Pentair FAIRBANKS NIJHUIS 5800-NSF User manual

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FAIRBANKS NIJHUIS™
2” AND LARGER 5800-NSF
SPLITCASE PUMPS
POTABLE WATER APPLICATION
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
NOTE! To the installer: Please make sure you provide this manual to the owner of the equipment or to the
responsible party who maintains the system prior to installation.

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PUMP IDENTIFICATION
Carefully record all of the following data from you pump nameplate. It will aid in obtaining the
correct replacement parts for your pump. In addition to the nameplate, the pump serial number
is stamped on the discharge flange.
Pump: Serial Number ___________________________________________
Model Number ___________________________________________
Pump Size ___________________________________________
Capacity (GPM) ___________________________________________
Head (Feet) ___________________________________________
Speed (RPM) ___________________________________________
Motor: Manufacturer ___________________________________________
Horsepower ___________________________________________
Serial Number ___________________________________________
Motor Frame ___________________________________________
Full Load Speed ___________________________________________
Full Load Amps ___________________________________________
Phase/Hz/Volts ___________________________________________
Date Placed In Service _____________________________________
Gear: Manufacturer ___________________________________________
Serial Number ___________________________________________
Model Number ___________________________________________
Ratio ___________________________________________
Rotation Figure ___________________________________________

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2” AND LARGER 5800-NSF SPLITCASE PUMPS
INSTALLATION, OPERATION AND MAINTENANCE
TABLE OF CONTENTS:
PUMP IDENTIFICATION...................................2
IMPORTANT SAFETY NOTICE: .............6
SAFETY NOTES: ................................... 6
Storage of Pumps: .............................................8
Short-Term Storage:.....................................8
Long-Term Storage:......................................8
Three Months to One Year: ..........................8
Mechanical Seal:...........................................8
Over One Year:.............................................9
Mechanical Seal:...........................................9
Common: ......................................................9
Removing From Storage:...................................9
Grease Lubricated: .......................................9
Oil Lubricated:.............................................10
Pump Identification:..........................................10
General Description:...................................10
Removable Bearing Housings/Arms:..........10
Non-Removable Bearing Housing Arms:....10
Casing:........................................................10
Impeller:......................................................10
Shaft:...........................................................10
Bearings:.....................................................11
Bearing Arms: ..................................................11
Removable Bearing Arms:..........................11
Non-Removable Bearing Arms:..................11
Wearing Rings:...........................................11
Sealing Box:................................................11
Baseplate, Coupling And Guard: ................11
Safety Notes:....................................................11
Housekeeping:............................................11
Environmental Conditions:..........................12
Section 3 Installation:........................ 13
General: ...........................................................13
Net Positive Suction Head (NPSH):............13
Lifting: .........................................................13
Location: .....................................................13
Foundation:.................................................14
Leveling Of The Unit:..................................14
Grouting:.....................................................14
Piping:.........................................................15
Final Coupling Alignment:...........................15
Periodic Check:...........................................15
Auxiliary Piping Connections:......................15
Rotation:......................................................15
Section 4 Operation: .......................... 17
General: ...........................................................17
Theory of Operation:...................................17
Normal Operating Procedures:...................17
Priming:.......................................................17
Starting The Pump:..........................................18
Initial Startup:..............................................18
Routine Starting:.........................................18
Bearing Operating Temperature:................18
Regulating / Control Procedure: .................18
Emergency Procedures: ..................................18
Start-Up: .....................................................19
Shut-Down:.................................................19
Special Operating Instructions:........................19
Operating At Reduced Capacity: ................19
Seasonal Operation:...................................19
Troubleshooting:..............................................19
Pump Symptoms: .......................................19
Section 5 Maintenance: ..................... 24
Preventative Maintenance:...............................24
Mechanical Seal:.........................................24
Seal Replacement: .....................................24
Bearing Lubrication:....................................24
Grease Lubricated Bearings:......................24
Oil Lubricated:.............................................26
Corrective Maintenance:..................................27
Mechanical Seal:.........................................27
Qualifications Required:..............................27
Disassembly: ..............................................27
General:......................................................27
Pump Disassembly:.........................................27
Oil Lubricated Bearings: .............................27
Non-Removable Bearing Arms:..................28
Removable Bearing Arms:..........................28
Common:....................................................28
Assembly:.........................................................29
Pump Assembly:..............................................29
Removable Bearing Arms:..........................29
Mechanical Seal:..............................................31
Mechanical Seal Removal:.........................31
Mechanical Seal Installation: ......................31
Wear Rings:.....................................................32
Wear Ring Removal: ..................................32
Installing New Wear Ring: ..........................32
Preventative Maintenance Schedule: 34
Preventative Maintenance Notes: ..... 35
Maintenance History:......................... 36
Maintenance Notes:........................... 37
Section 6 Repair Parts:...................... 39
Ordering Parts: ...........................................39
Recommended Spare Parts: ......................39
Predicted Life:.............................................40
Returning Parts:..........................................40
Service: ...................................... 41
Warranty Service: ............................................41
Service after Warranty:....................................41

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CONGRATULATIONS! You are the owner of the finest pump commercially available. If you give the
proper care as outlined and recommended by this manual, it will provide you with reliable service and
long life.
CALIFORNIA PROPOSITION 65 WARNING:
WARNING:
This product and related accessories contain chemicals known to the State of California to cause cancer,
birth defects or other reproductive harm.
IMPORTANT:
Read this complete manual and manuals for all component equipment before assembly or installation is
started. It is designed to supply adequate instructions for the installation, operation and maintenance of your
pump. Failure or neglect to properly install, operate, or maintain your pump may result in personal injury,
property damage, unnecessary damage to the pump, or may void your warranty.
This manual applies to the pump installation, operation and maintenance. Variations exist in both
the equipment used with these pumps and in the particular installation of the pump and driver.
Therefore, specific operating instructions are not within the scope of this manual. If your operating
conditions ever change, always refer to the factory for reapplication. Refer to the manuals provided
by manufacturers of the accessory equipment for their separate instructions.
If there are questions regarding the pump or its application that are not covered in this manual,
please contact the factory as follows:
Field Service Department
Fairbanks Nijhuis™™
3601 Fairbanks Avenue
Kansas City, KS 66106
Tel: [phone]
To obtain additional data on hydraulics and pump selection and operation, we suggest you purchase
the following reference books:
1. Hydraulic Institute Standards
Hydraulic Institute
9 Sylvan Way
Parsippany, NJ 07054-3802
2. Hydraulic Handbook
Fairbanks Nijhuis™™
3601 Fairbanks Avenue
Kansas City, KS 66106

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IMPORTANT SAFETY NOTICE:
Safety should be of the utmost importance when working on or near pumping equipment. Before
attempting to operate this equipment, read this manual in its entirety, taking special notice of all
CAUTIONS, WARNINGS and/or DANGER notifications. These warnings apply to pumps supplied
by Fairbanks Nijhuis™™. Refer to the manuals supplied by the driver control manufacturer for
additional warnings before operating this equipment.
The words DANGER, WARNING and CAUTION have different connotations and are generally
defined as follows:
DANGER:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING:
WARNING indicates a potentially hazardous situation which, if not avoided, will result in serious injury.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury or may indicate that improper practices will result in equipment malfunction or failure. It may also be
used to alert against unsafe practices.
IMPORTANT:
Another notation will appear throughout this manual. IMPORTANT indicates the highlight or accent of
specific information.
The installation, use and operation of this type of equipment is affected by various federal, state and
local laws. The regulations concerning OSHA Compliance with such laws relating to the proper
installation and safe operation of this type of equipment is the responsibility of the equipment owner.
All necessary steps should be taken by the owner to assure compliance with such laws before
operating or maintaining the equipment.
SAFETY NOTES:
These warnings apply to pumps supplied by Fairbanks Nijhuis™. Refer to the manuals supplied by
the driver or control manufacturers for additional warnings before operating this equipment.
Before attempting to install, operate, or service this pump:
IMPORTANT:
Familiarize yourself with this manual. DANGER:
Disconnect or lock out the power source to ensure the pump will not start. Check with appropriate electrical
test equipment. DANGER:
Do not attempt to service the pump until the electrical power has been disconnected and it has been verified
that the pump cannot start. WARNING:
Close the discharge valve before servicing the pump.
WARNING:
Certain procedures in disassembly and assembly require parts be heated to high temperatures. Heat
resistant gloves must be worn when handling heated parts. Heated parts can cause severe personal injury.

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CAUTION:
After the pump has been installed, make certain that the pump and all piping connections are tight and are
properly supported prior to start-up and operation.
DANGER:
Do not operate the pump without the protective guards in place over the rotating parts. Exposed rotating
parts can catch clothing, fingers or tools, causing severe injury. Any operation of this machine without a
protective guard can result in severe bodily injury. The responsibility for the installation of protective guards
is that of the equipment owner.
CAUTION:
This pump is designed for the exclusive use of pumping water. It should not be used for pumping other
media unless a specific Purchase/Buyer agreement is negotiated.
WARNING:
Do not attempt to try to clean the pump with bare hands. The pumped material may contain items that
may present health hazards such as needles and other sharp objects. Always wear heavy puncture resistant
gloves.
WARNING:
Because many installations use automatic starting equipment, the pump unit may start at any time
without warning.
CAUTION:
For pumps used in potable water service, all thread lubrication, grease, cleaning materials and paint must be
suitable for potable water.
WARNING:
Do not attempt to try to clean the pump with bare hands.
WARNING:
This product contains chemicals known to the State of California to cause cancer or birth defects or other
reproductive harm.
WARNING:
Certain procedures in disassembly and assembly require parts be heated to high temperatures. Heat
resistant gloves must be worn when handling heated parts. Heated parts can cause severe personal injury.

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Storage of Pumps:
CAUTION:
If the equipment is not to be immediately installed and operated, THE FOLLOWING INSTRUCTIONS SHOULD
BE ADHERED TO AS A MINIMUM.
If the equipment is not to be immediately installed and operated, store it in a clean, dry, well-ventilated place, free
from vibrations, moisture and rapid or wide variations in temperature.
Improper storage and preservation could damage the equipment, which would result in non-warranty covered
restoration requirements, or non-warranty covered product failures.
Consider a unit in storage when:
A. When it has been delivered to the job site and is awaiting installation.
B. When it has been installed but operation is delayed pending completion of construction.
C. When there are long (30 days or more) periods between operation cycles.
D. When the pump is shut down for periods of longer than 30 days.
Short-Term Storage:
Short-term storage is when the pump will be stored for periods not exceeding three months. The following are the
short-term storage requirements:
1. Rotate the shaft for several revolutions at least once every two weeks to:
A. Coat the bearing with lubricant.
B. Retard oxidation or corrosion.
C. Prevent possible false brinelling.
Long-Term Storage:
Long-term storage is when the pump will be stored for periods exceeding three months. The following are long-term
storage requirements:
Three Months to One Year:
Mechanical Seal:
A. Remove the pipe plug in the stuffing box or the seal gland and pour at least 4 ounces of food grade mineral
oil into the seal housing. Reinstall the pipe plug.
B. Fill the bearing housings with specified lubricating grease until grease exits from relief fittings.
C. Wipe clean all exposed machined surfaces and coat with layer of food grade mineral oil. For longer periods
of storage, recoat the exposed surfaces every 4 weeks until ready to use.
CAUTION:
For pumps used in potable water service, all thread lubrication, grease, cleaning materials and paint must be
suitable for potable water.
D. Cover the suction and discharge of the pump with waterproof plywood to prevent entry of foreign material or
varmints.
E. Rotate the pump shaft several times by hand repeating this every two (2) weeks during storage. Rotation of
the shaft will coat the bearings and retard oxidation, preventing possible false brinelling.

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Over One Year:
Mechanical Seal:
A. Remove the pipe plug in the stuffing box and pour at least 4 ounces of food grade mineral oil into the seal
housing. Reinstall the pipe plug.
Common:
B. If the pump is assembled with grease lubricated bearings, fill the bearing housings with specified
lubricating grease until grease exits from relief fittings.
C. Clean all accessible machined surfaces to remove dirt, corrosion, grease and any other foreign matter.
Clean water passages to remove all foreign matter. Dry the pump to remove all moisture.
D. Spray flushing water and seal water piping with food grade mineral oil. Seal all water inlet connections with
pipe caps or plugs.
E. All internal surfaces in contact with water should be sprayed with food grade mineral oil. Drain excess
compound by removing drain plugs. Treat the drain plugs with food grade mineral oil, replace and tighten.
F. Apply food grade mineral oil to all exposed shaft surfaces.
G. Cover inlet and outlet nozzles with Grade A of MIL-B-121 barrier material and a blank flange of mild steel
(1/16" minimum thickness), tempered hard board (1/4" minimum thickness) or fully waterproofed plywood
(1/4" minimum thickness). Secure the flanges with at least 4 bolts with lock washers.
H. Wrap the shaft, the frame and the stuffing box area with grease-proof barrier material, conforming to Type
I, Grade A of MIL-B-121. Secure the barrier with water-proof pressure sensitive tape.
I. Rotate the pump shaft several times by hand repeating this every two (2) weeks during storage. Rotation
of the shaft will coat the bearings and retard oxidation, preventing possible false brinelling.
CAUTION:
For pumps used in potable water service, all thread lubrication, grease, cleaning materials and paint must be
suitable for potable water. Do not attempt to try to clean the pump with bare hands.
Removing From Storage:
After the storage period is over and prior to operating the pump, remove the cover on the thrust bearing housing for
inspection of the bearing lubricant. If any water or foreign matter is found in the lubricant, all bearings must be
cleaned and the lubricant replaced.
Refer to the Installation section of this manual for installation instructions.
After the pump has been set and grouted in place, and is ready for operation, the following steps should be followed:
WARNING:
Do not attempt to try to clean the pump with bare hands.
A. Flush the mineral oil out of the mechanical seal.
Grease Lubricated:
B. Remove bearing housing covers and remove one-half of the grease in bearing housings. Remove all grease
relief fittings and grease relief nipples from upper and lower bearing housings.
C. Start the pump per start-up instructions and permit grease to be purged from bearing housings. Do not install
grease relief piping until purging has completely stopped after the pump has been operation for at least eight
(8) hours. Observe bearing temperatures, and stop and start the pump or run it at reduced speed until
temperatures stabilize within the specified limits.
D. Stop the pump, wipe any greaseoff the shaft and bearing frame and place the pump in service per instructions
in this manual.

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Oil Lubricated:
A. Drain the oil from the bearing housings and refill to the recommended level with new oil. Recycle old oil
according to local ordinances.
B. Place the pump in service per instructions in this manual.
DANGER:
Do not attempt to clean the pump until electrical power has been disconnected and it has been verified that
the pump cannot start.
Pump Identification:
General Description:
The 5800-NSF series pump consists of several components. The following is a list of those major parts (or
component assemblies) and a brief description of their design & function.
Removable Bearing Housings/Arms:
The pumps consists of upper and lower half casings containing the volute and suction passages, and removable
bearing housings that are doweled and securely bolted to the lower half casing. The inboard and outboard bearing
housings are replaceable without the need for field alignment.
Non-Removable Bearing Housing Arms:
The pumps consist of upper and lower half casings containing the volute and suction passages and bearing arms.
Casing:
Casing is axially split along the horizontal shaft centerline with flat-faced suction and discharge flanges and mounting
feet cast integral with the lower half casing. Casing is line-bored to assure concentricity and angular alignment. The
upper and lower half casings are a single volute design and doweled to permit easy removal and accurate
replacement of the upper half for inspection and maintenance.
The upper half casing shall be completely removable without disturbing the suction or discharge piping connections.
Suction and discharge connections are sized to reduce hydraulic friction losses and to reduce turbulence and pipe
noise. All suction and discharge flanges shall be designed for straight through nut-and-bolt flange connections.
Upper half casing shall have a drilled and tapped connection at the highest point on the casing for the purpose of
pump priming or air release. The lower half casing is drilled and tapped to allow for drainage piping.
Impeller:
Impeller is of the enclosed type, double-suction, Francis vane design, to minimize inlet losses and accommodate
high suction lifts. The Impeller is hydraulically and statically balanced to reduce bearing loading.
Impellers are precision cast in one piece with smooth flow contours to promote maximum efficiency. Impellers are
fixed axially along the shaft by shaft sleeves and nuts and secured to the shaft through a precision fit and full length
key.
The impeller skirt has sufficient metal thickness to allow machining for installation of impeller rings.
Shaft:
The pump shaft is manufactured of high quality heat treated steel of sufficient diameter to allow no greater than
0.003" maximum deflection measured at the sealing box for all normal performance conditions on the curve. The
shaft is manufactured to meet stiff shaft construction with a critical speed at least 25% in excess of operating speed,
in order to prevent vibration and fatigue and is accurately machined along its entire length. A keyway is machined at
the coupling end.
The shaft is reversible to provide for field change to opposite rotation if required. Renewable shaft sleeves are
provided to protect the shaft from wear and from contact with the pumped liquid. The sleeves also serve to
accurately position the impeller on the shaft.

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Bearings:
Bearings are single row and deep grove ball type bearings and are selected to carry radial and thrust loads.
Interchangeable inboard and outboard bearings are a press fit and positioned onto ground journals on both ends of
an accurately machined shaft.
Bearing Arms:
Removable Bearing Arms:
Bearing housings are doweled and accurately positioned onto the bearing shoulders located on the removable
bearing arms which are dowelled and fastened to the lower half casing to ensure accurate alignment.
Non-Removable Bearing Arms:
Bearing housings are doweled and accurately positioned onto the bearing shoulders located on the lower half casing
to ensure accurate alignment.
Wearing Rings:
Casing wear rings are the annular type, designed to minimize leakage across the ring fit. Casing ring are straight
sided, renewable type, pinned at the parting flange of the casing to prevent rotation.
Sealing Box:
The sealing box is machined into the casing and is fitted with a single mechanical seal.
Several types of mechanical seals can be used. The approved mechanical seals for certified potable water service
are listed below:
John Crane Type 1
John Crane Type 21
Chesterton Type 442 / 442C
Refer to the technical data section on Page 46 or contact Fairbanks Nijhuis™ for the list of approved material
combinations for each mechanical seal.
IMPORTANT:
Using any other mechanical seal than listed above, voids the certification for potable water. Please contact
Fairbanks Nijhuis™ for the approved material combinations.
Baseplate, Coupling And Guard:
A steel bent form or structural steel base for pump and driver mounting is supplied. The base is designed to resist
torsion and support the combined weight of both pump and driver. After leveling and alignment, the base must be
grouted and completely filled with a non-shrinking grout.
A flexible coupling and an enclosed type coupling guard is provided.
Safety Notes:
These warnings apply to pumps supplied by Fairbanks Nijhuis™. Refer to the manuals supplied by the driver or
control manufacturers for additional warnings before operating this equipment.
Before attempting to service this pump:
Housekeeping:
A. The area surrounding the pump installation area should be kept free of rags and debris. The area should be
kept clean and dry and should be checked periodically to ensure there is no water, oil or grease on the floor
that could cause accidental slippage of maintenance personnel.

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B. The pump & driver should be kept clean. Any spillage of lubricants on the pump/driver during periodic
maintenance should be wiped clean. Loose ends of packing should be picked up and properly discarded after
re-packing the pump.
C. Drain lines should be checked to ensure they are functioning properly.
D. Driver ventilation ports should be kept free to ensure proper cooling of the motor.
Environmental Conditions:
A. Pumps are designed to operate in moderate to severe environmental conditions. Normally they should not be
operated in an ambient temperature exceeding 130 degrees F or in conditions that would allow the sealing
water or the pumped media to freeze.

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SECTION 3 INSTALLATION:
General:
Carefully read all sections of this manual and all other instruction manuals provided by manufacturers of other
equipment supplied with this pump.
Upon receipt of the shipment, unpack and inspect the pump and driver assemblies and individual parts to insure
none are missing or damaged. Carefully inspect all boxes and packing material for loose parts to insure none are
missing or damaged. Carefully inspect all boxes and packing material for loose parts before discarding them. Report
immediately to the factory, and to the transportation company involved, any missing parts or damage incurred during
shipment, and file your "damaged and/or lost in shipment" claim with the carrier immediately.
Net Positive Suction Head (NPSH):
NPSH can be defined as the head (energy) that causes liquid to flow through the suction pipe and enter the eye of
the impeller.
NPSH is expressed in two values:
1. NPSH required (NPSHR)
2. NPSH available (NPSHA).
It is essential that NPSHA always be greater than NPSHR to prevent cavitation, vibration, wear and unstable
operation.
NPSHR is a function of the pump design and therefore varies with the make, size, capacity and speed of the pump.
The value for your pump can be obtained from your pump performance curve or the factory.
NPSHA is a function of your system and may be calculated as follows:
A. When the source of liquid is above the pump:
1. NPSHA = barometric pressure (feet) + static suction head (feet)* - friction losses in suction piping (feet) -
vapor pressure of liquid (feet)
B. When the source of liquid is below the pump:
1. NPSHA = barometric pressure (feet) - static suction lift (feet)* - friction losses in suction piping (feet) - vapor
pressure of liquid (feet)
*The datum elevation plane for horizontal pumps is the pump centerline.
Lifting:
The use of a crane or hoist of adequate capacity is required throughout the installation process.
DANGER:
The pump, pump components, driver and base are to be lifted using adequate crane and sling capacity. All
applicable hoisting practices should be employed.
WARNING:
Do not pick up the complete unit by the driver eyebolts or lifting lugs.
NOTE:
The driver may be lifted using the proper eyebolts provided by the manufacturer.
Location:
The pump should be installed as near the fluid as possible so a short direct suction pipe can be used to keep suction
losses at a minimum. If possible, locate the pump so the fluid will flow to the suction opening by gravity. The
discharge piping should be direct and with as few elbows and fittings as possible. The total net positive suction head
available (NPSHA), which includes the suction lift and pipe friction losses, must be greater than the net positive
suction head required (NPSHR) by the pump.

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The pump and driver should be located in an area that will permit periodic inspection and maintenance. Head and
access room should be provided and all units should be installed in a dry location with adequate drainage.
Foundation:
The pump foundation should have a level surface and be of sufficient mass to prevent vibration and form a
permanent rigid support for the unit. The most satisfactory foundations are concrete with anchor bolts of adequate
size imbedded in the foundation in pipe sleeves with an inside diameter 2-1/2 times larger than the bolt diameter.
This will allow for final accurate positioning of the unit.
Recommended anchor bolt design is available from the factory.
Leveling Of The Unit:
Lower the unit onto the foundation and position the base so the anchor bolts are aligned in the middle of the holes in
the base. Disconnect the coupling halves and do not reconnect until all alignment operations are complete.
Set the base on metal shims or metal wedges placed directly under the part of the base carrying the greatest weight,
and spaced close enough to give uniform support and stability. (Refer to the typical baseplate installation illustration
shown below).
Figure A
Adjust the metal shims or wedges until the shaft of the pump and driver are level or horizontal as appropriate and
until pump and driver shaft are aligned with each other. Make sure that all shims or wedges fit firmly between the
foundation and the base.
If leveling nuts are installed on the anchor bolts and are used for alignment, follow the same procedure as with shims
or wedges. Support the base with additional shims or wedges if necessary. Make sure that all nuts and shims are in
firm contact with the base.
Tighten the foundation bolts snugly, but not too firmly, and recheck the shafts for alignment before grouting.
Grouting:
When the alignment is correct, the unit should be grouted using a high grade, non-shrinking grout. The base is to be
completely filled with grout.
CAUTION:
Damaging vibration may result if the base plate is not solidly in contact with the grout bed.
NOTE:
Do not fill the pipe sleeves with grout.
If leveling nuts are used, make sure they are not imbedded in grout. Provide access in the grout to the leveling nuts
so that they can be backed off after the grout has cured.
Allow the grout to fully cure before backing off the leveling nuts (if used) and firmly tightening the foundation bolts.
Then recheck the alignment before connecting the piping as even the highest quality non-shrink grouts contract
slightly during drying.

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Piping:
IMPORTANT:
All piping connections must be made with the pipe in a free supported state, and without the need to apply
vertical or side pressure to obtain alignment of the piping with pump flange.
All piping should be independently supported near the pump so that pipe strain will not be transmitted to the pump
casing. The weight of the piping and of the contained liquid must be considered in support design.
The suction and discharge piping should be one or two sizes larger than the pump flange sizes, especially where the
piping is of considerable length. Any flexible joints installed in the piping must be equipped with tension rods to
absorb piping axial thrust.
The suction pipe must be air tight and sloped upward to the pump flange to avoid air pockets that will impair
satisfactory pump operation. The discharge pipe should be as direct as possible with a minimum of valves to reduce
pipe friction losses.
A check valve and closing valve should be installed in the discharge line and a closing valve in the suction line. The
check valve, between the pump and closing valve, protects the pump from water hammer and prevents reverse
rotation in the event of power failure.
The closing valves are used in priming, starting and when the pump is shut down. The pump must never be throttled
by the use of a valve in the suction line.
Final Coupling Alignment:
Check safety codes, and always install protective guard or shield as required by the various federal, state and local
laws and the regulations concerning OSHA.
The final coupling alignment must be made after the piping has been connected. If realignment is required,
disconnect the piping first then proceed with the alignment. Reconnect the piping after alignment has been
completed, and check the alignment before connecting the coupling.
A flexible coupling must not be used to compensate for misalignment resulting from poor installation or temperature
changes.
Periodic Check:
Coupling misalignment can occur because of shifts in grouting, foundation or because of large objects going through
the pump causing shock-loading conditions.
Coupling alignment should be checked periodically for changes. Coupling misalignment can lead to or cause bearing
failure, coupling failure, shaft breakage, and high power consumption.
Refer to the coupling installation instructions supplied with this O&M for alignment tolerances.
Auxiliary Piping Connections:
Install any additional piping connections, your pump may require such as water seal piping, stuffing box drain,
baseplate drain, and pressure gauges.
NOTE:
For satisfactory pump operation and life, these auxiliary pipe lines must be kept clean.
Rotation:
Before connecting the motor to the pump, bump start the driver and verify rotation is in the proper direction. A
directional arrow on the pump casing indicates the correct pump rotation.

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SECTION 4 OPERATION:
General:
This section contains applicable start-up and break-in procedures for operation. Because variations may exist in a
particular installation between the pumps, the drivers and the accessory equipment, specific operating instructions
are not within the scope of this manual.
Before starting or operating the pump, read this entire manual and especially comply with the following instructions:
A. Before starting the pump, install guards around all exposed rotating parts.
B. Before starting the pump, rotate the unit or assembly by hand to assure all moving parts are free.
C. Observe all caution or danger tags attached to the equipment.
D. Never run the pump dry as the liquid lubricates the close running fits within the pump. Running dry may result
in pump seizure.
E. Before starting the pump, fill the casing and suction line with liquid, the pump may be primed by using a
priming system.
F. If excessive vibration or noise occurs during operation, shut the pump down and consult a Fairbanks Nijhuis™
representative.
Theory of Operation:
The pump is used to elevate liquid from one level to another. This is accomplished by centrifugal force. Energy
supplied to the motor turns the pump impeller at a specified speed. As the impeller rotates it imparts energy to the
fluid as it is discharged from all points around the impeller circumference. The volute encases the impeller and
directs the flow while it converts the liquid velocity from the impeller to the pressure energy which moves the liquid to
the required level.
Normal Operating Procedures:
Monitor the following during running cycles:
A. Unit vibration or noise.
B. Driver lubrication.
C. Pump lubrication.
D. Mechanical seal leakage.
Check the following before normal start-up:
A. Repeat those procedures covered by initial start-up.
1. Driver lubrication.
2. General condition of all equipment.
Priming:
The priming procedure is different for positive and negative suction head systems and the following procedures
should be followed:
A. Positive suction head
1. Open the vent on the highest point on the pump casing.
2. Open all suction valves.
3. Allow the liquid to flow from the vent hole until all air bubbles are vented, and then close the vent.
4. The pump is now primed.
B. Negative suction head
1. Install the priming system on the vent on the highest point of the, pump casing.
2. Close the discharge valve.

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3. Open the suction valve.
4. Start the priming system.
5. Run the priming system until a continuous stream flows through the suction line, then close the valve to
the vent.
6. The pump is now primed.
Starting The Pump:
Initial Startup:
No specific procedures are required for initial startup unless the pump has been in storage. If the pump has been in
storage, refer to Storage of Pumps found in section 1, of this manual. Start the pump in accordance with Routine
Starting below.
Routine Starting:
A. After the pump is primed, and with the discharge valve closed and the suction valve open, start the driver
according to the driver manufacturer's instructions.
B. Open the discharge valve slowly to prevent water hammer.
C. Immediately after the pump has been started, check the following:
1. Bearing temperature,
2. Stuffing box lubrication and operation
3. Pump unit noise level.
4. Pump unit vibration level.
D. Continue to monitor these values for the first several hours of operation.
E. After the unit has stabilized and is operating normally, record readings for future use in preventative
maintenance.
Bearing Operating Temperature:
These pumps are designed to operate over a wide ambient temperature. The temperature, when measured on the
outside surface of the bearing housing, should not exceed 190 degrees F. Temperatures in excess of 190 degrees F
may indicate a lack of lubricant, or bearing problems. If the temperature exceeds this limit, the pump should be
stopped and the cause investigated and corrected.
Regulating / Control Procedure:
Pump stations are usually designed to have the pumps started and stopped automatically using a controller. Since
this is a function of station design, the operators should be thoroughly familiar with the systems operating
parameters and in the use of the controller.
A. Disconnect the electrical power.
1. Lock out the power to the driver.
DANGER:
Check power source with appropriate electrical test equipment to ensure driver cannot accidentally start
B. If the pump is to be removed for repair, close the suction and discharge valves.
Emergency Procedures:
Many installations are equipped with emergency shut off switches near the pump location. These locations should be
plainly marked and be readily accessible at all times.
The control panel (if used) may be equipped with an emergency stop button or switch.
IMPORTANT:

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FN-1060 1/7/2019 Fairbanks Nijhuis™
The operator or persons working around the equipment should be familiar with locations of emergency shut
off points.
Start-Up:
A. Open the suction valve.
B. Start the driver.
C. Open the discharge valve.
Shut-Down:
Shut off the power at the nearest switch.
Special Operating Instructions:
Operating At Reduced Capacity:
In a typical application covering a wide range of flow rates, a variable speed driver is often used to adjust pump
capacity, and Fairbanks Nijhuis™ when selecting the pump and impeller trim takes this into consideration. Although
these pumps are applicable over a wide range of operating conditions, care should be exercised when doing so,
especially when the actual conditions differ from the sold for conditions. You should always contact your nearest
Fairbanks Nijhuis™ distributor or factory before operating the pumps at any condition other than that for which they
were sold.
Seasonal Operation:
If the pump is located in an area that is subject to below freezing temperatures for extended periods of time and will
not be operated enough to prevent freezing, it should be drained to prevent damage to the casing caused by
freezing.
Troubleshooting:
Pump Symptoms:
Your Fairbanks Nijhuis™ pump has been engineered and carefully selected for your application. It should provide
years of trouble free service. However, any piece of machinery is subject to occasional malfunction. To help you
quickly isolate and rectify any malfunctions, the following troubleshooting guide has been prepared. Frequent use of
this chart to determine the cause of minor operating problems can prevent a major problem from developing or a
possible break down of your pump.
DANGER:
Electrical power must be disconnected and locked to prevent accidentally starting during mechanical
systems check.
Pump Fails To Prime Or Loses Prime:
1. Air leaks in suction.
a. Clean and tighten all suction connections.
b. Relocate suction inlet in liquid source.
2. Suction Strainer is clogged.
a. Remove dirt, leaves or other material from the strainer.
3. Suction lift is too high.
a. Re-evaluate pump requirements and correct suction conditions.
4. Defective priming valve.
a. Replace priming valve.

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FN-1060 1/7/2019 Fairbanks Nijhuis™
5. Defective mechanical seal.
a. Replace mechanical seal.
No Discharge From The Pump:
1. Pump is not properly primed.
a. Prime the pump. Refer to priming troubles and remedies.
2. Total head is too high.
a. Re-evaluate head calculations. Consult your local Fairbanks Nijhuis™ office.
3. Driver not operating at rated speed.
a. Check voltage or engine RPM. Refer to appropriate manuals.
4. Impeller or discharge line is clogged.
a. Backflush the pump to clear obstruction.
b. Disassemble pump/piping & remove obstruction.
5. Wrong direction of rotation.
a. Reverse any two power leads on a 3-phase motor. Replace single-phase motor.
6. Pump is vapor bound.
a. Provide additional pressure on pumped liquid either by elevating liquid source or pressurizing the supply
tank.
Pump Does Not Deliver Rated Capacity:
1. Pump is not properly primed.
a. Prime the pump. Refer to priming troubles and remedies.
2. Suction lift is too high
a. Re-evaluate pump requirements and correct suction conditions.
3. Excessive air in liquid.
a. Clean and tighten all suction connections
b. Relocate suction inlet in liquid source.
4. Air leakage at stuffing box.
a. Replace mechanical seal.
5. Driver not operating at rated speed.
a. Check voltage or engine RPM. Refer to appropriate manuals.
6. Impeller is clogged
a. Backflush the pump to clear obstruction.
b. Disassemble pump/piping & remove obstruction.
7. Wearing surfaces are worn
a. Replace worn component
b. Add wear rings.
8. Impeller is damaged.
a. Replace impeller
b. Add wear ring.
9. Pump is vapor bound.