risk for leakages.

The flexible fuel lines for customer connection on the engine are marked with the text Fuel inlet and Fuel outlet.

Do not guide fuel lines along dangerous locations such as places with a high damage risk, places with high temperature (exhaust system, turbocharger).

If it is unavoidable that part of the fuel lines are guided along dangerous locations, at least care should be taken for thorough protection of the fuel lines at these places.

Fuel lines are to be isolated from engine-vibrations by means of flexible metallic or hose connections. These flexible connections generally are already fitted to the diesel-engine and marked with the text Fuel inlet and Fuel outlet. These are only marked when the fuel tank is not installed on the skid.

The fuel supply line has to be connected to the appropriate connection for this purpose at the fuel tank. A fuel bowl-filter with drainvalve (option) can be assembled to this connection instead of the fuel-supply line. In this case the fuel supply line has to be assembled to the bowl filter's outlet.

The other side of the fuel-supply line has to be connected to the fuel injection pump. Further, more detailed, information about this can be obtained in the diesel-engine's guide.

Fuel-return from fuel-injection system to fuel tank: For the fuel-return line the demands regarding materials, protections, isolations and sizing mentioned for the fuel-supply line should also be met with.

It is NOT allowed to install a shut-off valve in the fuel return. A check-valve has to be installed, as near as possible to the tank, prevent to siphon over of fuel. The max. pressure loss over the checkvalve = 0,1 bargauge.

The fuel-return line has to be connected to the flexible fuel-return connection. Further, more detailed, information regarding this connection can be found in the engine's guide.

The fuel-return line has to be connected to the appropriate connection for this purpose at the fuel tank.

Fuel tank ventilation: The fuel-tank ventilation must end in a properly ventilated space, 3,05m above the filling cap, if possible in the open air, conform NFPA 20. The ventilation line should be constructed so that no water (rain) and/or other pollution will be able to penetrate into the fuel tank. Therefore also a screen is delivered with the ventilation which has to prevent dirt or other pollutions to be able to penetrate into the ventilation line. This screen has to be assembled to the end of the ventilation line. It preferred to install the cap as mentioned on above fueltank drawing.

The ventilation line has to be connected to the appropriate connection on the fuel-tank.

6.5.2 Fuel level indicating instruments:The fueltank is execute with a the follow instruments for monitoring of the fuellevel and a leakage indicator for double walled fueltanks. The monitoring are:

Level gauge

Level switch for low level 50% and high level 95% alarm (option)

Leakage indicator (only for double walled fueltank)

Unimes level gauge

Murphy level switch Leakage indicator

Level gauge

Each fueltank is standard execute with a Unimes universal mechanical level gauge with continuous readout. The adjustment has already done by Nijhuis.

Level switch for low level 50% and high level 95% alarm (option)

The fueltank can be execute with a Murphy level switch type EL150K1. The level switch for 50% alarm is installed in the middle of the fueltank. When the fueltank and the controller are installed on the skid Nijhuis wired both to each other. When one of these are not installed on the skid the client must connect them to each other. The wiring diagram is depend of the controller type, see wiring diagram below.

In some case the a extra levelswitch (95%) is mounted on the fuel tank above the 50% levelswitch for prevent the fueltank for overfill. The client must connect this switch to their system, therefore consult the wiring diagram of their system. Leakage indicator (only for double walled fueltank)

Each double walled fueltank is execute with a leakage indicator in the out most tank wall. When there is fuel behind this indicate there is a leakage in the inner fuel tank. It is no problem to run with the diesel engine at this moment but contact Nijhuis Pompen B.V.. It is important to check the fuel tank regular till you have installed a new fuel tank. To release the fuel between both walls open the drain valve on the bottom of the fueltank. Do this only when it is necessary and do it with the most care as possible. To drain the whole tank open the 1 drain valve on the bottom of the fueltank.

PRIVATE 6.6 Connecting exhaustsystem :TC " 6.6 Connecting exhaustsystem \:" 6.6.1 General :If it necessary to work on the exhaust system, it must be done with the most care as possible. The temperature of the exhaust system can rise up to extremely high temperatures. Therefore the piping must be protected by heat resistant coversheet or other heat resistant isolation material.

Depending on the diesel engine that drives your pump, one or two exhaust

systems have to be connected when installing the unit. When assembling an exhaust system, the following points of attention have to be taken care with:

1) Maximum back-pressure :The back-pressure of the total exhaust system should not be larger than the maximum back-pressure that the engine's manufacturer allows. The allowable back-pressure depends on make and execution of the engine and can be found in the diesel engine's guide. There is no minimum back-pressure requirement. In order to reduce the exhaust system's back-pressure as much as possible, the following should be taken care of :

Keep the exhaust system as short and straight as possible.

The exhaust system's inside diameter should be dimensioned capaciously. In no case, the inside diameter should be smaller than the inside diameter of the exhaust flange at the engine.

2) Flexible expansion joint :To the engine exhaust manifold (or to the turbocharger) a flexible expansion joint is assembled. This expansion joint has to take care that engine vibrations and expansions due to temperature changes are damped sufficiently so that the (rest of) the exhaust system will not be loaded by this. When mounting the (rest of) the exhaust system to the expansion joint,care has to be taken to:

See that the expansion joint is loaded as little as possible in an axial direction. Therefore take care that as little as possible of the weight of the exhaust system is transferred onto the expansion joint.

See that the expansion joint is not deformed (or as little as possible) in radial as well as in a tangential direction. Therefore assemble the exhaust system so that the joint is preloaded as little as possible in these directions ; take care that the centres of the exhaust system and expansion joint coincide (without load) as good as possible.

It is possible that a number of protective strips are assembled over the expansion joint, to provide protection against deformation of the joint during transport and assembly of the exhaust system. Before the exhaust system is mounted to the expansion joint these strips have to be removed.

3) Muffler To reduce exhaust noise, generally a muffler is in Nijhuis scope of supply. If this muffler is an absorption type (H . ) it has to be mounted at the end of the exhaust line. If this muffler is a resonant type (L . ) it has to be mounted near the engine.

The muffler is calculate by Nijhuis for 4,5 meter piping and 2 elbows. If it is practical necessary to use more meters of pipe and elbows ask Nijhuis for a new calculation.

4) Safety / miscellaneous : The exhaust system has to be kept isolated from inflammable and/or explosive objects and should, at least at places with danger of (inattentive) personel coming into contact with it, be screened with a heat-resistant screen. However, it is advisable to screen the exhaust system, for as far as it is in the pump-room, entirely or as much as possible. This will also affect the pump-room's temperature positively.

The exhaust system should end in a safe place in the open air. The shape of the end of the exhaust system should be thus that no water (rain) will be able to penetrate into the system. For this purpose the exhaust system should end with the opening pointing (angled) downwards, or the end of the exhaust has to be equipped with a rain-hood.

Before assembling, take care the exhaust system is free of debris, dirt and other foreign objects, which, especially for engines with turbocharger, could cause considerable damage.

Take care all connections are and will remain gas-tight. For this purpose, use suitable packing-rings for all connections. Do not use packing-rings with inside diameters smaller than the flange connection inside diameters.

Exhaust pipes shall be installed with clearances of at least 229mm (acc. NFPA 20) to combustible materials. There are some exceptions.

Drawing A:

Exhaust pipes passing directly through combustible roofs shall be guarded at the point of passage by ventilated metal thimbles that extend not less than 229mm above and 229mm below roof construction and are at least 152mm larger in diameter than the exhaust pipe.

Exhaust pipes passing directly through combustible walls or partitions shall be guarded at the point of passage by one by a metal ventilated thimbles not less than 305 mm larger in diameter than the exhaust pipe or

Drawing C:

Metal or burned clay thimbles built in brickwork or other approved materials providing not less than 203mm of insulation between the thimble and construction material.

PRIVATE 6.7 Connecting lead-acid batteries :

Safety / maintenance:If it necessary to work on the battery system, it must be done with the most care as possible. The following rules and the local rules must always be taken into account.

Wear safety glasses when removing the transport / ventilation plugs.

Do always use tools with insulated hand-grips.

Handle the electrolyte carefully. Electrolyte is corrosive and toxic. Avoid electrolyte getting into contact with the eyes and skin. If skin or eyes should ever get into contact with electrolyte, then rinse the eyes / skin with a copious amount of water. After that cover the skin with a dry sterilized gauze. Eyes should be rinsed with a saline solution after having rinsed them with water. IN ALL CASES, OBTAIN MEDICAL ATTENTION ! Keep batteries clean and dry.

At least once a year, check the battery-clamps for tightness. Battery-clamps and poles should be kept greased with Komoline / Vaseline-grease. DO not use solvents to clean plastic batteries.

The electrolyte-level may only be topped up, if necessary, with pure, distilled water. The electrolyte level should not drop below the top of the plates and should not rise above the MAX-markings (Ni-Cd batteries).

Keep batteries away from open fire and sparks, especially during charging.

TC " 6.7 Connecting lead-acid batteries \:" 6.7.1 General :Depending on the type ordered, pump-units can be delivered with already connected and assembled batteries, or with separately delivered batteries. If the batteries are delivered separately, they should be connected according to the schedule above . The connections to be made according the schedules in this case are :

Connecting the + of batteries A to the starter relay

Connecting the + of batteries B to the other starter relay

Connecting the - of batteries A and B to a earth point on the engine

Connecting the batteries A in series

Connecting the batteries B in series

Batteries that are delivered separately, are usually shipped within the (also separately delivered) battery-container. Cable material and clamps usually are delivered in separate packaging or in the controller.

When connecting the batteries it is most important that the battery-clamps are assembled properly onto the batteries. It is important to fasten these

6.7.2 Filling / charging batteries :In case the batteries are delivered separately distinction can be made between deliveries whereby the batteries are delivered filled and charged (generally, deliveries within Europe) and deliveries whereby the batteries haven't been filled yet (generally, deliveries outside of Europe). This distinction can also be made for units delivered with batteries that have already been assembled and connected.

If the batteries still have to be filled, the following directions should be applied :

Lead-acid batteries :Batteries that should operate in hot-climates should be fill up with a different electrolyte. Make sure the electrolyte delivered is suitable for the operating circumstances.

Before filling the batteries, read the directions given by battery- and electrolyte manufacturers carefully.

Remove the ventilation-plugs from the cells and fill up the cells with electrolyte until the electrolyte-level is about 6 to 10 mm above the lead-plates. Handle the electrolyte with care ! With new batteries a part of the electrolyte will be absorbed by the lead-plates and seperators. After about 20 - 30 minutes, the plates and separators will be saturated, so that no more electrolyte will be absorbed. Now add the level, if necessary, until it is about 6 - 10 mm beyond the lead-plates again.

Wait a couple of minutes, check the electrolyte level again and, if the level has been found correctly, replace the vent-plugs.

Clean the batteries. Remove possibly spilled electrolyte carefully. Make sure the electrolyte doesn't get into contact with skin or clothing.

Your pump-unit is equipped with a trickle-charger, which charges the batteries continuously, when necessary, with max. charging current. After initial filling the battery charger has to be switched on for at least 5 hours before batteries can be used for starting duties.

PRIVATE 7 ALIGNING HOR.PUMP UNITS TC " 7 ALIGNING HOR.PUMP UNITS "PRIVATE

7.1 Aligning the pump-unit : 7.1 Aligning the pump-unit \:"

7.1.1 General:After the unit is fastened on the foundation and piping is connected, the pump-unit has to be aligned. Although pump-units are already aligned when manufactured, it remains necessary to check and, if necessary, adjust the unit's alignment when installing, because it is possible that the unit's alignment is disturbed by forces that could occur during the transport and the connection of suction- and discharge piping.

7.1.2 Deviations:The alignment of a pump-unit is determined by the position of the coupling halves with respect to another, therefore alignment should be performed by checking (and if necessary adjusting) the coupling half positions with respect to another. When aligning the coupling half positions, the following 3 possible kinds of deviation should be taken into account :

1) Non-parallelism of the shafts (coupling halves)

2) Non-concentricity of the shafts (coupling-halves)

3) Clearance in axial direction between the coupling halves

Non-parallelism

6

ad 1) Non-parallelism of the shafts :

Checking the mutual angle between two shaftparts (coupling halves) can be done a.o. with the help of feeler gauges. These are to be positioned at 4 places equally divided (every 90) around the circumference of the circle. The angle between the two shafts can be estimated by comparing the distances (in axial direction) between the coupling halves. The allowable deviations (Kw (mm)) between the largest measured axial distance (Smax) and the smallest distance (Smin), dependend on the coupling size, are to be found in table 1.

Always check the angular deviation in both the horizontal and the vertical plane !

Non-concentricity7

ad 2) Non-concentricity of the shafts :

Checking the deviation in the position of the centres of the shafts (coupling halves) in relation to each other, can be done with the help of a straight edge. This should be positioned over both the coupling halves (see figure non-concentricity). Just as when checking the deviations in non-aligment of the shafts, checking of the deviation in non-concentricity should always be performed in both the horizontal and the vertical plane. For pump-units driven by a diesel-engine the coupling-halves should be positioned exactly concentric in the horizontal plane ideally ; in the vertical plane though, the coupling halves ideally should NOT be positioned exactly concentric ! Ideally, the coupling halve on engine-side should lay about 0,1 mm lower than the coupling halve on pump side, when not operating.

At the moment the engine is started and oil pressure rises, an oil-film will exist between crankshaft and bearing sleeves, as a result of which crankshaft and flywheel will rise about 0,1 mm. By adjusting the vertical engine halve coupling position thus that it is about 0,1 mm lower in stationary condition, will be archieved that the coupling halves will be properly aligned when operating. The allowable deviations (Kr) dependend on the coupling size, are to be found in table 1.

Clearance in axial direction8

ad 3) Clearance in axial direction between the coupling halves :

The 3th magnitude that is of importance when aligning the unit is the distance in axial direction between the coupling-halves. This distance shouldn't be too small in order to permit axial movements of the shafts in relation to another (these movements are caused by expansion of the shafts due to temperature changes, or are as a result of bearing wear). On the other hand, the axial distance shouldn't be too large.If the clearance between the two coupling halves gets too large, the forces the coupling has to transmit will be transmitted on a too a small part of the coupling pins and rubbers. This will cause premature wear and decrease the service-life of the coupling. The axial clearance can be estimated easily by measuring the distance with a vernier caliper. Permissble clearances (S1) (minimum as well as maximum) are to be found in table 1.

Adjustment :

If the alignment of the unit doesn't fulfill the standards that it is to comply with, the alignment has to be adjusted. By moving pump in hor. plane with the adjusting bolts and/or moving driver in vert.plane with installed adjustingjacks (engine) or shims (e-motor)

ISStemine

Stemin coupling 7.1.3 Coupling data Table 1 : General data regarding flexible Stemin couplings

PRIVATE Coupling size S1 (average) (mm)Ka +/-

(mm) Bold

TA (Nm) Kw (mm) Kr (mm)

0442,04xM6x20 14 0,15 0,36

0542,04xM8x25 34 0,18 0,42

0652,54xM8x30 34 0,21 0,50

0752,54xM8x30 34 0,26 0,60

0852,5 6xM10x35 68 0,30 0,70

0963,06xM10x40 68 0,34 0,76

1063,06xM12x40 117 0,39 0,84

1173,56xM12x45 117 0,45 0,95

1284,06xM12x50 280 0,50 1,00

1384,06xM16x55 280 0,55 1,15

14105,06xM20x60 560 0,62 1,30

15105,06xM24x65 960 0,71 1,40

16105,06xM24x80 960 0,81 1,50

Explanation used abbreviations :

- S1 :The average distance (mm) between the two coupling halves in axial direction.

- Ka :The allowed tolerance for S1: The allowed distance S1 for a coupling 12 is 6mm ( 10mm

- TA :The tightening torque (Nm) with which the bolts, with which coupling part 3 is attached to part 2 (see figure Stemin coupling) are to be tightened.

- Kw:The maximal allowable deviation (mm) in (non) parallelity of the shafts, measured as suggested in figure Non-parallity. Kw = Smax - Smin .

- Kr :The maximal allowable deviation (mm) in (non) concentricity of the shafts, measured as suggested in figure Non-concentricity.

7.1.4 Pump adjustment with adjustingbolts 7.1.4.1 GeneralFour adjusting bolts are positioned around the pump pedestal. Loosing two bolts and tightening the two opposite bolts causes pump movement. First loosen the pump foundation bolts. With this feature it is possible to correct coupling NON concentricity in horizontal plane. After adjusting, all four adjusting bolts and pump foundation bolts have to be re-tightened.

PRIVATE 7.2 Driver alignment with adjusting jacks :

The unit is execute with a Vibracon SM adjusters. This is foreseen of two conical parts, so deviation in the engine support can be take easily away.

When adjusting the engine, proceed as follows :

Loosen the bolts (A) of all the supports, so that the engine can be moved easily to some extent.

After having loosened the bolts (A), the lock bold (C) of all supports should also be loosened. To turn the bold (B) in our out, the alignment of the engine will change. Use only a good fitted hookspanner to rotate the bold (B).

When the tolerance of the coupling is in between the acceptable values turn lock bold and bold A should be tightened.fast.

Always check the shaft alignment in both the vertical and the horizontal plane ; even if the engine's position has only be adjusted in one of these planes. An adjustment in the horizontal (vertical) plane may also influence the engine's position in the vertical (horizontal) plane !

If the unit's alignment is checked (and if necessary adjusted), without suction- and discharge piping mounted, the unit's alignment should always be checked (and adjusted, if necessary) after having mounted suction- and discharge piping.

After the alignment procedure has been finished, the tightening torques of the engine/pump connections to the skid as well as of the coupling bolts should be checked. The proper tightening torques for the engine/pump - skid bolts are to be found in appendix 1.

PRIVATE 8 SYSTEM DESCRIPTIONTC " 8 SYSTEM DESCRIPTION"PRIVATE 8.1 GeneralTC " 8.1 General"The firepump controller is designed for automatic starting at loss of water pressure in the fire main and complies with the NFPA 20 requirements.

Starting device is an electrical starting motor mounted on the engine, powered from starting batteries.

Two sets of batteries are provided. Each battery unit has a capacity (at 4,5C) to maintain recommended cranking speed for 12 consecutive starting cycles.

PRIVATE 8.2 Controller TC " 8.2 Nijhuis controller NFP/NFPA/D "Components are contained in an IP54 type sheet steel enclosure with lockable access door on which is mounted the indicators and switches. The controller is designed to operate in exposed non hazardous installlations.

Remote volt free change over contacts are provided for :

Pump on demand

Controller in automatic or in off position

Engine running

Engine failed to start

Fault on engine or controller

Only if specially ordered a controller will be equipped with optional features.

Each controller will have his own operating instruction manual related to the controller serial no..

It is very important to read this manual carefully before operating.PRIVATE 8.3 Cooling-water system :TC " 8.3 Cooling-water system \:"Normal operation :The engine heat exchanger receives raw cooling water from pump discharge normally through the main circuit of the cooling water system. For this purpose ball valves in the main circuit should be entirely opened while the ball valves in the bypass line should be closed.

System operating pressure : The system operating pressure is factory set to normal expected coolingwater consumption. Ideally, the system operating pressure in normal circumstances should be about 1 to 1 bar,or max. working pressure for heat exchanger if this is lower. If the system pressure should become too high, the pressure can be adjusted by changing the setting of the pressure reducer. Normally however, adjustment of this valve shouldn't be necessary. The cooling-system pressure is indicated by a pressure gauge that is located in the system.

Emergency operation :The bypass cooling line should only be used in cases of emergency ; e.g. in cases in which the filter in the main cooling system is stopped up, or in case leakage should occur in the main circuit. In these cases the ball valves in the main circuit should be closed while ball valves in the bypass line should be opened. The last ball valve in the bypass circuit should not be opened entirely in these cases! This valve should be opened just as far as needed for the system pressure to stabilise on a healthy level, as expected during normal operation.

Maintenance :In addition to the maintenance programme ( 1 of the maintenance part of this manual) it is to be recommended to check and clean all filters in the cooling water system regularly.

PRIVATE 8.4 Diesel engine :TC " 8.4 Diesel engine \:"For diesel engine operating directions we refer to the diesel engine's operating manual that is delivered with this pump operation and maintenance manual.

PRIVATE 9 PUTTING THE PUMP-UNIT INTO TC " 9 PUTTING THE PUMP-UNIT INTO " OPERATION FOR THE 1st TIME :PRIVATE 9.1 Before putting into operation for the 1st time :TC " 9.1 Before putting into operation for the 1st time \:" Check the complete installation carefully.

Check all liquid levels (e.g. oil,coolant) diesel-engine and in the right-angle gear when applicable. If there is no oil, look on the identification plate that is attached to the motor for the qulity and quantity.

Check fuel level in fuel tank and fuel supply / fuel return piping.

Make sure all bolts and nuts have been properly tightened.

Check battery connections and state of batteries.

Check electric supply to controller.

Check battery charger performance.

Check that the pumpshaft can rotate freely.

If not already done, install a pressure gauge so that the result of pump-operation can be monitored and checked properly.

Check water level is sufficient for operating.

Check that the discharge valve and / or test line valves are closed.

Check the direction of rotation. The arrow fixed on the pump discharge head indicates the correct direction of rotation. Checking the direction of rotation can be performed by a short-termed switch-on (only a few revolutions of the driver).

PRIVATE 9.2 First starting (on site) :TC " 9.2 First starting (on site) \:" Start the pump by initiating a manual start on either the controller or engine.

Observe that the pump starts easily and runs without unusual vibration on a low speed. About 600rpm. Therefore change the setting of speed control lever. If there is any starting difficulty or excessive vibration, then stop the engine immediately and determine the probable cause.

Slowly open the discharge valve until the discharge pressure reaches the desired value.

Adjust (tighten) the gland nuts gradually over an extended period. Check leakage from stuffing-box. Leakage must be somewhere in between 40 to 60 drops / minute. Leakage may only occur between shaft-sleeve and soft packing-rings; no leakage may occur between stuffing-box and soft packing rings. Adjust stuffing-box leakage if necessary. Adjustment of stuffing-box leakage has to be performed in accordance with gland packing instructions.

For more details: see 10.2 the maintenance part of this manual : 'gland packing directions'.

Turn up the speed of the engine by changing the speed control lever. This may not be higher than the rated speed. The maximum speed can you find on the test sheet.

During the 1st operation period, check and note all gauge readings and compare them to the respective values in the pump, engine and gearbox manuals. If considerable deviations from the guidelines in these manuals are met with, the cause of this should be located and corrected if necessary.

Lock engine speed control lever after speed adjustment is made.

PRIVATE 9.3 After first operation :TC " 9.3 After first operation \:" After the 1st running period it is recommended to check and, if necessary, readjust the pumpshaft's position.

PRIVATE 10 MAINTENANCE :TC " 10 MAINTENANCE \:" PRIVATE 10.1 Preventive maintenance programme :TC " 10.1 Preventive maintenance programme \:" 10.1.1 General : A carefully planned and regulary performed maintenance programme is of essential importance for a proper long term operation and a long service life of your pump-unit.

The following maintenance advice is only to be considered as a guideline for maintenance of a pumping-unit in average operating circumstances. Depending on the circumstances and frequency your pumping-unit has to operate (in), another maintenance program might be considered. An important guide for establishing the ideal maintenance programme for your pumping-unit is to be found in recording the results of previous inspections.

Before, during and after all maintenance and inspection programmes it is of the utmost importance that the pumping-unit and it's operating environment are kept as clean as possible.

10.1.2 Weekly : before taking into operation 10.1.2.1 Diesel engine

Walk-around inspectionCheck the engine, heat exchanger(s) and pump for debris, foreign objects,loose or broken fittings, guards and components.Repair as necessary.

Belts

Inspect for worn, broken or loose belts (alternator, fan, drive etc.).

Cooling system

Maintain proper coolant level.

Block heater

Check for proper operation. Maintain 32C (90F) coolant temperature in the block at all times.

Air cleaner indicatorCheck the indicator (if equipped). Change the air cleaner elements when the indicator diaphragm remains locked.

Engine crankcase

Check the oil level. Maintain the oil level between the "add" and "full" marks on the engine stopped side of the dipstick.

Governor

Check and maintain the oil level (only if required)

Fuel system

Check for leaks and drain water separator (if equipped). Keep fuel tank full. Check fuel filter indicator (if equipped).

Batteries

Maintain electrolyte level, clean batteries if necessary, check connections.

Gauges

Check the condition of all gauges. Repair or replace any broken gauge.

Battery charger

Check for proper operation.

Exhaust system

Drain exhaust condens-drain (if equipped).

10.1.2.2 Pump :

Walk-around inspectionPerform a visual check for leakages, loose bolts, corrosion and presence of debris or foreign objects.

10.1.3 Weekly : during operation

10.1.3.1 Diesel engine :

Start the engine

Run the engine for approximately 30 minutes while performing these checks.

Oil pressure

Check for proper operating oil pressure. Refer to the Operation section of the engine guide for the correct pressure reading.

Fuel pressure

Check for proper operating fuel pressure (only for engines with fuel pressure gauge). Refer to the Operation section of the engine guide for the correct pressure reading.

Frequency (rpm)

Check and record readings.

Leaks and noises

Check for leaks and unusual noises. NOTE : Engine must be stopped before making necessary repairs.

10.1.3.2 Pump :

Noises / vibrations

Check the pump for unusual noises and vibrations.

Stuffing box

Check leakage from stuffing-box. Leakage must be somewhere in between 40 to 60 drops / minute. Leakage may only occur between shaft-sleeve and soft packing-rings; no leakage may occur between stuffing-box and soft packing rings. Adjust stuffing-box leakage if necessary. Adjustment of stuffing-box leakage has to be performed in accordance with gland packing instructions.

Stuffing box drain

Check stuffing-box waste-pipes for free flow.

Bearings

Check bearing temperature. Bearing temperature may not exceed 45 Cabove ambient and may also not exceed 95C.

10.1.4 Weekly : after stopping 10.1.4.1 Diesel engine :

Automatic switches

Check that all switches are in proper postion for automatic start.

Fuel level

Check the fuel level; refill when below 50 % full.

Malfunctions

Report any malfunction and make necessary repairs.

Battery charger

Record charging amperage reading.

10.1.5 Monthly : 10.1.5.1 Controller :

Signal-lamp bulbs

Replace those signal-lamp bulbs that are illuminated continuously (A.C. mains ON, battery A healthy, battery B healthy) .

10.1.6 Yearly : before taking into operation 10.1.6.1 Diesel engine :

Walk-around inspectionCheck the engine, heat exchanger(s), and pump for debris, foreign objects, loose or broken fittings, guards and components. Repair as necessary.

Cooling system

Check for leaks. Add coolant conditioner (if required).

Fuel system

Drain water and sediment from tank. Change fuel filters.

Air cleaner elementInspect; Clean or replace.

Engine crankcase

Check oil level. Maintain oil level between the add and full marks on the engine stopped side of the dipstick.

Engine crankcase breatherClean.

Valve lash

Check, adjust if necessary. Refer to the engine Service Manual for proper procedure and settings.

Linkages

Check and adjust all linkages, if necessary. Lubricate all linkage fittings.

Alarm & shutdown devices Check; test for proper operation.

Batteries

Check electrolyte level, clean terminals and connections.

Engine

Wipe down; clean as needed.

10.1.6.2 Pump :

Walk-around inspectionPerform a visual check for leakages, loose bolts, corrosion and presence of debris or foreign objects.

Bearings

Check bearings and change bearing grease. For this purpose the old grease must be removed and bearings have to be cleaned .

Bearings may not be filled for more than 50 % with new grease. Use Texaco Multi Purpose No. 2 Marfak or equivalent. Check general operation of the bearings and, if necessary, replace them.

10.1.7 Yearly : during operation 10.1.7.1 Diesel engine :

Start the engine

Check all gauges, oil pressure, fuel pressure, frequency (rpm) and engine jacket water temperature, for correct readings.

Leaks and noises

Check for leaks and unusual noises. NOTE : Engine must be stopped before making necessary repairs.

Gauge readings

Check and record readings of all gauges : oil pressure, fuel pressure (if equipped), oil level, frequency (rpm), service meter, engine jacket water temperature, exhaust temperature (if equipped) and manifold vacuum (if equipped).

10.1.7.2 Pump :

General

Same as all weekly during operation Pump inspections.

10.1.8 Yearly : after stopping 10.1.8.1 Diesel engine :

Repair or adjust

Make any repairs or adjustments as necessary.

Engine crankcase

Change oil. Change oil filters.

Fuel level

Record the fuel tank level. Fill if below 50 % full.

Battery charger

Record charging amperage reading.

Automatic switches

Check that all switches are in proper position for automatic start.

10.1.9 Every three years : before taking into operation 10.1.9.1 Diesel engine :

Before starting

Perform all Yearly before taking into operation Preventive Maintenance procedures.

Cooling system

Drain, clean and flush the cooling system. Replace thermostat(s). Refill with coolant solution and conditioner.

Rubber hoses and beltsIt is recommended that all hoses and belts be replaced at this time to minimize downtime and additional repair cost of component failures caused by these items.

Batteries

Replace all batteries at this interval.

Turbocharger

Inspect, repair or replace if necessary to minimize additional associated component failures.

Engine

Perform a complete engine adjustment and tune-up.

10.1.9.2 Pump :

General

The 3 yearly or 20.000 hours inspection must contain the same inspections/checks that are to be performed yearly.

Bearings

Replace bearings.

Stuffing box

Replace all soft packing rings at this time.

Wearrings

Check casing (and impeller, if equipped) for wear. Maximum permissible diametrical clearance between impeller and casing depends on impeller size and can be found in figure 1.

CLEARANCES IMPELLER-CASING WEARRING

single stage and two stages centrifugal pumps ( Tmax=80C )

Shaftsleeves

Check shaftsleeves for damage and wear. If necessary, replace them. Permisseble wear and/or damage should be considered for each case separately. It may not be necessary to replace shaftsleeves in cases where small damage, or minor wear is established. Damage or wear that does (or may) influence pump performance considerably is not permissible. In cases where smaller damage or wear is established, and shaftsleeves are not replaced, a more frequent inspection of the damaged or worn part should be performed.

Oil seal

Check the oil seal ring in the bearing housing on the coupling side and replace it, if necessary.

Felt rings

Check the feltrings in both bearing houssings and replace them, if necessary.

Miscellaneous

Clean the entire pump thoroughly (inside as well as outside) and make sure the old flange sealant between the two casing halves is removed entirely before new sealant is applied. Flange sealant between the two casing halves should be Loctite Superfast 573. Make sure all casing bolts are tightened crosswise with the proper tightening torque (tighening torques : table 1 ,appendix 1).

10.1.10 Every three years : during operation 10.1.10.1 Diesel engine :

Engine running

Same as all Yearly during operation Preventive Maintenance procedures.

Exhaust system

Check for leaks. Repair or replace defective components with engine stopped.

10.1.10.2 Pump :

General

Same as all yearly during operation PUMP inspections.

10.1.11 Every three years : after stopping 10.1.11.1 Diesel engine :

After stopping

Same as all Yearly after stopping Preventive Maintenance procedures.

PRIVATE

PRIVATE 10.2 Gland packing directions : 10.2.1 General :If a large leakage flow, or a leakage in the wrong location, should occur and the gland has already been adjusted several times (or in case adjusting doesn't result in an improvement), the packing-rings most likely are worn or damaged so that a replacement of the rings becomes necessary. When removing and assembling the rings the following procedure should be followed :

10.2.2 Removing old packing-rings : 10.2.2.1Make sure the stuffing-box is not under pressure. For this purpose check :

- Readings discharge pressure gauge

- Water supply to lantern-rings

If possible, drain the water that is in the pump, until the water level has at least dropped below the lowest

stuffing-box level. Draining can be done by removing one of the plugs that are placed in the discharge

flange.

10Figure 110.2.2.2After having checked the points mentioned in the maintenance, the gland should be removed. For this purpose the gland-nuts should be removed, wherefore the gland should be pulled back as far as possible (figure 1) .

11Figure 210.2.2.3After the gland has been removed, the old packing-rings and the lantern-ring can be removed. Always replace all packing-rings ! Replacing only one or two rings will not result enough effect. Removing the packing-rings should be done with the help of a packing-extractor (see figure 2) and should be performed with ample care, in order to prevent damages to stuffing-box and/or shaft(sleeve).

Make sure the packing-extractor's sharp side is pointed towards the stuffing-box and not towards the shaft(sleeve), so that in case of shooting out the shaft(sleeve) will not be damaged.

The lantern-ring also should be removed in order to be able to remove the packing-rings that are placed on the other side of the ring. For this purpose the lantern-ring is executed with, generally 2, savings through which hooks can be inserted. Pull the lantern-ring out with one hook in both the savings simultaneously so that the ring can be pulled out of the stuffing-box straight. Obviously, removing the lantern-ring should be performed with the same care as is required when removing the packing-rings.

12Figure 310.2.2.4After having removed packing- and lantern-ring(s) the shaft(sleeve) and stuffing box should be cleaned and checked for damage or wear thoroughly. If shaft(sleeve) and/or stuffing-box show considerable wear/damage these failures should be corrected.

In case abnormal packing-wear seems to occur, it is recommended to also check whether shaft(sleeve) and stuffing-box are positioned concentric (see figure 3) and aligned, apart from wear and damage to shaft(sleeve) and stuffing-box. Also check the shaft run-out.

13Figure 4

Also check the gland's dimensions (see figure 4). For this purpose place the gland into the stuffing-box and measure the clearance on the inside-diameter (with the shaft(sleeve)) as well as on the outside-diameter (with the stuffing-box). These clearances should (diametrical) not be more than 1,6 mm respective 1,0 mm, to prevent that the gland will be able to contact the shaft or shaftsleeve.

Check the clearance between the bottom of the shaft (sleeve) and the stuffing-box (see figure 5). In case this clearance should be larger than 0,8 mm (radial) than mount a neckring with the proper dimensions. When using such a ring it's not possible that packing-rings are pressed between shaft(sleeve) and stuffing-box, what would cause damage to the rings.

14Figure 5 10.2.3 New packing-rings :10.2.3.1Only apply original packing-rings of the proper material and manufacture.

15Figure 610.2.3.2Packing usually is delivered in pre-formed rings of the proper sizes or in one spiral-formed length.

In case packing is not delivered in one of the forms mentioned above, but in one length (non-spiral formed) it is necessary to cut off the proper length that is needed for one ring. In these cases proceed as follows :

* Wind the packing-length tightly around a shaft with the same diameter as the shaft(sleeve) is (see figure 6) .

* Draw two lines on the packing-'spiral' parallel to each other in axial direction with a space that is equal to the packing-width (or packing-height, as the packing-width is generally equal to the packing-height).

16Figure 7

Now cut rings out of the spiral, between the two parallel lines in an angle of 45, in the

horizontal plane, with the axial direction (see figure 7).

* Packing-rings made out of a stiff material should be cut in (see figure 8) , over about 2/3 of the packing-height, on the inside-diameter on one or more spots so that the rings can be bent open somewhat when mounting onto the shaft(sleeve).

17Figure 8

* Check whether all packing-rings are the proper dimensions, before mounting them into the stuffing-box.

10.2.4 Mounting the new packing-rings :10.2.4.1Before mounting the new packing-rings first check whether stuffing-box and shaft(sleeve) are clean ; also check whether the old packing-rings are completely removed. Also check that the pump-shaft can rotate freely.

10.2.4.2Always place only one packing-ring at a time and mount each packing-ring about 120 rotated with respect to the previously mounted ring.

After the mounting of each ring, always check whether the shaft can still rotate freely.

18Figure 910.2.4.3Do not forget to replace the lantern-ring (if equipped) ! Before replacing the lantern-ring check the ring for cleanliness and damage.

Make sure the lantern-ring is mounted so that the ring will be placed straight under the lantern-ring water-supply connections (see figure 9), after the gland-nuts have been tightened again .

10.2.4.4After having placed the lantern-ring, the rest of the packing-rings can be placed. Placing these rings should be done in accordance with the directions given in the maintenance.

10.2.4.5After having placed the last packing-ring, the gland has to be mounted again. When replacing the gland, the gland-nuts should equally be tightened until they are hand-tight to loose. Check again that the shaft can still be rotated freely.

10.2.4.6After having checked and approved that the shaft can be rotated freely, the gland-nuts should be equally and firmly tightened.

10.2.5 Adjusting / running in of the packing :10.2.5.1Untighten the gland-nuts until they are hand-tight to loose again.

10.2.5.2Start the pump.

NOTE : NEVER COMPLETELY LOOSEN THE GLAND-NUTS WHEN THE PUMP IS RUNNING !10.2.5.3After having started the pump (almost) immediately a leakage should occur between packing-rings and shaft(sleeve). In case no leakage should occur read and apply the maintenance.

10.2.5.4Leakage does occur : If leakage does occur between packing and shaft(sleeve), the packing-rings have been mounted properly ; the packing should now be adjusted. When adjusting, proceed as follows :

a)

Leakage should ideally be about 40 to 60 drops per minute. Generally, the leakage with the gland-nuts hand-tight to loose will be (much) more than the mentioned 40 - 60 drops / minute. In these cases the gland has to be adjusted.

b)

Before the gland may be adjusted the pump should first have operated about 10 minutes with a constant leakage, so that leakage will be able to stabilise itself and therefore can be estimated more correctly.

c)

After having let the pump operate for about 10 minutes the gland-nuts can be tightened. The gland-nuts should never be tightened more than 1/16 turn at a time. After each time the gland-nuts have been adjusted the pump should be operated for about 10 minutes again before further adjustment may be performed.

d) Repeat the steps mentioned under point c) until leakage has stabilised to the mentioned 40 - 60 drops/minute.

10.2.5.5No leakage occurs : If no leakage (or a leakage on the wrong place) should occur the packing is likely to become overheated rapidly. Therefore, if leakage does not occur (almost) immediately, stop the pump and let it cool down.

Check whether the gland-nuts are still hand-tight to loose.

a) The nuts are still hand-tight to loose :

If the nuts are still hand-tight to loose, after having stopped, tighten the nuts slightly (about 1 complete turn).

b) The nuts are not hand-tight to loose anymore :

If the nuts are not placed hand-tight to loose anymore the packing will most likely have been tightened to much when the gland was mounted, this has probably caused an expansion of the packing during pump-test operation. Therefore undo the nuts slightly until they are hand-tight to loose again.

After having executed one of these procedures a) or b), the pump can be started again. After starting leakage should occur (almost) immediately. If still no leakage occurs, or a leakage on the wrong place occurs, then immediately stop the pump again.

Let the pump cool down again and disassemble the gland and packing-rings again. Locate and correct the cause of the failure.

PRIVATE 11PRIVATE .(DIS) ASSEMBLING THE PUMPItc \l 1 ".DISMANTLING AND ASSEMBLY"PRIVATE

Subject:

Cross-section drawing 344404, HGT1.

Prior to commencing work on the pump unit, drain the pump housing and isolate the motor from the mains supply. During the work, ensure that it is impossible for anyone to fill the pump or to start the motor.

It is advisable, during the dismounting of the pump, to lay aside the various components in a systematic manner, so that the reassembly of the pump is simplified.

PRIVATE 11.1 Disassembling the pump:Atc \l 2 ".Dismantling sequence"

First remove the motor, including the 2 coupling halves or, if applicable, the spacer coupling.

Remove the key (14) and the gland nuts (57), and withdraw the gland rings (42) as far as possible. Turn the nut (86) on the conical pin (84) until it releases. Remove it. Remove all nuts (82) from the upper half of the pump casing and turning the jacking bolts (83), lift the upper half away from the lower half. Lifting vertically, and taking care not to damage the impeller (70), lift the upper cover off the lower half.

Remove the bolts (10) from the bearing housings (1+2) and raise the complete shaft out of the lower half. Carefully place the shaft on a wooden surface.

Remove the seal rings (73) from the impeller (70). Unscrew the v-ring (16) and the bolts (12) of the bearing housing covers (3). Take care of the gamma seals (17). Remove the bearing housings (1+2). Prise away the lip of the tab washer (8) and remove the shaft nuts (7) and the tab washer (8). Using a bearing extractor, the entire bearings (6) can be drawn off the pump shaft (4). Subsequently remove bearing covers (3), bush (5), glands (42), packingrings (50), lanternrings 44, neckbushes (45) and shaft sleeve (40) be aware of the o-rings (18+52). The impeller can now be drawn of the pump shaft (4) and key (15) can be removed.

The pump is now fully dismantled.

PRIVATE 11.2 After disassembling the pump:Btc \l 2 ".After dismantling"

Protect all components against damage.

Clean the bearing with white spirit, acid-free paraffin or another suitable cleaning agent. Dry the bearing with clean and dry compressed air. Inspect the bearing and, if necessary, replace it. If replacement is not necessary, it is advisable to treat the bearing immediately with oil or grease, so preventing any rust occurring.

Inspect the shaft sleeves for wear. Replace as necessary.

Check the play between the sealing ring(s) and the impeller(s).

After dismantling, continued Inspect the packing rings, 'O'-rings, etc. for wear or damage. Replace as necessary.

Thoroughly clean all join surfaces and inspect the fitting flange edges for damage. If the pump is not to be reassembled immediately, treat all uncoated surfaces with a protective film of preserving oil. E.g. Shell Ensis.

PRIVATE 11.3 Assembling the pump:Ctc \l 2 ".Assembly sequence"

Starting with the shaft group, first check the direction of rotation of the impeller (70). Assemble the impeller key (15) and slide the impeller (70) onto the shaft (4). Insert the shaft sleeves (40) and the o-rings (18+52. Then fit the following components to the pump shaft : the neckbushes (45), lantern rings (44), gland rings (42), bush (5), gamma seals (17) and bearing covers (3). Position the sealing rings (73) round the impeller (70).

Position the bearings (6), put some grease on them and mount the onto the shaft (4). Heat the innering of the bearings up to 80(C (not with an open flame). Subsequently bearing nuts (7) and lock washers (8) can be mounted. Ensuring that the lip of the lock washer is located in the recess in the bearing nut! Now the bearing housings (1+2) can be positioned and the bearings covers (3) can be assembled with nuts (12). De gamma seals (17) can be shoved against the bearing covers (3).

After cleaning (degrease) and inspecting the stuffing box, the joint surfaces and the fitting recesses, position the complete shaft section. When the impeller (70) is correctly assembled on the shaft, the impeller will be located exactly in the centre of the pump. Slide the neck bushes (45) into the lower half and hold the lantern ring(s) (44) and the gland rings (42) out of the stuffing box.

Apply a line of liquid packing on the jointing surface of the lower half, ensuring that no gaps occur in the line of liquid packing. Also, apply liquid packing to the studs.

Use for this purpose 'LOCTITE SUPERFAST' No. 573Position the loose cover, over the conical pins (84), on the lower half. Fit the nuts (82) on the studs (81), and tighten the pump halves together. Note that the nuts need to be tightened crosswise.

Secure the bearing housings (1+2) with bolts (10). Check that the pump shaft rotates freely. If not, recheck the above instructions, step by step. If the shaft rotates freely, the packing can be fitted and key be mounted. To do this, proceed as detailed in the chapter GLAND PACKING INSTRUCTIONS.

When the pump has been assembled, recheck for certainty that all bolts and nuts are securely tightened.ordance with the directions given in attached appendix.

Partlist

BILL OF MATERIAL

Splitcase fire-fighting pump (FM)

Sectional drawing 344404 rev. 0

Material code: 014

Pos.PartnameNijhuis codeMaterialEquivalent to

1.Bearinghouse106DIN1691/0.6025ASTM A48-40B

2.Bearinghouse106DIN1691/0.6025ASTM A48-40B

3.Bearingcover106DIN1691/0.6025ASTM A48-40B

4.Pumpshaft235SEW 400/1.4122

5.Distance bush240DIN17440/1.4301ASTM 304

6.Bearing000Steel SKF

7.Lock Washer000Steel SKF

8.Bearing nut000Steel SKF

9.Set screw250DIN17440/1.4401ASTM 316

10.Hexagon bolt215Steel 8.8

11.Lock washer210Steel

12.Hexagon bolt215Steel 8.8

13.Lock washer210Steel

14.Coupling key213Steel C45k

15.Impeller key255DIN17440/1.4571ASTM 316 Ti

16.V-ring000Nitrile rubber

17.Gamma seal000Nitrile rubber with a metal case

18.O-ring000Nitrile rubber

40.Sleeve305DIN1705/2.1090ASTM B584-C93200

42.Gland packing302DIN1805/2.1086ASTM B384-C90500

44.Lanternring305DIN1705/2.1090ASTM.B584-C93200

45.Neck ring305DIN1705/2.1090ASTM B584-C93200

50.Packing000Thermoflon

52.O-ring000Nitrile rubber

54.Lock washer240DIN17440/1.4301ASTM 304

56.Gland stud240DIN17440/1.4301ASTM 304

57.

Hexagon nut240DIN17440/1.4301ASTM 304

70.Impeller301DIN 1705/2.1096ASTM B584-C83600

73.

Wearring305DIN1705/2.1090ASTM B584-C93200

80.Pumpcasing112DIN 1693/0.7050ASTM A536-80-55-06

81.Stud210Steel 5.8

82.Hexagon domed cap nut210Steel 6

83.Hexagon bolt215Steel 8.8

84.Taper pin000Steel

85.Lock washer210Steel

86.Hexagon nut215Steel 8.87.Hexagon head screw plug345DIN 1651/9SMnPb28K

88.Sealing washer350Copper annealed

89.Hexagon head screw plug