Diesel Electric Fire Pumpset Manual 2

Diesel Electric Fire Pumpset
Operation & Maintenance Manual
Client / Project Name
Allied Pumps Packaged Water Solutions 1

Diesel Electric Fire Pumpset Manual

CONTENTS
Diesel Electric Fire Pumpset 4 - 22

1. Safety precautions 4–5
2. Operating Instruction 6
3. Specific warning and precautions 7-8
4. Installation note 9 - 11
5. Initial start-up procedure 12 - 13
6. Test starting 14
7. Emergency procedures 15
8. Shut down and Isolation procedures 16 - 17
9. Specific maintenance 18
10. Testing checklist 19 - 21
11. Typical Drawing 22 - 23
Diesel Electric Fire Pumpset Controller 24 - 26
Appendix A: Diesel Engine Information and Operating Manual

Appendix B: Warranty and Service Information

SAFETY PRECAUTIONS
Before installation, operation or maintenance of the pump system, read instructions and equipment
manufacturer’s specific instructions carefully.
System operation may cause injury. Take all necessary precautions. Wear necessary protective
equipment. Refer to the engineers’ department. Any maintenance of pump systems must be carried out
by authorised qualified personnel only.
WARNING - PUMP MAY START AT ANY TIME

In normal automatic mode, pumps may start automatically at any time. Before maintenance or any
work is carried out on pumps or motors, ensure proper isolation of motors at the relevant controller.
WARNING - SYSTEM IS PRESSURISED

Under normal operating conditions, the piper, pumps and components or water supply and pressure
systems are pressurised. Before unbolting or dismantling any pipework or equipment, ensure water
supply to the areas of maintenance is isolated and water pressure relieved.
DANGER - HIGH VOLTAGE

Control boxes contain high voltage live wiring and terminals. Entry of control boxes is not permitted
except by authorised service personnel only. Ensure controller is correctly isolated before entering.
CAUTION - EXPOSED MOVING PARTS

Keep clear of all moving parts on pumps, motors and couplings and keep the area around pump system
clear at all times.
CAUTION - HIGH TEMPERATURE
Parts of diesel engine, exhaust pipe and cooling pipework are hot when the engine is running and for
some time after engine stops. Keep clear of these areas during these times.
BATTERY EXPLOSION RISK

Warning – battery may explode. Wear personal protective equipment including face shield. Do not
allow battery to be exposed to high ambient conditions and ensure batteries are replaced in accordance
with the current Australian Standards requirements.
MSDS – DIESEL, OIL, COOLANT – REFER APPENDIX A

Finally, take care and use common sense when working on or near pumpset and report all faults to the
maintenance manager.

OPERATING INSTRUCTIONS
ELECTRIC PUMP
To START push the emergency start button
To STOP push the pump stop button or turn off the main isolator
DIESEL PUMP
To START push and hold either (or both) emergency start button until engine starts
To STOP push and hold the pump stop button for 10 seconds
If the diesel motor won’t STOP or continues to crank over turn the key switch to isolate.
Then press stop or pull the yellow lever on the side of the motor.
Refer notice on diesel tank for correct isolation and de-isolation procedures.
Refer to manual for full operating instructions

SPECIFIC WARNING & PRECAUTIONS
1. MAINTENANCE
Fire Protection Pumpset must be tested and maintained on a regular basis in accordance
with relevant Australian Standards including AS1851-14. Regular testing to be carried out by a
fire systems maintenance contractor. For routine servicing please contact ALLIED PUMPS
SERVICE (08) 9350 1000.
2. MANUAL SHUT DOWN
The Australian Standard prohibits automatic shut down of fire pumps. The fire pumps will
not automatically shut down after they have started and must be manually stopped.
3. EXTERNAL WARNING DEVICE
The fire pump system generates alarm and warning outputs which must be connected to an
adequate external warning device or system and maintained to the relevant Australian
Standards. Procedures must be instigated to ensure warning signals are responded to in a
competent manner, on a 24 hour per day basis.
Ignoring these signals could result in serious system damage / failure.
4. MONITORING EQUIPMENT
The Fire Pumps must never be allowed to run unattended (with the exception of a
jacking pump). Pumps must be constantly monitored by suitably qualified personnel while pump
is running.
Monitoring must include, but not be limited to:
4.1 ELECTRIC PUMP

- Motor current on each phase
- Water flow through pump
- Out of balance or abnormal noise

4.2 DIESEL PUMP
- Engine Oil pressure
- Engine temperature
- Engine speed
- Water flow through pump
- Fuel supply
- Engine coolant level
- Heat exchange rejects water flow
- Out of balance or abnormal noise
5. INTENDED USE OF EQUIPMENT
The Fire Pumps must not be used other than for the intended purpose, ie fire
protection, training and system pressure maintenance. Failure to comply with this may void
warranty.
6. VENTILATION AND DRAINAGE
Pump room must be adequately vented and drained. Failure to do this may result in severe
damage to property and personnel. Radiator cooled engines should have the radiator exhaust air
ducted directly out of the exhaust room with a suitably sized duct. Ventilation should be
sufficient to cope with the radient heat load of the engine and ensure there is less then 10˚C
temperature load rise down ambient during a 30 minute fell load operation. Radiator cooled
engines should have the radiator exhaust air ducted directly out of the pump room with a
suitably sized vent.
7. EXHAUST
Diesel exhaust must be piped to a suitable external location in a manner that will preclude the
entry of water. Exhaust pipework should include a condensate trap and must be sized to engine
manufacturer’s recommendations. Exhaust pipework and accessories must be logged in a
suitable method to industry standards. If the pipe run is more than 10 metres, the pipe diameter
will need to be increased. Refer to diesel engineer.
8. Equipment to be mounted on suitable vibration isolation mounts and fixed to floor.
9. Fire Protection Pumpset is to be located out of the influence of direct weather and sunlight.

INSTALLATION NOTES
IMPORTANT – Install in accordance with relevant Australian Standards and local regulation. Standards
include, but not limited to, AS2941-2013.
1. PLANTROOM
Pumpset must be installed in a well ventilated area. Mechanical ventilation may be required in
limited ventilation area. Pumpset should be protected from weather (rain and UV). Plantroom
must have a minimum of 1m clear all around the pumpset for pumpsets up to 110kW and
greater to suit for larger sizes.
2. MOUNTING
Pumpset must be mounted on a level concrete pad on rubber resilient pads provided. Pumpset
to be anchored down securely. Great care should be taken not to twist base when tightening
down – ie. do not force base down with anchor bolts.
3. PIPEWORK CONNECTIONS
Pipework connections include:
a) Main suction from tank – care must be taken to ensure there are no leaks, no potential air
locks (ie. air will automatically bleed from suction line) and no prohibited devices in the
suction line (refer AS2941-2013)
b) Main discharge to fire protection system
c) Relief valve connection back to storage tank
d) Diesel heat exchanger outlet to drain (discharge must be visible)
e) Electric Pumpset Only – Circulation relief valve to drain (discharge must be visible)
f) Test line back to supply tank
4. Please ensure that heat exchange of waste pipework is of adequate size. Pipework size to be at
least the same size as the outlet of the heat exchanger. EACH ENGINE MUST HAVE ITS
OWN PIPE RUN TO WASTE AND BE VISIABLE IN ACCORDANCE WITH
AS2941-2013.
5. ELECTRIC CONNECTION
Electrical connections include separate supply for each pumpset, including the jacking pump:
a) Diesel Pumpset – Single phase 15A supply to operate control system. Supply to be classed
‘essential supply’ and in fire rated cabling.
b) Electric Pumpset – Suitable sized 3 phase neutral and earth supply capable of starting
motors. Supply is essential and should be fire rated cabling. Supply shall be in accordance
with AS3000 and be suitable for inrush current.
c) Jackering/hose reel Pump – 3 or 1 phase supply to suit motor size.
6. COUPLING
Coupling alignment must be checked after installation. Transit and/or installation may have
disturbed coupling alignment. Alignment should be within 1mm parallel alignment and 2
degrees angle alignment. Alignment should be rechecked after the first month and 6 monthly
thereafter.
7. PLANTROOM
Pump room must be adequately drained. Drainage should be sufficient to cope with a
catastrophic failure of any component without flooding the pump room.

8. EXHAUST SYSTEM
Care should be taken installing the exhaust system. Exhaust systems run at a high temperature.
Where applicable exhaust should be shielded to prevent burns. All material used in exhaust
system and in contact with adjacent to exhaust system should be suitable for high temperature.
Exhaust system should not be supported by engine connections. Suitable bracketing should
support system for the entire length. Connection to the engine must be via flexible connection.
Exhaust system must be configured so as the entry of water is precluded. Exhaust turn down is
recommended. Final discharge of exhaust should be in a sheltered environment and care
should be taken to ensure no person is at risk from discharge of hot exhaust or fumes. At the
bottom of any rise in the exhaust system a condensate/water trap should be installed. Exhaust
pipe sizing should be one size larger than exhaust engine connections for discharge lengths up
to 3m. Exhaust runs over this length will require further upsizing to ensure no excessive back
pressure on engine. Refer to manufacturer.
9. CONTROL OUTPUTS
It is critical that the system outputs (including power on, pump(s) run, faults) should be
monitored on a continuous basis with a management plan in place to respond to signals.
Unattended running can cause damage to pump equipment and associated building/grounds.
10. ALARMS
Remote audible and visual alarm should be installed in a suitable location. Interwiring required.
11. REMOTE START

Remote start panel to be installed as indicated on drawings – refer to Design Engineer for
sizing. Typically six wires per panel capable of up to 240Vac and currents of 3.5A.
12. WIRING & ELECTRICAL

All wiring and electrical work to be in accordance with AS3000 and other applicable standards.
Supply circuit breakers must be sized in accordance with AS3000 (including specific references
to Fire pumps) and other relevant codes and standards to suit the application. Particular note
should be taken of motor start inrush current specific to the starting method. Supply circuit
breaker sizing is not the responsibility of Allied Pumps and should be refered to the electrical
engineer.
13. BATTERIES
Prior to system being commissioned, BATTERIES must be left disconnected and stored
correctly as per manufacturers recommendations. If it is likely that there is any length of time
(in excess of 6 months) from delivery of pumpset to commission, arrangements can be made
for ALLIED PUMPS to retain batteries at time of delivery and make them available for
collection at time of commission. Failure to follow procedure may cause battery failure which
is not covered by warranty.
14. FLOAT SWITCHES

Float switches are supplied with the package and are to be located in the supply tanks (1 per
tank) and wired back to the diesel pump controller (or electric pump controller in the case of
no diesel). The floats should be installed so that a fall in the normal water level of no more that
250mm results in activation of the alarm. Floats should be accessible from tank access point.


INITIAL START-UP PROCEDURE
Fire pumps have been pre-commissioned and tested to AS 2941-2013 prior to dispatch from workshop
however a site commission is still necessary. It is suggested initial start up is done with the site
electrician present.
1. Visual inspection of complete system to ensure pipework connections is in place and nothing is
out of order.
2. Open necessary valves to allow water from supply tank to pumpset.
3. Open suction and discharge isolation valves on electric pump, diesel pump and jacking pump.
4. Open bleed ball valve on top manifold to allow air to escape.
5. If jacking pump is a vertical multistage pump, a separate bleed valve will be fitted at the top of
pump. Open to allow air to escape. Close once water starts flowing.
6. Ensure ball valves to pressure switches and gauges are open.
7. Bleed any residual air out of suction manifold via ball valve.
8. Check the site electrician to ensure power is present in both the electric and the diesel panel.
9. Isolated diesel engine start via ‘start isolate’ key witch on board.
10. Connect battery terminal lugs. (Removed for shipping purpose).
11. Mute audible alarm if necessary.
12. Turn ‘mains isolator’ switches on – WARNING electric duty pump will start immediately. Unit
can be stopped by pressing ‘pump stop’ button on electric panel.
13. Check rotation of motor to be correct. (Correct rotation is indicated on pump casing by an
arrow). If rotation is incorrect, site electrician should reverse incoming mains.
14. Jacking pump can be switch to automatic to talk up system pressure. (Rotation must be
checked on jacking pump it if is 3 phase.)
15. Ensure jacking pump shuts down automatically via pressure switch once system is at full
pressure.
16. Check current draw of duty and jacking pump to be correct.
17. Check diesel engine has correct levels of coolant water, diesel fuel and engine oil prior to start
up. Refer to engine manual.
18. Switch ‘engine isolate’ switch off if system pressure is high, diesel pump should not start.

19. Switch power circuit breaker in diesel panel on. Power available light should illuminate. Check
gauges, lights and charge rates.
20. Press ‘emergency start’ Button. WARNING engine will start immediately. The engine can be
stopped by pressing pump stop button and holding on till engine has completely stopped.

TEST STARTING
1. AUTOMATIC START TEST
1) Turn Hose Reel on. Hose Reel Pump should start and maintain pressure. Turn Hose Reel off.
Pump should stop within 1-2 minutes. (Only applicable if Hose Reel System installed).
2) Open Hydrant. Duty diesel Pump should start and maintain pressure. Shut Hydrant down.
Pump should continue to run. Press ‘Pump Stop; button on electric panel to shut down pump.
3) Turn ‘Main Isolator’ on duty diesel panel to ‘Off’. Open Hydrant. Standby Diesel Pumpset
should start. Shut Hydrant. Diesel Pumpset should continue to run. Turn ‘Main Isolator’ on
electric panel back on. Wait approx ½ minute then press ‘Pump Stop’ on diesel panel and hold
down until diesel engine has completely stopped. If main electric pump starts at this point
follow shut down procedure in step 2.
2. MANUAL START TEST
1) Jacking Pump – Turn Jacking Pump selector to ‘Manual’, pump should run and pressure will
increase. Return to auto.
2) Diesel Duty Pump

Test 1 – Press one of the ‘Pump Start’ buttons on diesel panel and hold down until engine
starts. Pump will run. Press ‘Pump Stop’ on diesel panel and hold down until pump
stops completely.
Test 2 – Press other ‘Pump Start’ on diesel panel and hold down until engine starts. Press
‘Pump Stop’ and hold down until pump stops completely.
3) Standby Diesel Pump

Test 1 – Press one of the ‘Pump Start’ buttons on diesel panel and hold down until engine
starts. Pump will run. Press ‘Pump Stop’ on diesel panel and hold down until pump
stops completely.
Test 2 – Press other ‘Pump Start’ on diesel panel and hold down until engine starts. Press
‘Pump Stop’ and hold down until pump stops completely.
NOTE: Engine can be prevented from starting by turning key switch on diesel panel to isolate. This will
cause an alarm condition and should not be left in this position unnecessarily.
Fire Protection Pumpset should be tested and maintained in accordance with relevant Australian
Standards including AS1851.14.
After operating fire pump set, the system should be visually inspected. Check engine levels, exhaust
system (including exhaust flap if fitted) to ensure all is back to normal condition.

EMERGENCY PROCEDURES
(In Case of Fire)
Pumps should start automatically on loss of pressure. If pumps fail to start, the following procedure
should be followed.
Manually start diesel pump by pressing ‘MANUAL START’ Button on DIESEL FIRE PUMP
CONTROLLER or on REMOTE PANEL.
In the case of failure to start or power failure, proceed immediately to manually start diesel fire pump
by pressing one of the ‘MANUAL START’ buttons on DIESEL FIRE PUMP CONTROLLER or on
REMOTE PANEL.
Should engine fail to start, press the second ‘MANUAL START’ button located on DIESEL FIRE PUMP
CONTROLLER.
If engine cranks but refuses to start, check diesel fuel level in tank.
In case of all systems fail, 12 volt DIESEL ENGINE can be started using standard car battery, either
using jumper leads immediately on the start solenoid or in the place of the crank battery. A 24 volt
DIESEL ENGINE requires two 12 volt batteries connected in series.
Should pumps be running and there is lack of water at the hydrants, check valves positions. Ensure
bypass valves are off. Also check water level in main tank.

SHUT DOWN AND ISOLATION PROCEDURES
(TO BE PERFOMRED ONLY BY SUITABLY QUALIFIED AND AUTHORISED PERSONNEL)
1. DIESEL FIRE PUMP SET
1.1. TO SHUT DOWN A PUMP THAT IS RUNNING
A shut down is performed with the controls mounted on front of ‘Diesel Fire Pump Controller’.
1) Select ‘Isolate’ position in ‘Start Isolator’ selector switch.

2) Press red ‘Pump Stop’ push button and hold until engine has completely stopped.
3) Return ‘Start Isolator’ selector to ‘Normal’. (Engine may attempt to restart if controller is still
receiving a start signal.)
CAUTION: Never leave ‘Start Isolator’ selector in ‘Isolate’ position.
1.2. ISOLATE DIESEL FIRE PUMP
(If engine is running use above procedure to stop engine.)
1) Notify relevant management personnel.

2) Select ‘Isolate’ position on ‘Start Isolator’ selector switch. (Mounted on face of the Diesel Fire
Pump Controller).
3) Isolate mains power supply to ‘Diesel Control Panel’.
4) Remove battery leads off both crank and control batteries.
2. ELECTRIC FIRE PUMP
2.1. To Shut Down Electric Fire Pump
Press red ‘Stop’ button mounted on face of ‘Electric Fire Pump Controller’ (Motor may attempt to
start if controller is still receiving a start signal.)
2.2. Isolate Electric Fire Pump

(If motor is running use above procedure to stop motor.)

2) Select ‘Off’ position on ‘Electric Fire Pump main Isolator’ and fit padlock through isolator
handle.

3. ELECTRIC JACKING PUMP
3.1. ISOLATE ELECTRIC JACKING PUMP
(Isolation is performed from the ‘Jacking Pump Controller’)

2) Select the ‘Off’ position of jacking pump selector switch.
3) Isolate jacking pump motor starter circuit breaker and lock off.
CAUTION: The jacking pump is designed to maintain system pressure. Isolating jacking pump is likely to
result in a main pump start up.

SPECIFIC MAINTENANCE
COUPLINGS
Check alignment after the first month then on a ongoing 6 monthly basis. Check for worn coupling
rubbers etc. Alignment should be within manufacturers recommendations.
PRESSURE VESSEL
Check, on a 6 monthly basis, that air pressure in vessel is charged and at correct pressure. Air
pressure should be checked when there is no water pressure in system. Air pressure can be checked
with a tyre pressure gauge. Air pressure in vessel should be charged (without water pressure) to
approximately 50 kPa below ‘cut in’ of jacking pump.
BATTERIES
Check, on a 2 monthly basis serviceability of battery, voltage and charge amps and in accordance with
AS1851. Check battery temperature, liquid level (if applicable) and that the battery is maintained and
replaced in accordance with the current Australian Standards. Ensure that the appropriate warning
stickers and covers as required by Australian Standards are in place.
DIESEL ENGINE
Change oil, flush radiator (if applicable), check fan belts, and go through other maintenance procedures,
as per Diesel Engine Manual.
PUMPSET
Fire Protection Pumpset must be tested and maintained on a regular basis in accordance with relevant
Australian Standards including AS1851-14.
MOUNTS
Check mount bolt down system on a 6 monthly basis.
BOLTS/FASTENINGS
Check bolts/nut tensions for correct levels after the first month and then on a 6 monthly ongoing basis.

TESTING CHECKLIST
IMPORTANT SERVICE INFORMATION – should be carried out by qualified personnel
These checks are only intended as a guide, and do not replace an approved management system. After
commissioning, these checks should be followed – failure to do so may void warranty. It should be
noted that all fire systems are required to be maintained as per AS1851 this involves weekly/monthly
checks, inspections & reporting – this should commence immediately after the fire system is
commissioned. For further information on schedule service please fill in the form at the back of this
manual and fax or email to Allied Pumps. Fire Protection Pump set is to be fully tested on a regular
basis by suitably qualified fire service personnel to the relevant Australian Standards including
AS1851.14.
Testing should include, but not be limited to the following items.
Weekly
1 Fault indication 
2 Lamp / alarm test 
3 Fuel level 
4 Diesel engine oil level 
5 Diesel engine coolant 
6 Battery voltage – crank battery 
7 Battery voltage – control battery 
8 Charge amps – crank battery 
9 Charge amps – control battery 
10 Water level in supply tank (if applicable) 
11 System pressure 
12 Test run electric pump in auto mode 
13 Electric pump cut in pressure* 
14 Test run electric pump in manual mode 
15 Electric motor amps 
16 Test run diesel engine in auto mode 
17 Diesel engine cut in pressure* 
18 Test run diesel engine in manual mode 
19 Test run jacking pump in manual mode 
20 General system condition 
21 Check for damage or wear on pump system 
22 Exhaust system – gas and water leaks 
23 Drain condensate trap 
24 Clean heat exchange feed filter. Check heat exchange flow rate 

Check belts, cooling fan (if fitted), sound attenuator canopy (if fitted) are free
25 of debris or loose material. Ensure adequate air flow through canopy (if
fitted) and all vents free.
26 sprinkler tests and heat exchanger flow check
3 months
1 Voltage on volt meter 
2 Float current on charging 
3 All switches in correct position 
4 No fault lights 
5 Diesel start and run for 10mins without overheating 
6 Electric start and run for 2mins without failure 
7 All external hydrants & hose reels are locked and pad locked shut 
8 Power supply OK 
9 All Volt free contacts connected to BMS or monitored 
10 Volt outputs hooked into monitoring or remote indicator 
11 Check and clean heat exchange filter 
12 Retention tie down bolts 
13 Retention pipe work bolts 
14 Retention monitoring bolts 
15 Check and retention/reseal exhaust pipe work fittings 
6 months
1 Voltage on volt meter 
2 Float current on charging circuit 
3 All switches in correct position 
4 No fault light 
5 Diesel start and run for 10mins without overheating 
6 Electric start and run for 2mins without failure 
7 All external hydrants and hose reels are locked and pad locked shut 
8 Power supply OK 
9 All Volt free contacts connected to BMS or monitored 
10 Check and clean heat exchange filter 
11 Heavy controls in electric control are in good condition and free of dust 
12 System start and stops as intended on pressure drop 

12 months
1 Voltage on volt meter 
2 Float current on charging circuit 
3 All switches in correct position 
4 No fault light 
5 Diesel start and run for 10mins without overheating 
6 Electric start and run for 2mins without failure 
7 All external hydrants and hose reels are locked and pad locked shut 
8 Power supply OK 
9 All Volt free contacts connected to BMS or monitored 
10 Check and clean heat exchange filter 
11 Heavy controls in electric control are in good condition and free of dust 
12 System start and stops as intended on pressure drop 
13 Diesel serviced 
14 System serviced to AS 1851 
15 Flow test completed and logged 
16 Replace rubber mounts as necessary 
If any condition exists or functions is not correct report immediately to maintenance manager for
immediate action and rectification.
Date:
Service Personnel:
CONTACT INFORMATION
ALLIED PUMPS SERVICE DEPARTMENT

Phone: (08) 9350 1000
Fax: (08) 9358 0060
Email: service@alliedpumps.com.au



ELECTRIC FIRE PUMP CONTROLLER
Electric Fire Pump Controller (E.F.P.C.) is supplied from Distribution Board and has the function of
controlling Electric Pump / Motor and Jacking Pump.
MAIN ISOLATOR – To isolate Electric Board.
PHASE AMMETER – To indicate current draw per phase.
PHASE SELECTOR SWITCH – To select the phase that is to be monitored by the Ammeter.
EMERGENCY START – To initiate Electric Pump / Motor Start.
STOP – To Stop Pump / Motor after being started by automatic or manual means.
LAMP / ALARM TEST – To test indicator lights and alarm for serviceability.
ALARM MUTE - To silence alarm whilst attending fault.
MANUAL: Pump will run. (Do not leave unattended in this mode)
OFF: Pump Isolated
AUTO: Pump controlled via pressure switch to maintain pressure.
INDICATOR LIGHTS – To indicate status of system.
JACKING PUMP CONTROLLER
Jacking Pump controller (JPC) requires a separate supply and has the function of automatically
controlling the jacking pump start and stop
MAN / OFF / AUTO (Jacking Pump) – Selector Switch to control function of Jacking Pump.

DIESEL FIRE PUMP CONTROLLER
Diesel Fire Pump Controller (D.F.P.C.) has a 240 Vac supply from E.F.P.C. and has the function of
starting and controlling Diesel Pump / Engine via 2 or 4 12 VDC Batteries (4 batteries for 24 VDC
system). Battery chargers are located inside D.F.P.C.
1.0 SELECTORS/PUSH BUTTONS
START ISOLATOR – Key lockable selector switch to prevent diesel engine starting should
maintenance on engine be required.
EMERGENCY START BUTTONS (2) – To manually start engine
STOP – To stop engine. Operations fuel rack solenoid.
LAMP/ALARM TEST – To test indicator lights and aural alarm for serviceability
MAIN ISOLATOR – To isolate mains power from DFPC
ALARM MUTE – To silence aural alarm whilst attending a fault
OVERSPEED TEST – To simulate an overspeed fault. Engine must be running and the start isolator in
the ‘isolate’ position. Engine will shut down & alarm raised when operated. Reset set fault via the ‘fault
re-set’.
2.0 ENGINE MONITORING DISPLAYS/INDICATORS
ALARM RESET – To reset fault once fault condition has been rectified
CRANK/CONTROL CHARGER VOLT METERS – To indicate rate of charge into batteries from
electric chargers in D.F.P.C.
ALTERNATOR CHARGE CURRENT – To indicate rate of charge from alternator or engine to crank
battery.
ENGINE OIL PRESSURE – To indicate oil pressure in the engine
ENGINE TEMPERATURE – To indicate temperature in the engine
ENGINE SPEED – To indicate the status of the system
INDICATOR LIGHTS – To indicate the status of the system
FUEL TANK LEVEL – To indicate the level of the fuel in the fuel tank. Below 70%, the low fuel light will
illuminate and alarm activates.

REMOTE CONTROL PANEL
Remote Control Panel (R.C.P.) (if supplied) is interfaced with both Diesel Pump Control Panels. Its
function is to allow the remote starting of both the Diesel Pumps and to indicate the status of the
system.


APPENDIX A
Diesel Engine Information and Operating Manual

OPERATION & MAINTENANCE MANUAL
A380 SERIES
A480 SERIES
A485 SERIES
A490 SERIES
POW ER TO P ER FO R M
SAFETY PRECAUTIONS
Ensure all precautions are followed carefully.
GENERAL SAFETY NOTES
 Never attempt to perform maintenance work, adjustments or resetting whilst the engine is
moving.
 Make sure no people or animals are in the vicinity of the engine before starting it.
 Never disable or tamper with the safety devices on the engine.
 Always use safety gloves and heat resistant clothing when operating or working on a hot
engine.
EXHAUST PRECAUTIONS
 Do not inhale exhaust fumes. It contains carbon monoxide, a colourless, odorless and
extremely dangerous gas which can cause unconsciousness or death.
 Use respiratory protection when working in the vicinity of engine exhaust fumes.
 Do not operate the engine indoors or in a poorly ventilated area unless exhaust fumes are
ducted outside.
 Keep the exhaust pipe free of external objects.
REFUELLING PRECAUTIONS
 Be sure to stop the engine prior to refueling.

 Do not overfill the fuel tank.
 If fuel is spilt, wipe it away carefully and wait until the fuel has evaporated before starting the
engine.
FIRE PREVENTION
 Do not operate the engine near a flame.

 Do not use the engine near flammable materials.
 Keep the engine at least 3 feet (1 meter) away from buildings or other structures.
DIESEL ENGINE SPECIFICATIONS AND TECHNICAL DATA
Model A380 A480 A485 A490

Type Vertical water cooling, four stroke, direct injection, dry liner
Combustion
Direct Injection
Chamber Type
Number of 3
4 4 4
Cylinders
Bore (mm) 80 80 85 90
Stroke (mm) 90 90 95 100
Compression ratio 22 22 18 18
Total displacement
1.357 1.809 2043 2540
(L)
Firing order 1-3-2 1-3-4-2 1-3-4-2 1-3-4-2
Rated power (kW) 22 29 35 41
Rated speed
3200 3200 3000 3000
(r/min)
Specific lube oil
consumption <2.72
(g/kW.h)
12+_/>2800(with
Advance Injection
Advance Device) 10+_ 1/3000(with 10+_ 1/3000(with 10+_1/3000(with
Angle/speed
18+_1/2600, Advance Device), Advance Device) Advance Device),
(before TDC)
16+_1/2400, 18+_1/2800 18+_1/2800 18+_1/2800
(g/rpm)
15+_1/2200
Injection Pressure 19.6 13.2+_0.5 13.2+_0.5 13.2+_0.5
Direction of
crankshaft rotation Counter Clockwise
(facing to flywheel)
Cooling method Forced Water Cooling
Starting method Electric
Net mass (kg) 185 210 220 250
SPECIFICATION OF MAIN ACCESSORIES
DESIGNATION SPECIFICATION
Type 1 or BQ pump
Fuel injection pump
Governor All speed, mechanical centrifugal
Model P21
Fuel injector
Nozzle Set Single hole, pintle-type ZS4SI
Type Rotor
Speed(r/min) 1300
Lube Pump
Capacity(L/min) 18
Pressure (kpa) 0.4
Type Centrifugal, volute, single suction
Speed(r/min) 3000
Water Pump
Capacity (L/min) 80
Lift(m) 5
Type Series DC motor
Starting Motor Model QD138C
Voltage (V) 12
Type Silicon rectifying shunt dynamo
Model JF11
Alternator Dynamo
Power(W) 350
Voltage (V) 14
Type Single stage, paper element
Fuel filter
Model C0506A
Lube Oil Filter Type Single stage, paper element
Air filter Type Single stage, paper element
Temp Sender 287-23ohms
Oil Pressure Sender 10-199ohms
Radiator
Heat Exchange
MAG Pick Up
Stop Solenoid Power to close fuel supply.
TECHNICAL MAINTENANCE OF DIESEL ENGINE
Daily Check and Maintenance
Check oil level of diesel engine oil, is it between upper and low limit.
Check coolant level every day and top up with identical mixture when necessary.
Regular Check and Maintenance
Regular Check and Maintenance are very important for normal operation and durability of
the engine. The following table indicates what is necessary and when to maintain the engine.
Item/ Time Daily After 20 100 hours 250 500 hours 1000
hours or every hours or every 6 hours or
or 1 3 months months every
month year
Check & tighten the nut &

screw
Check & fill machine oil 
 Second
 First
Change lubricating oil Time &  
Time
Later
Change oil filter     
Check oil leakage 
Clean fuel tank 
Change fuel filter  
Check nozzle  
Check injection pump  

Check pipeline of fuel (Change if
necessary)
Airfilter  (Clean) Every month or 50 hours 
Coolant/Water heat

exchanger/radiator
DIESEL MSDS
NALCOOL MAXIMUM MSDS
MOBIL DEVAC MX 15W-40 MSDS
SEALED MAINTENANCE FREE LEAD ACID
BATTERY MSDS
alliedpumps.com.au
Hot Water Circulation System Manual

Disclaimer: Allied Pumps reserves the right to modify the information and illustrations contained in this document without prior notice. The information
provided in this document is intended to be helpful. However, this document is not intended to cover all regulations that apply to your practice. If you need
advice regarding specific product operations and maintenances, you are encouraged to consult with an Allied Pumps Pty Ltd professional.
APPENDIX B
Warranty and Service Information

WARRANTY
Warranty is limited to replacement or repair, at Manufacturer’s discretion, of any parts or equipment
without removal and reinstallation cost for a period of twelve months from date of invoice, provided
such part of equipment that is deemed by the respective manufacturer to be faulty. Any work done on
site to inspect or remedy faults that are subsequently not accepted as being under warranty by the
manufacturer, or are caused by misuse, fair wear or operating procedures, will be charged at parts and
labour and travelling time rates applicable at the time.
Warranty does not cover equipment that is not being tested and maintained to AS1851.
Warranty does not cover pump systems that are not monitored on a continuous basis. Part
of monitoring requirement is a suitable management plan to attend to alarm and running
signals immediately.
Warranty does not cover damage resulted from ingress of water into the engine via the
exhaust system or other means.
Australian Standards AS2941-2013 preludes the use of shutdown protection devices that shut down
equipment in the case for malfunction. Consequently any damage result from equipment continuing to
operate whilst an abnormal condition is present is expressly excluded from manufactures warranty.
If buyer requires our services in respect of site inspection or service outside of what is covered by
Manufacturers’ warranties, then Buyer should enter into a separate agreement with ALLIED PUMPS in
respect to the same. In the event of no such separate agreement, all operation, calibrating, cleaning and
maintenance of plant is the responsibility of the buyer.
ALLIED PUMPS have not acted as a consultant or charged design fees on this project, and are in no way
responsible for, nor guarantee any particular level or performance of equipment supplied unless such
guarantee is specially given in writing.
Under no circumstances is ALLIED PUMPS liable for any direct or consequential loss or damage to
persons or properties of any nature due to any cause whatsoever.
Application of warranties is conditional on ALLIED PUMPS having received in cash the total contact
price. Furthermore, ALLIED PUMPS reserves the right to withdraw any code compliance, Australian
Standard compliance or selection compliance, should the contract not be paid in full.
Concrete Submersible Pump Station Manual

alliedpumps.com.au
Hot Water Circulation System Manual

Disclaimer: Allied Pumps reserves the right to modify the information and illustrations contained in this document without prior notice. The information
provided in this document is intended to be helpful. However, this document is not intended to cover all regulations that apply to your practice. If you need
advice regarding specific product operations and maintenances, you are encouraged to consult with an Allied Pumps Pty Ltd professional.

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Diesel Electric Fire Pumpset 4 - 22

Appendix A: Diesel Engine Information and Operating Manual

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WARNING - PUMP MAY START AT ANY TIME

WARNING - SYSTEM IS PRESSURISED

DANGER - HIGH VOLTAGE

CAUTION - EXPOSED MOVING PARTS

CAUTION - HIGH TEMPERATURE

BATTERY EXPLOSION RISK

MSDS – DIESEL, OIL, COOLANT – REFER APPENDIX A

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To START push the emergency start button

Refer to manual for full operating instructions

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2. MANUAL SHUT DOWN

3. EXTERNAL WARNING DEVICE

Ignoring these signals could result in serious system damage / failure.

Monitoring must include, but not be limited to:

4.1 ELECTRIC PUMP

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5. INTENDED USE OF EQUIPMENT

6. VENTILATION AND DRAINAGE

8. Equipment to be mounted on suitable vibration isolation mounts and fixed to floor.

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11. REMOTE START

12. WIRING & ELECTRICAL

14. FLOAT SWITCHES

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2. Open necessary valves to allow water from supply tank to pumpset.

4. Open bleed ball valve on top manifold to allow air to escape.

6. Ensure ball valves to pressure switches and gauges are open.

10. Connect battery terminal lugs. (Removed for shipping purpose).

11. Mute audible alarm if necessary.

16. Check current draw of duty and jacking pump to be correct.

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1. AUTOMATIC START TEST

2. MANUAL START TEST

2) Diesel Duty Pump

3) Standby Diesel Pump

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1. DIESEL FIRE PUMP SET

1.1. TO SHUT DOWN A PUMP THAT IS RUNNING