INSTRUCTION AND REPAIR MANUAL - Aurora Pump

1 SECTION 914 ITEM VT. DATED APRIL 2006. INSTRUCTION AND REPAIR MANUAL . VERTICAL TURBINE. VERTICAL TURBINE MODELS. PUMP IDENTIFICATION. Carefully record all of the following data from your pump nameplate. It will aid in obtaining the cor- rect replacement parts for your pump. In addition to the nameplate, the pump serial number is stamped on the discharge flange. Pump: Serial Number _____ GPM _____. Pump Size _____ Head (PSI) _____. Model Number _____. Number of Stages _____. Motor: Manufacturer _____ Horsepower _____. Serial Number _____ Motor Frame _____. Full Load Speed _____ Full Load Amps _____. Phase/Hz/Volts _____ Date in Service _____. Engine: Manufacturer _____ Horsepower _____. RPM _____ Serial Number _____. Model Number _____ Date in Service _____. Gear: Manufacturer _____ Serial Number _____. Model Number _____ Ratio _____ : _____. Rotation Figure # 1. Controller: Manufacturer _____ Serial Number _____. Model Number _____ Phase/Hz/Volts _____.

2 2. VERTICAL TURBINE MODELS. 10 FEM THRU 19 FGHF - VERTICAL TURBINE Over-Heating ..21. FIRE PUMPS Driver / Controller Symptoms ..21. Driver Does Not Start ..22. INSTALLATION, OPERATION AND MAINTENANCE Driver Fails To Come Up To Speed..22. Motor Runs Hot ..22. TABLE OF CONTENTS Motor Vibrates ..22. Driver Is Noisy ..22. Warranty Highlights ..4 Incorrect Rotation..22. Introduction ..5. Section 5 Maintenance Section 1 General Preventive Maintenance ..22. Safety ..6 Grease Recommendation ..23. Storage of Pumps ..7 Packing Adjustment ..23. Consider a Unit in Storage ..7 Packing Replacement ..23. Assembled Pumps ..7 Pump Disassembly ..24. Unassembled Pumps ..7 Driver Removal ..24. Vertical Hollow Shaft(VHS) Driver ..24. Section 2 Introduction Discharge Head Removal ..24. General Description ..8 Column Removal ..24. Bowl ..8 Pump Bowl Disassembly ..25. Column Pipe ..8 Inspection for Replacement ..26. Line Shafting ..8 Shaft Straightness ..27.

3 Discharge Heads ..8 Pump Bowl Assembly ..27. Drivers ..8 Wear Rings ..28. Assembly Tools ..29. Section 3 Installation Maintenance History ..31. General ..9 Maintenance Notes ..32. Foundation ..9. Well and Pit Inspection ..9 Section 6 REPAIR Parts Bowl Assembly ..10 Ordering Parts ..33. Suction Strainer ..10 Recommended Spare Parts ..33. Leveling and Grouting ..10 Returning Parts ..33. Hoisting and Piping ..11 Service ..33. Pump Assembly ..11 Warranty Service ..33. Product Lubricated Open Line Shaft ..13 Service After Warranty ..33. Oil Lube Enclosed Line Shaft ..14. Driver Installation ..17 Section 7 Reference Information Vertical Hollow Shaft Drivers ..17 Technical Data ..34. Figures ..37. Section 4 Operation Drawings and Diagrams ..39. General ..19 Notes ..45. Before Starting the Pump ..19. Initial Startup ..19. Normal Operation ..20. Shutdown ..20. Troubleshooting ..20. Pump Symptoms ..20. Insufficient Pressure or Flow ..20. Loss of Suction Operation.

4 21. Excessive Power Consumption ..21. Vibration or Noise ..21. Execessive Packing Box Leakage ..21. 3. VERTICAL TURBINE MODELS. WARRANTY HIGHLIGHTS. 1. Seller warrants products of its own manufacture against defects in materials and workmanship under normal use and service for one (1) year from date of installation orstart-up, but not more than eighteen (18) months after date of shipment. 2. Accessories and components not manufactured by seller are warranted only to the extent of the original manufacturer's warranty. 3. No allowances will be made for repairs or alterations effected without specific written authorization from Seller. 4. The equipment as manufactured by Aurora Pump is precision machinery. Proper care can give a lifetime of satisfactory service. Guarantees of performance and warranties are based on the use of original equipment manufactured (OEM) replacement parts. Aurora Pump assumes no responsibility when alterations, non-authorized design modifications and/or non-OEM replacement parts are incorporated.

5 5. This warranty is VOID unless the purchaser provides protective storage, installs and maintains the equipment in accordance with manufacturer's instructions . 6. Under the terms of this warranty, Seller shall not be responsible nor liable for: a. Consequential, collateral or special losses or damages. b. Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect, or misuse of said equipment. c. Labor charges, loss or damage resulting from supplying of defective part(s) or improper repairs by unauthorized person(s). d. Damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage or mishandling. e. Labor charges for installation, removal or reinstallation of equipment. 7. The above listed warranty highlights do not constitute our total terms and conditions regarding warranty. For complete warranty information please refer to complete warranty statement herein.

6 LOSS OR DAMAGE IN TRANSIT. Immediately upon receipt a complete inspection and accounting against the packing list should be made of all major components, and accompanying boxes or pallets. All material is shipped our factory, or our vendor's shipping point unless other, contractual, arrangements are made. Under these terms, any claims for loss or damage in transit should be immedi- ately directed to the delivering freight carrier. The factory will assist the customer in receiving fair compensation, but assumes no responsibility to mediate such claims. This policy includes shipments wherein Aurora Pump pays freight costs as part of the sales terms. 4. VERTICAL TURBINE MODELS. INTRODUCTION. Congratulations! You are the owner of the finest To obtain additional data on hydraulics and pump commercially available. If you give it the pump selection and operation, we suggest you proper care as outlined and recommended by purchase the following reference books: this MANUAL , it will provide you with reliable service and long life.

7 1. Hydraulic Institute Standards Hydraulic Institute IMPORTANT 9 Sylvan Way Read this complete MANUAL and manuals for Parsippany, NJ 07054-3802. all component equipment before assembly or installation is started. It contains information 2. Fairbanks Morse Hydraulic Handbook which is the result of engineering and Aurora Pump research efforts. It is designed to supply ade- 3601 Fairbanks Avenue quate instruc-tions for the installation, opera- PO Box 6999. tion and maintenance of your pump. Failure Kansas City, KS 66106. or neglect to properly install, operate or maintain your pump may result in personal 3. National Fire Protection Association injury, property damage or unnecessary NFPA Pamphlet 20 & 25. damage to the pump. 1 Batterymarch Park PO Box 9101. This MANUAL applies to the pump installation, Quincy, MA 02269. operation and maintenance. If your operating conditions ever change, always refer to the fac- 4. Underwriters Laboratories, Inc.

8 Tory for reapplication. Always refer to the man- Underwriters Laboratories, Inc. uals provided by manufacturers of the accessory 333 Pfingsten Road equipment for their separate instructions . Northbrook, IL 60062. Variations exist in both the equipment used with these pumps and in the particular installation of 5. Factory Mutual the pump and driver. Therefore, specific operat- Factory Mutual ing instructions are not within the scope of this 1151 Boston-Providence Turnpike MANUAL . This MANUAL contains general rules for PO Box 9102. installation, operation and maintenance of the Norwood, MA 02062. pump. If there are questions regarding the pump or its application which are not covered in this MANUAL , please contact the factory as follows: Kansas City, Kansas: Aurora Pump 3601 Fairbanks Avenue PO Box 6999. Kansas City, KS 66106. Tel: (913) 748-4253. Fax: (913) 748-4030. 5. VERTICAL TURBINE MODELS. SECTION 1 GENERAL. The installation, use and operation of this type Safety of equipment is affected by various Federal, State and Local Laws and the regulations con- Safety should be of utmost importance when in cerning OSHA.

9 Compliance with such laws close proximity of this pumping equipment. relating to the proper installation and safe oper- Before attempting to operate this equipment, ation of this type of equipment is the responsi- you should read this MANUAL in its entirety, tak- bility of the equipment Owner and all necessary ing special notice of all cautions, warnings steps should be taken by the Owner to assure and/or danger notifications. These warnings compliance with such laws before operating the apply to pumps supplied by Aurora Pump. equipment. Refer to the manuals supplied by the driver and control manufacturer for additional warnings before operating this equipment. DANGER. Do not attempt to service the pump until the The words DANGER, WARNING and CAU- electrical power has been disconnected and it TION have different connotations and are gen- has been verified that the pump cannot start. erally defined as follows: Because many installations utilize automatic starting equipment, the pump unit may start at any time without warning.

10 Proper precau- DANGER tions should be taken to avoid injury as a Indicates an imminently hazardous situation result of automatic starting of the equipment. which, if not avoided, will result in death or serious injury. DANGER. Do not operate the pump without guards in WARNING place over the rotating parts. Exposed rotat- Indicates a potentially hazardous situation ing parts can catch clothing, fingers, or tools, which, if not avoided, will result in serious causing severe injury to personnel. Any injury. operation of this machine without a protec- tive guard can result in severe bodily injury. CAUTION The responsibility for the installation of pro- Indicates a potentially hazardous situation tective guards is that of the equipment which, if not avoided, may result in minor owner. or moderate injury or may indicate that improper practices will result in equipment DANGER. malfunction or failure. It may also be used This pump is designed for the exclusive use to alert against unsafe practices.