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INSTALLATION,
MODEL 441
OPERATION AND
MAINTENANCE HORIZONTAL SPLIT CASE
&
INSTRUCTIONS
FOR
MODEL 491
SPLIT CASE FIRE PUMP
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TABLE OF CONTENTS PAGE i TOPIC PAGE PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STORAGE OF PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CAUTION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PUMP IDENTIFICATION PAGE 1 PUMP IDENTIFICATION Congratulations! You are the owner of one of the finest pumps commercially available. If you give it the proper care as outlined and recommended by this manual, it will provide you with reliable service and long life. 441 & 491 SPLIT CASE PUMPS Your Aurora Model 441 & 491 is a Split Case Pump, meaning the casing is split along the horizontal centerline. This new compact design, with its shorter bearing span, has l
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PAGE 2 STORAGE OF PUMPS AND CAUTION NOTES THESE INSTRUCTIONS APPLY TO THE PUMP ONLY. THEY ARE INTENDED TO BE GENERAL AND NOT SPECIFIC. IF YOUR OPERATING CONDITIONS EVER CHANGE, ALWAYS REFER TO THE FACTORY FOR REAPPLICATION. ALWAYS REFER TO THE MANUALS PROVIDED BY MANUFACTURERS OF THE OTHER EQUIPMENT FOR THEIR SEPARATE INSTRUCTIONS. CAUTION IMPORTANT SAFETY NOTICE THE INSTALLATION, USE AND OPERATION OF THIS TYPE OF EQUIPMENT IS AFFECTED BY VARIOUS FEDERAL, STATE AND LOCAL L
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INTRODUCTION AND INSTALLATION PAGE 3 INTRODUCTION This manual contains information which is the result of carefully conducted engineering and research efforts. It is designed to supply adequate instructions for the safe and efficient installation, operation maintenance of your pump. Failure or neglect to properly install, operate or maintain your pump may result in personal injury, property damage or unnecessary damage to the pump. Variations exist in both the equipment us
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PAGE 4 INSTALLATION (continued) 3. MINIMUM SUBMERGENCE OF SICTION PIPE AND PIT DESIGN For installations where the pump draws fluid from a sump, the hydraulic characteristics of the pump, the suction inlet submergence and NPSH must be considered. Generally, it is required that an evenly distributed flow of non-aerated water be supplied to the suction bell. Improper pit design or insufficient suction pipe submergence can result in intake vortexing which reduces the pump’s perf
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INSTALLATION (continued) PAGE 5 7. GROUTING When the alignment is correct, the unit should be grouted using high grade non-shrinking grout. The entire base should be filled with grout. Be sure to fill all gaps and voids. Allow the grout to fully cure before firmly tightening the foundation bolts. Then recheck the alignment before connecting the piping. 8. PIPING CAUTION: ALL PIPING CONNECTIONS MUST BE MADE WITH THE PIPING IN A FREE SUPPORTED STATE, AND WITHOUT THE NEE
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PAGE 6 INSTALLATION (continued) BEARING HOUSING OIL LEVEL CHART 4-441-11A/C 5-441-18A 5-441-11A PUMP MODEL 3-441-9A/C 4-441-14C 6-441-14A/C 6-441-19A 2-441-8A (PUMP SIZE) 4-441-8A 5-441-14A 6-441-18C 8-441-18A 6-441-12A 8-441-14A 10-441-20 Centerline of shaft to oil level 3/4" 7/8" 1-3/16" 1-1/2" 1-13/16" NOTE: For Fire Pumps, the Model designation changes from “441” to “491.” Adjust the oil level, if necessary, by loosening the setscrews on the side of the dust cap, raising th
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INSTALLATION (continued) PAGE 7 FIGURE 3 COUPLING ALIGNMENT 11. FINAL COUPLING ALIGNMENT (continued) C Check the angular alignment with a micrometer or caliper. Measure from the outside of one flange to the outside of the other at intervals around the periphery of the coupling. Determine the maximum and minimum dimensions. DO NOT ROTATE THE COUPLING. The difference between the maximum and minimum dimensions should not exceed the figure shown under “Angular” in the
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PAGE 8 INSTALLATION continued) 14. MECHANICAL SEALS CAUTION: DRY OPERATION OF THE PUMP MAY CAUSE DAMAGE TO THE MECHANICAL SEAL AND IMPELLER. Model 441 pumps can be supplied with optional single face mechanical shaft seals. Mechanical seals are installed and adjusted in the factory and require no further adjustments in the field. For further information, refer to the seal manufacturer’s instructions. FIGURE 4 TYPICAL MECHANICAL SEAL
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OPERATION PAGE 9 Because variations exist in both the equipment used with these pumps and in the particular installation of the pump and driver, specific operating instructions are not within the scope of this manual. However, there are general rules and practices that apply to all pump installations and operation. CAUTION: BEFORE STARTING OR OPERATING THE PUMP, READ THIS ENTIRE MANUAL, ESPECIALLY THE FOLLOWING INSTRUCTIONS: A. BEFORE STARTING THE PUMP, INSTALL CLOSED GU
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PAGE 10 OPERATION (continued) 3. STARTING THE PUMP 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. After the pump has been started, check bearing temperatures, packing box lubrication and operation and pump noise level for a period of several hours. CAUTION: BEGIN THESE CHECKS IMMEDIATELY UPON STA
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MAINTENANCE PAGE 11 1. MAINTENANCE HISTORY SYMBOL DATE MAINTENANCE PERFORMED PARTS USED NUMBER(S)
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PAGE 12 MAINTENANCE (continued) 2. INSPECTIONS AND PREVENTIVE MAINTENANCE REQUIREMENTS To assure satisfactory operation of the pump, daily inspections and periodic maintenance are required. We suggest that an inspection and maintenance log be kept and that the inspector immediately report any problems. A guide for preventive maintenance for normal applications is given below. Unusual applications, with abnormal heat, moisture, dust, etc. may require more frequent inspections
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MAINTENANCE (continued) PAGE 13 3. BEARING LUBRICATION (continued) Check the oiler setting periodically to be sure it is correct. Refer to the following table for the correct setting. RECOMMENDED OILS: The oil used should be non-detergent type containing rust and oxidation inhibitors, supplied by a reputable manufacturer. Depending on bearing/pump operating temperature, the grade and viscosity should be as follows: o Below 120 F – ISO Vg Grade 40-70 (SAE 20) o 120F to
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PAGE 14 MAINTENANCE (continued) 5. PACKING REPLACEMENT (continued) PUMP MODEL (PUMP SIZE) 4-441-11A 5-441-18A 2-441-8A 3-441-9A/C 4-441-14C 6-441-14A/C 6-441-19A 4-441-8 5-441-14A 6-441-18A 10-441-20 6-441-12A 8-441-14A PACKING BOX Sleeve O.D. 1-5/8 2 2-1/2 3 3-1/2 Packing Box I.D. 2-7/16 2-15/16 3-9/16 4-3/16 4-13/16 Packing Box Depth 2-15/16 2-7/8 3-7/8 4-5/16 4-3/4 PACKING SIZE 3/8 3/8 1/2 9/16 5/8 Qty. of Rings per Box 7 7 777 (Without Lantern Ring) Lantern Ring Width 3/4 3/4
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MAINTENANCE (continued) PAGE 15 6. PUMP DISASSEMBLY (continued) E. Remove the capscrews (159D) that secure the bearing housing covers (159) to the bearing housings and remove the housings from the rotating assembly. F. Remove the outer snap ring (345) from the outboard bearing end of the rotating assembly, and use a wheel/bearing puller to remove the outboard (168) and inboard (163) bearings. WARNING: TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY, EXTREME CARE SHOULD BE EXER
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PAGE 16 MAINTENANCE (continued) 7. PUMP ASSEMBLY CAUTION: READ THIS ENTIRE PROCEDURE BEFORE CONTINUING. Following are step-by-step instructions for assembly of the pump and are essentially the reverse order of the instructions for disassembly. A. Thoroughly clean all parts to remove oil, grease and foreign material. Inspect for wear or damage and replace if required. Remove all parts to a clean and dust-free location for assembly. Gaskets, grease seals and bearings should
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MAINTENANCE (continued) PAGE 17 7. PUMP ASSEMBLY (continued) Sleeves Secured With Loctite Only: Clean the shaft, the bore of the sleeves and the bore of the impeller with Loctite “Safety Solvent #75559. Install the impeller key in the shaft and coat the impeller area on the shaft with Loctite 601. Press the impeller onto the shaft, centering it between the shoulders as shown in Figure 5. Coat the shaft on the shaft/sleeve fit and the bore of the sleeves with Loctite 601.
