Peerless Pump THF Installation and operating instructions

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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Peerless Pump Company
MODEL THF, TYF, TXF, and HYF
HORIZONTAL SPLIT CASE
FIRE PUMPS
INSTALLATION, OPERATION and MAINTENANCE
Peerless Pump Company
2005 Dr. Martin Luther King Jr. Street
P. O. Box 7026
Indianapolis, Indiana 46207-7026
Phone [phone] Fax [phone]
www.peerlesspump.com

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
- 1 -
CONTENTS
1 INTRODUCTION .............................................................................................................................................................. 3
1.1 GENERAL............................................................................................................................................................. 3
1.2 WARRANTY.......................................................................................................................................................... 3
1.3 PUMP IDENTIFICATION....................................................................................................................................... 4
1.4 HEALTH and SAFETY .......................................................................................................................................... 4
1.4.1 GENERAL................................................................................................................................................... 4
1.4.2 SPECIFIC RECOMMENDATIONS.............................................................................................................. 4
2 INSTALLATION................................................................................................................................................................ 6
2.1 RECEIVING PUMP ............................................................................................................................................... 6
2.2 TEMPORARY STORAGE ..................................................................................................................................... 6
2.3 PREPARATION..................................................................................................................................................... 7
2.4 LOCATION............................................................................................................................................................ 7
2.5 FOUNDATION....................................................................................................................................................... 7
2.6 INSTALLATION OF BASE PLATES...................................................................................................................... 7
2.7 ALIGNMENT PROCEDURE.................................................................................................................................. 11
2.7.1 ANGULAR................................................................................................................................................... 12
2.7.2 PARALLEL.................................................................................................................................................. 12
2.7.3 AXIAL.......................................................................................................................................................... 12
2.8 SUCTION and DISCHARGE PIPING .................................................................................................................... 12
3 OPERATION .................................................................................................................................................................... 13
3.1 BEFORE STARTING (After Installation or Maintenance)....................................................................................... 13
3.2 STARTING............................................................................................................................................................ 13
3.3 RUNNING.............................................................................................................................................................. 14
3.4 STOPPING............................................................................................................................................................ 14
TABLE 1 FAULT FINDING CHART..................................................................................................................................... 15
TABLE 2 FAULT RECTIFICATION CHART ........................................................................................................................ 16
4 MAINTENANCE................................................................................................................................................................ 17
4.1 ROUTINE MAINTENANCE ................................................................................................................................... 17
4.2 LUBRICATION...................................................................................................................................................... 17
TABLE 3 BEARING RE-GREASING INTERVALS............................................................................................................... 17
4.3 BEARINGS - GENERAL........................................................................................................................................ 18
4.4 SOFT PACKED SEALING..................................................................................................................................... 19
TABLE 4 ROUTINE MAINTENANCE CHART..................................................................................................................... 20

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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INTRODUCTION
1.1 GENERAL
The pumps covered by this manual, when correctly installed and maintained, will give long and reliable service.
It is essential therefore that the instructions given here are followed at all times.
1.2 WARRANTY
New equipment manufactured by Peerless Pump
Company (Seller) is warranted to be free from defects in
material and workmanship under normal use and service
for a period of one year from date of shipment, Seller's
obligation under this warranty being limited to repairing or
replacing at its option any part found to be so defective
provided that such part is, upon request, returned to
Seller's factory from which it was shipped, transportation
prepaid.
This warranty does not cover parts damaged by
decomposition from chemical action or wear caused by
abrasive materials, nor does it cover damage resulting
from misuse, accident, neglect, or from improper
operation, maintenance, installation, modification or
adjustment.
This warranty does not cover parts repaired outside
Seller's factory without prior written approval. Seller
makes no warranty as to starting equipment, electrical
apparatus or other material not of its manufacture, since
the same are usually covered by warranties of the
respective manufacturers thereof.
In the event, notwithstanding the terms of this agreement,
it is determined by a court of competent jurisdiction that
an express warranty has been given by Seller to
Purchaser with respect to the head, capacity or other like
performance characteristics of said equipment, Seller's
liability for breach of the same shall be limited to
accepting return of such equipment F.O.B. plant of
manufacture, refunding any amount paid thereon by
Purchaser (less depreciation at the rate of 15% per year
if Purchaser has used equipment for more than thirty (30)
days) and canceling any balance still owing on the
equipment.
Peerless Pump Company in no event will be liable for
indirect or consequential damages.
This warranty is expressly in lieu of any other
warranties, expressed or implied, and seller
specifically disclaims any implied warranty of
merchantability or fitness for a particular purpose.

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
- 4 -
1.3 PUMP IDENTIFICATION
An identification plate is attached to the body of all pumps and contains the following minimum information:
PUMP TYPE, SERIAL No., CAPACITY, SPEED, HEAD.
Additional information may also be given covering impeller details, materials used, sales order line number
etc. Reference should be made to this data when reading the manual.
1.4 HEALTH and SAFETY
1.4.1 GENERAL
I. QUALIFICATION AND TRAINING OF PERSONNEL
Personnel responsible for the installation, startup, operation and maintenance of this pump unit must
be adequately qualified for their respective tasks. Scope of responsibility must be defined by the
operator and appropriate supervision provided. The operator should also ensure that the contents of
this manual are fully understood by the personnel.
Il NON-COMPLIANCE WITH SAFETY INSTRUCTIONS
Non-compliance with safety instructions may produce a risk to personnel as well as to the
environment and the pump unit, and result in loss of any right to claim damages.
Risks may include:
a. Failure of the pump unit.
b. Exposure of people to electrical, mechanical and chemical hazards.
c. Endangering the environment by releasing hazardous substances.
Ill COMPLIANCE WITH SAFETY AT WORK REGULATIONS
When operating the pump unit, the instructions contained in this manual, the relevant national
accident prevention regulations and any other service and safety instructions issued by the operator
are to be observed.
IV UNAUTHORIZED ALTERATIONS AND FITTING OF SPARE PARTS
Modifications should not be carried out without consultation with Peerless Pump Company In the
interests of safety and reliability only fit spare parts supplied with Peerless Pump Company Failure to
comply in these respects could affect warranty.
V. UNAUTHORIZED USE
Pump performance and reliability can only be guaranteed providing that it is used in the manner and
for the purpose for which it was intended.
1.4.2 SPECIFIC RECOMMENDATIONS
1.4.2.1 Your safety and that of others must always be the first consideration when working on machines.
Safety is a matter of understanding the operations being undertaken and the potential dangers.
Be on your guard at all times.
WARNING! The following health and safety recommendations must be strictly observed.
(1) While this pump unit has been designed to be safe under normal operating conditions, there are
potential hazards which the operator should be aware of. These can include: rotating
components; electrical potentials; high temperature exhaust surfaces and gases (where diesel
driven); and hazardous fluids.

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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(2) When lifting the unit ensure that all lifting equipment has a safe working load rating, suitable for the
operation. Only perform lifting operations using suitably trained personnel, and in line with
instructions contained in this manual.
(3) Persons working on the unit should always wear suitable protective clothing and footwear. Loose,
frayed or baggy clothing and light footwear can be extremely dangerous. Clothing impregnated
with oil or similar can constitute a health hazard through prolonged contact with the skin and may
also create a fire risk. Wear protective goggles and gloves when handling battery acid.
(4) Liquids used with some pump units are harmful if taken internally or come into contact with
unprotected skin or eyes. In the event of an accident, obtain qualified medical assistance
immediately.
(5) Always ensure that all guards supplied are correctly installed following any maintenance operation.
(6) Ensure that the pump unit is not run outside its operational limits. This can put the unit under
excessive loads and cause breakdown.
(7) Before starting any repairs disconnect power to the pump driver and place a conspicuous notice is
displayed warning that the unit is under repair. If a major overhaul is being carried out it is
advisable to have a qualified electrician temporarily disconnect the unit.
1.4.2.2 PUMP HAZARDS
(1) Ensure that the pump has no air in the suction line and casing. The pump rotating components
rely on the liquid being pumped for cooling and lubrication. A failure to prime could result in pump
failure.
(2) Pump operation with insufficient lubrication to the bearings could result in overheating and seizure,
with potentially catastrophic results.
(3) Where soft packed sealing is used it is essential that a small leakage is present. Over tightening
of the gland will result in damage to the packing, scoring of the shaft or sleeves and bearing
seizure.
(4) Ensure that all pressure has been released before working on the unit.
(5) Always check that the drive shafts are correctly aligned following installation. Failure to do so
could result in reduced life or a possible failure of the coupling, or bearings. (see Section 2.7).
1.4.2.3 HAZARDS RELATED TO ENGINE DRIVEN PUMP UNITS
(1) When working with gaseous fuels, ensure that the area is well ventilated and avoid open flames,
smoking, sparks etc. A Carbon Dioxide fire extinguisher should be kept close at hand.
(2) Parts of the package, in particular, the exhaust system and engine surfaces can become very hot
during and after operation and can cause severe burns.
(3) Beware of the danger of scalding when removing cooling system pressure caps and hoses,

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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or draining engine oil. Allow the system to cool first, then remove caps slowly.
(4) Rectify all water, oil or fuel leaks immediately and clean up any spillage.
(5) Before carrying out any work on the pump unit confirm that the fuel and electrical supplies to the
engine are isolated correctly, and that there is no danger that it can be started. A conspicuous
notice should be placed on the unit warning others that the unit is under repair.
1.4.2.4 PUMP UNITS FITTED WITH ELECTRONIC COMPONENTS
CAUTION Damage can occur to the internal components when electric welding or high voltage "Megger"
tests are carried out. Electronic components should always be disconnected before carrying
out any work of this kind.
2. INSTALLATION
2.1 RECEIVING PUMP
On receipt of pump, a visual check should be made to determine if any damage has occurred in transit.
Typical points to look for, are:
a. Broken or cracked equipment e.g. base plate, motor, pump feet and flanges.
b. Bent shafts.
c. Damaged motor end bells, bent eyebolts or damaged boxes.
d. Missing items.
Loose parts are often wrapped individually and/or fastened to the equipment. If any damage or losses have
occurred notify the transit company immediately and PEERLESS PUMP COMPANY.
When unloading pump units, only lift using the lifting eyes on the base plate or support frame. DO NOT
USE THE LIFTING POINTS ON THE PUMP OR MOTOR
Pump and motor shafts are in alignment when shipped, however the alignment must be re-checked before
use.
2.2 TEMPORARY STORAGE
If the pump is not to be installed immediately it should be stored in a clean, dry area, with protection from
moisture, dust, dirt and foreign bodies. In particular, the following action should be taken:
a. Ensure the bearings are packed with the recommended grease, to prevent moisture from
entering around the shaft.
b. Remove the glands, packing and lantern rings from the stuffing box, where soft packed sealing is
used.
c. Check that the pump suction and discharge ports are covered to prevent foreign objects entering.
d. If, for a short period only, the pump has to be stored outside it should be covered to protect it
from the effects of the weather.
e. Every 6 weeks, rotate the pump shaft to prevent bearing pitting.

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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PREPARATION
Before installing the pump, clean the suction and discharge flanges thoroughly and remove the protective
coating from pump shafts, where applicable.
If the pump has been in storage and prepared in the manner as above, the bearing grease should be
removed, the bearings cleaned (using an approved cleaning fluid) and then re-lubricated following the
procedure detailed in Section 4. It is strongly recommended that this work is carried out by PEERLESS
PUMP COMPANY Service. This is a chargeable service; however pump warranty will be protected.
2.4 LOCATION
The pump should be installed as near to the liquid source as possible, with the shortest and most direct
suction pipe practical.
Allow sufficient accessibility for inspection and maintenance, and ample headroom should be allowed for
the use of an overhead crane or hoist sufficiently strong to lift the unit.
Where pumps are electric motor driven, power source electrical characteristics should be appropriate for
those shown on motor data plate.
2.5 FOUNDATION
The foundation should be sufficiently substantial to absorb vibrations and rigid enough to avoid any twisting
or misalignment. As a rough guide it should be 12 inches wider on all sides with the weight at least 1-1.5
times as heavy as the pump unit. Depth should be sufficient to achieve the necessary weight and deep
enough to accommodate holes for foundation bolts. A suitable concrete mixture by volume is 1:2:3 (Cement
: Sand : Aggregate). The foundation should be reinforced with layers of 6 inch square No.8 gauge steel wire
fabric, or equivalent, horizontally placed 6 inch apart.
Loose bolt type anchors should be checked for tightness periodically, as there is a tendency to loosen with
vibration. Chemical type anchors are a suitable alternative.
2.6 INSTALLATION OF BASE PLATES
Foundation concrete should be poured without interruption to within .5 to 1.5 inch of the finished height. The
top surface should be well scored and grooved, before the concrete sets, to provide a bonding surface for
the grout. The foundation should be allowed to cure for several days before the base plate is shimmed and
grouted.
Chemical Anchor type foundation bolts are recommended as these are less inclined to loosen in service,
and generally simplify installation. Manufacturer's instructions for installation and final torque figures should
be rigorously followed. Allow enough bolt length for grout, shims, lower base plate flange, nuts and
washers. Anchor bolt diameter should be the largest capable of being inserted through the base plate
foundation holes.

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
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For installation purposes, base plates can generally be divided into 4 different categories:
a. Channel Section
b. Folded Sheet Metal with side flange
c. Folded Sheet-metal without side flange
d. Box Section, and Cast Iron base plates.
e. Follow the appropriate installation procedure.
2.6.1 INSTALLATION FOR CHANNEL SECTION BASE PLATES
Position pump unit and mark through base plate fixing bolt holes. Move pump unit to one side and
drill holes for foundation bolts. Install foundation anchors in line with manufacturers instructions.
Reposition pump unit using blocks and shims under the base for support either side of foundation
bolts, and midway between the bolts, to locate the base approximately 1 inch above the concrete
foundation with the studs extending through the holes in the base plate.

TECHNICAL INSTRUCTIONS
4853989
10/ 2003
Our policy is one of continuous improvement and we reserve the right to alter specifications of our products at any time.
- 9 -
Add or remove shims under the base to level the pump-shaft of horizontally mounted pump units. The
base plate itself does not have to be level.
Torque down foundation nuts tight against the base plate and observe pump and motor shafts or
coupling hubs for alignment.
Note: Square tapered washers should be used on the channel section flanges, to ensure that the
foundation bolts are not bent.
Grout base plate in completely using non-shrink grout and allow it to dry thoroughly before attaching
piping to pump (24 hours is sufficient time with the approved grouting procedure).
The suction and discharge piping should be installed after the pump unit, ensuring that no pipe strain
is placed on either flange, and that both pump and pipe flanges are square to each other
GROUTING PROCEDURE
Grouting compensates for uneven foundations, distributes weight of unit and prevents shifting. Use
an approved, non-shrinking grout as follows:
Soak top of concrete foundation thoroughly, then remove surface water. Completely fill base plate
with grout.
After grout has thoroughly hardened check foundation bolts and re-tighten if necessary, then re-check
alignment.
Approximately 14 days after the grout has been poured or when the grout has thoroughly dried, apply
an oil based paint to the exposed faces of the grout to prevent air and moisture from coming into
contact.
2.6.2 INSTALLATION FOR FOLDED METAL BASE PLATES WITH SIDE FLANGES
Move pump unit into position and drill holes using base plate foundation holes as a guide. Install
anchors in line with manufacturers instructions. Use blocks and shims under the base for support,
either side of foundation bolts and midway between bolts, to raise the base approximately 1 inch
above the concrete foundation.