Waterous CM, CMU Fire pump Overhaul Instructions

CM/CMU Series Overhaul Instructions

CM/CMU Series Fire Pumps

Overhaul Instructions

Form No.

F-1031

Section

4212

Issue Date

06/30/95

Rev. Date

12/17/12

Table of Contents

Type of Overhaul

Complete Disassembly of Pump

Replacement of Packing or Mechanical

Seals Without Disassembling the Pump

Removal and Installation of Transfer

Valve

Pump Drive

Transmission Mounted Directly to the Rear of the Pump

Transmission Mounted Directly to the Front of the Pump

Direct Drive (The pump is driven by a remotely mounted transmission or P.T.O., the pump is turned by an end yoke on the impeller shaft.)

Direct Drive or Transmission Mounted

Directly to the Pump

Direct Drive or Transmission Mounted

Directly to the Pump

See

Table Page

1 3

2

3

4

5

4

5

6

7

Visit us at www.waterousco.com

Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000

Instructions subject to change without notice.

Safety Information

Please read through the safety information and operating instructions carefully before using your Waterous Fire Pump.

WARNING

Death or serious personal injury might occur if proper operating procedures are not followed. The pump operator, as well as individuals connecting supply or discharge hoses to the apparatus must be familiar with these pump operating instructions as well as other operating instructions and manuals for the apparatus, water hydraulics and component limitation.

WARNING

Unexpected Truck Movement. May result in serious personal injury or death.

Failure to properly shift transmission in accordance to the transmission operating instructions may result in unexpected truck movement which may result in serious personal injury or death.

WARNING

Pressure Hazard. May result in personal injury.

Prior to connection or removal of hoses, caps or other closures with pump intake or pump discharge connections, relieve pressure by opening drains or bleeder valves. Bleeder valves should also be used while filling a hose connected to an intake with water.

WARNING

Rotating Parts Hazard or Unexpected Truck Movement. May result in seri ous personal injury or death.

Stop the engine, set parking brake and chock the wheels before going under the truck to adjust packing or to check packing gland temperature.

WARNING

Scalding Water Hazard. May result in serious burns.

When operating the pump, be sure to open at least one discharge valve slightly to prevent the pump from overheating. If the pump runs for a few minutes completely closed, it may heat the water enough to scald some one when the valve is opened. Overheating can damage the packing, seals and other pump parts. If the apparatus builder has installed a bypass system or other provision designed to prevent overheating, opening a discharge valve may be unnecessary.

WARNING

Packing Gland and Pump Body Temperature Hazard. May result in serious burns.

Heat is dissipated through the cross-section of the packing, transferring the heat to the packing gland and pump body.

F-1031, Section 4212 Page 2 of 61

Table 1: Complete Disassembly of Transmission Mounted Pumps

(For Transmissions Mounted Direcly to the Rear of the Pump)

Overhaul Operation

Safety Information

General Information

Removal Of:

Transmission

Intake Adapters

Impeller Shaft Assembly

Outboard Bearing Removal

Disassembly of

Impeller Shaft

Components

Interstage Seal and Seal Housing

Impeller Removal

Cooling Line Check

Installing Undersize Wear Rings

Impeller / Wear Ring Installation

Seal Housing Installation

Mechanical Seal Installation

Packing

Reassembly of

Impeller Shaft

Components

Outboard Bearing Installation

Installing Impeller Shaft Assembly

Installing Body Hardware

Installation of Transmission

Vacuum Test

Prior to April 21, 2006

After April 21, 2006

Removal

Check

Installation

Adjustment

Prior to April 21, 2006

After April 21, 2006

Pumps with

Mechanical Seals

2

See Page

Pumps with Packing

2

8

9

11

12

8

9

11

12

14, 19, 20

15, 21

26

29

28

29

31, 32

33, 34

16, 19, 20

17, 21

27

30

28

30

31, 32

33, 34

26

41, 42

-

-

14, 22

15, 23

35

37

9

45

27

-

44

44

16, 22

17, 23

35

37

9

45


Table 2: Complete Disassembly of Transmission Mounted Pumps

(For Transmissions Mounted Direcly to the Front of the Pump)


Safety Information

General Information

Removal Of:

Transmission

Intake Adapters



Disassembly of

Impeller Shaft

Components

Interstage Seal and Seal Housing

Impeller Removal

Cooling Line Check





Reassembly of

Impeller Shaft

Components

Packing




Installation of Transmission

Vacuum Test

Removal

Check

Installation

Adjustment

Pumps with


2

See Page


2

8

10

11

13

8

10

11

13

15, 21

26

29

28

29

31, 32

33, 34

26

17, 21

27

30

28

30

31, 32

33, 34

27

41, 42

-

-

15, 23

36

37

10

45

-

44

44

17, 23

36

37

10

45


Safety Information

General Information

Removal Of:

Disassembly of

Impeller Shaft

Components

Reassembly of

Impeller Shaft

Components

Vacuum Test

Table 3: Complete Disassembly of Direct Drive Pumps


Intake Adapters



End Yoke Removal on Drive End

Seal Housing Removal

Impeller Removal

Interstage Seal and Seal Housing Check





Packing


End Yoke Installation on Drive End


Rear Drive

Front Drive

Front or Rear Drive w/o Tachometer

Front Drive with Tachometer



Installation

Adjustment





Rear Drive

Front Drive


33, 34

26

41, 42

-

-

14

18

24

25

35

36

37

45

See Page

Pumps with



2

8

11

12

2

8

11

12

13

14

18

24

25

26

28

29

31, 32

13

16

18

24

25

27

28

30

31, 32

33, 34

27

-

44

45

16

18

24

25

35

36

37

45


Table 4: Replacement of Packing / Mechanical Seal Without Disassembly the Pump

Pump Driven By Type of Seal

Transmission

(Mounted Directly to the Pump)

Direct Drive

(Pump is driven by a remotely mounted transmission or P.T.O.

The pump is turned by an end yoke on the impeller shaft)

Mechanical Seals

Packing

Mechanical Seals

Packing

Operation

Safety Information

General Information

Removal Of: Transmission

Outboard Bearing

Mounted to Rear of Pump

Mounted to Front of Pump

Prior to 4/21/2006

After 4/21/2006

Removal Of:

Seals

Cooling Line Check

Seals

Installation Of: Outboard Bearing

Prior to 4/21/2006

After 4/21/2006

Transmission

Vacuum Test

Safety Information

General Information

Packing Removal

Cooling Line Check

Packing

Vacuum Test

Safety Information

General Information

Installation

Adjustment

Removal Of:

Outboard Bearing

Drive End Yoke

With Tachometer

Without Tachometer

With Tachometer

Without Tachometer

Seals

Cooling Line Check

Installation Of:

Cooling Line Check

Safety Information

General Information

Packing Removal

Cooling Line Check

Seal Installation



Drive End Yoke

Front or Rear Drive without

Tachometer

Packing

Packing

Vacuum Test

Installation

Adjustment

25

44

44

45

29

2

8

43

30

See Page

2

8

9

24

25

38, 39, 40

29

39, 40

14, 22

24

8

18

16

44

44

45

2

10

14, 19, 20

15, 21

38, 39, 40

29

41, 42

14, 22

15, 23

9

45

2

8

43

30


Date of Pump

After January 1, 2000

After January 1, 2000

F-1031, Section 4212

Style

Rotary

Table 5: Removal / Replacement of Transfer Valve

Actuator

Mounting Operation

Reciprocating

Bottom

Top

Bottom

Top

Manual

Electric Motor

Manual

Electric Motor

Manual

Electric Motor

Manual

Electric Motor

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator

Transfer Valve

Actuator


Transfer Valve

Removal From Pump

Installation in Pump

Overhaul

Removal From Pump


Removal From Pump


Overhaul

Removal From Pump


Removal From Pump


Overhaul

Removal From Pump


Removal From Pump


Overhaul

Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


Removal From Pump


See Page

46


50, 51, 52, 53

47


50, 51, 52, 53

48


50, 51, 52, 53

49


50, 51, 52, 53

54

59, 60, 61

55

59, 60, 61

56

59, 60, 61

57, 58

59, 60, 61

Page 7 of 61

Tools and Equipment

The following tools and equipment may be needed to overhaul a pump:

1.

Usual automotive mechanic's hand tools.

2.

An arbor press for assembling or disassembling components.

3.

An engine lathe for turning impeller hubs.

4.

A suitable hoist and slings.

5.

Torque capability up to 325 lb-ft.

While no special tools and equipment are required, a few special items are illustrated or described so the mechanic can make them or they are avail able from the apparatus manufacturer or the Waterous Company. These special items are not absolutely necessary, but they will make the me chanic's work much easier.

Preliminary Testing

Before disassembling a pump, test it thoroughly, if possible, and record the results. A comparison of this test with periodic tests recommended in form F-1031, Section 1000 can often reveal specific pump troubles. Ex cessive speed, for instance, indicates that impellers and/or wear rings are probably worn. For a two stage pump in series, excessive speed may indi cate a worn transfer valve or interstage seal, leaking flap valve or a mal functioning relief valve.

Cleaning

The continued satisfactory operation of a pump depends to a great extent upon the cleanliness of its internal parts. Sand, dirt or other abrasive mate rial will wear gears and related parts. Before disassembling a pump for repairs, be sure to clean its exterior. Make sure the working space, benches and tools are clean. Use only clean, lint-free cloths to wipe off components. Before reassembling a pump or its components, be sure to clean them thoroughly.

Pump Bodies, Impellers and Transfer Valves

Flush out these components and related parts with clean water. Use a stiff brush to remove loose scale, caked sediment, etc. Be sure to remove all traces of old gaskets. Examine pump bodies, covers, adapters and fittings for cracks, severe corrosion or other damage. Almost all damage to these parts results from improper use or maintenance, or from freezing. Replace defective parts.


General Overhaul Information

Bearings, Gaskets, Seals and O-rings

Parts of this nature are frequently damaged during removal or disassemb ly. In addition, they sometimes deteriorate or lose their effectiveness be cause of age or misuse. Replacing these parts whenever overhauling a pump is a good policy.

Impeller Shafts

Examine shaft for severe scratches, grooves or corrosion - especially un der packing or mechanical seals. If scratches are not severe, and are not under packing and seals, clean them with a fine-cut file. Grooves are usu ally permissible if they are not sharp or too deep. Even slight longitudinal scratches will cause leaks and should be removed.

Installing Ball Bearings

Most Waterous pumps are designed so that ball bearings fit tightly on their shafts and have relatively loose fits in the bearing housings. When mount ing these bearings on shafts, always apply force to the inner races. When bearings have a tight fit in the housings, and a heavy force is necessary to install them, be sure to apply force only to the outer bearing races. For either type of fit, applying force to the wrong bearing race may damage the balls and race.

Installing Body Gaskets

To provide added sealing for gaskets between bodies and intake adapters, coat both sides of these gaskets with a suitable sealant. A compound such as Permatex Super 300 is recommended for this application. Be sure all traces of previous gaskets and sealant are removed before installing new gaskets.

End Yoke and Companion Flange Nuts

Do not reuse self-locking nuts. Apply lubrication oil to the threads before removing. Apply anti-seize to the threads before installing a new self- lock ing nut.

Page 8 of 61

Transmission Removal / Installation

(Transmission Mounted Directly to the Rear of the Pump)

Pump

Transmission

1.

Remove the four cap screws and lock washers that attach the transmission to the pump.

2.

Apply Loctite #242 (blue) to threads when transmission is reattached to the pump.

3.

Use the jacking screw holes to separate the transmission from the pump body.

4.

Support transmission and pull straight back from pump.


IL1206

Jacking Screw Holes

IL2729

Page 9 of 61

Transmission Removal / Installation

(Transmission Mounted Directly to the Front of the Pump)

Transmission

Pump

1.

Remove the four cap screws and lock washers that attach the transmission to the pump.

2.

Apply Loctite #242 (blue) to threads when transmission is reattached to the pump.

3.

Use the jacking screw holes to separate the transmission from the pump body.

4.

Support transmission and pull straight back from pump.


Jacking Screw Hole

(One Per Side)

Jacking Screw

Hole

(One Per Side)

Page 10 of 61

Intake Adapter Removal / Installation

1.

Remove the hex hd screws that attach the intake adapters to the pump body.

2.

Remove the adapters and gaskets.

NOTE: Removal of intake adapters is only necessary if pump body or adapt ers need to be replaced.

Discharge Flange

Gasket

Plain Bearing, TFE

Hex Hd Screw,

3/4-10 x 2 in.

Torque to

160-180 Ft-Lbs

Hex Hd Screw

Hex Hd Screw,

3/4-10 x 2 in.

Torque to

160-180 Ft-Lbs

Discharge Flange

Gasket

Gasket

Flap Valve

Intake Adapter, RH

Intake Flange Gasket

(Bronze Body Only)



Flap Valve


Intake Adapter, LH


Gasket

Hex Hd Screw

O-ring,

6-3/4 x 7 in.

Optional

Tank To Pump

Check Valve



(Bronze Body Only)

IL1238

Tank Intake Adapter (or Valve)

Hex Hd Screw,

1/2-13 x 1-1/4 in.

Page 11 of 61

Removal of Impeller Shaft Assembly

Transmissions Mounted Directly to the Rear of the Pump and Rear Driven Direct Drive Pumps

Volute Body

IL2732

Loosen but do not remove these screws.

1.

Use either threaded rods or a transmission jack to lower the cover from the body.

2.

Remove the two screws that attach the bearing housing to the volute body (upper half).

3.

Loosen but do not remove the two screws that attach the bearing housing to the volute cover

(lower half). The impeller shaft assembly will re main in the volute cover.

4.

Remove the screws that attach the volute cover to the volute body and separate the body and cover using the tapped holes.

5.

Remove gasket material and O-ring from the two pump halves.

Jacking

Screw Hole

O-ring


Bearing Housing

Volute Cover


IL1208

Page 12 of 61

Removal of Impeller Shaft Assembly

Transmissions Mounted Directly to the Front of the Pump and Rear Driven Direct Drive Pumps

Volute Body

Bearing Housing

IL2732

Loosen but do not remove these screws.

1.

Use either threaded rods or a transmission jack to lower the cover from the body.

2.

Remove the two screws that attach the bearing housing to the volute body (upper half).

3.

Loosen but do not remove the two screws that at tach the bearing housing to the volute cover (lower half). The impeller shaft assembly will remain in the volute cover.

4.

Remove the screws that attach the volute cover to the volute body and separate the body and cover using the tapped holes.

5.

Remove gasket material and O-ring from the two pump halves.

Jacking

Screw Hole

O-ring


Volute Cover

Jacking

Screw

Hole

Bearing Housing

IL3515

Page 13 of 61

Outboard Bearing Removal / Installation - Prior to 4/21/2006

(Transmission Mounted Pumps with Mechanical Seals or Direct Drive Pumps without Tachometer with Mechanical Seals)

(Reference Pages 16, 17 and 19)

Pipe Plug, 1/4 in.

NOTE: Fill the bearing housing

chamber with a medium consistancy ball and roller bearing grease until the grease comes out of the lube relief fitting. Check that the seal has not leaked.

Retaining Ring, 1-17/64 in.

NOTE: If groove in shaft is:

1/16 in. wide: Use .050 in. thick ring W 4510-137


Hex Hd Screw,

3/8-16 x 1 in.

Bearing Housing

Lock Washer, 3/8 in.

Bearing Housing Cap

Gasket

Lubrication Seal

Retaining Ring, 1-3/8

(Flinger Ring)

Make sure slot lines up with lube fitting when reassembling.

Ball Bearing

CAUTION

To prevent seal from pushing out of housing, do not use power grease gun.


Hex Hd Screw,

1/2-13 x 1-1/4 in.


Lubrication Relief Fitting

Lubrication Fitting, 1/8 in.

Seal Housing Assembly

IL1223

Page 14 of 61

Hex Hd Screw,

1/2-13 x 1-1/4 in.

Bearing Housing

Plug

Retaining Ring,

.109 in. Thick

Bearing Housing

Retaining Ring,

.093 in. Thick

Outboard Bearing Removal / Installation - After 4/21/2006

(Transmission Mounted Pumps with Mechanical Seals)

(Reference Pages 18 and 20)


Retaining Ring,

.093 in. Thick

Shield Bearing

Retaining Ring

(Flinger Ring)

.062 in. Thick

Retaining Ring,

.109 in. Thick



IL2730

Page 15 of 61

Outboard Bearing Removal / Installation (Prior to 4/21/06)

(Transmission Mounted Pumps with Packing or Direct Drive Pumps without Tachometer with Packing)

(Reference Pages 16, 17 and 19)

V-Ring Flinger Installation

Pipe Plug, 1/4 in.

Gasket

Hex Hd Screw,

3/8-16 x 1 in.


Bearing Housing Cap

Make sure slot lines up with lube fitting when reassembling.

NOTE: Fill the bearing housing

chamber with a medium consistancy ball and roller bearing grease until the grease comes out of the lube relief fitting. Check that the seal has not leaked.

CAUTION



Ball Bearing

Make sure flat side is facing away from bearing housing when reassembled on shaft.

Bearing Housing


V-Ring Flinger


Hex Hd Screw,

1/2-13 x 1-1/4 in.

Retaining Ring, 1-17/64 in.

NOTE: If groove in shaft is:




Lubrication Fitting, 1/8 in.

IL1219


Page 16 of 61

Hex Hd Screw,

1/2-13 x 1-1/4 in.

Outboard Bearing Removal / Installation (After 4/21/06)

(Transmission Mounted Pumps with Packing)

(Reference Pages 18 and 20)


Bearing Housing

Plug

Retaining Ring,

.109 in. Thick

Bearing Housing

Retaining Ring,

.093 in. Thick

Sealed Ball Bearing

Retaining Ring,

.109 in. Thick

Bearing Shield

V-Ring Flinger

Make sure flat side is facing away from bear ing housing when installed on the shaft.



IL2731

Page 17 of 61

Impeller Shaft

Outboard Bearing Removal / Installation

(Direct Drive Pumps - Front Drive with Tachometer)

V-Ring Flinger

NOTE: Fill the bearing housing chamber with a medium consistancy ball and roller bearing grease until the grease comes out of the lube relief fitting. Check that the seal has not leaked.

Bearing Spacer

Bearing Seal


Ball Bearing


Bearing Housing


IL1291




IL1227


Hex Nut, 1/2-20

Lubrication Fitting, 1/8 NPT

Hex Hd Screw, 1/2-20 x 1-3/4 in.

Page 18 of 61

Outboard Bearing Removal (Prior to 4/21/2006)

1.

Remove the oil pump (if so equipped) and the bearing housing cap.

2.

Remove the bearing outer retaining ring from the impeller shaft

3.

Remove the (4) hex hd screws attaching the bearing housing to the pump body.

4.

Install hub puller bar. (Use bearing removal tool if removing outboard bearing on units equipped with lube pump - See Page 17).

5.

Tighten hub puller screw, causing the bearing housing to pull the bearing off of the end of the impeller shaft.

6.

Remove inner bearing retaining ring from impeller shaft. (Note: Inner retain ing ring not used on pumps with packing).

7.

Remove and discard lubrication seal. Remove bearing from bearing housing.

Completely clean bearing housing of grease and replace bearing.

CAUTION

8.

Remove inner bearing retaining ring from impeller shaft. (Note: Inner retain ing ring not used on pumps with packing).

Make sure center of hub puller screw does not damage the threaded center of shaft. Apply grease to shaft center or bearing removal tool before installing hub puller.

Outboard Bearing Removal (without Lube pump, Prior to 4/21/2006)

Hex Hd Screw, 3/8-16 x 3 (Coarse Thread)

Hub Puller Screw, tighten screw to pull bearing off shaft

CAUTION

Remove outer retaining ring before installing puller.

Bearing Housing

CAUTION

Do not damage internal thread of impeller shaft.

Hub Puller Bar

Hub puller bar, attach to bearing housing in place of bearing housing cap


Hex Hd Screw,

3/8-16 x 3

(Coarse Thread)


Inner Retaining Ring

(Mechanical seal equipped pumps only)

Apply grease to center of shaft

IL2026

Page 19 of 61

Outboard Bearing Removal with Lube Pump (Prior to 4/21/2006)

Hex Hd Screw, 3/8-16 x 3

(Coarse Thread)

CAUTION

Remove outer retaining ring before installing puller.

Bearing Housing

CAUTION

Do not damage external thread of impeller shaft.

Hub Puller Bar



Hex Hd Screw,

3/8-16 x 3 (Coarse Thread)



(Mechanical seal equipped pumps only)

Bearing Removal Tool

Apply grease to pilot in bearing removal tool

IL2003


Outboard Bearing Removal (After 4/21/2006)

1.

Remove plug from bearing housing.

2.

Remove the bearing outer retaining rings from the impeller shaft.

3.

Remove (4) hex hd screws attaching the bearing housing to the pump body.

4.

Install hub puller bar. (Use bearing removal tool if removing outboard bear ing on units equipped with lube pump - See Page 17).

CAUTION

Make sure center of hub puller screw does not damage threaded center of shaft. Apply grease to shaft center or bearing removal tool before installing hub puller.

5.

Tighten hub puller screw, causing the bearing housing to pull the bearing off of the end of the impeller shaft.

6.

Remove inner bearing retaining rings from impeller shaft and bearing housing.

(NOTE: Inner retaining ring on shaft is not used on pumps with pack ing).

7.

Remove bearing from bearing housing.

Outboard Bearing Removal (After to 4/21/2006)

Hex Hd Screw, 5/8-11 x 3 (Coarse Thread)

CAUTION

Remove outer retaining rings before installing puller.


Bearing Housing

Inner Retaining Rings

Note: This ring is used on pumps with

Mechanical seals only, not used on pumps with packing, these shafts have a machined shoulder.



Hub Puller Bar

CAUTION

Do not damage internal thread of impeller shaft.

Shield

Apply grease to center of shaft

Hex Hd Screw,

5/8-11 x 3 (Coarse Thread)

IL2717

Page 21 of 61

Outboard Bearing Installation (Prior to 4/21/2006)

1.

Packed Pumps: Install v-ring flinger on impeller shaft. Mechanical Seal Pumps:

Install (flinger) retaining ring on impeller shaft.

2.

Install new lubrication seal in bearing housing and reinstall bearing housing on pump.

3.

Install inner bearing retaining ring. (Note: Inner retaining ring not used on pumps with packing). Ensure correct retaining ring is used.

NOTE: Retaining rings changed 7/1/95. If groove width is 1/16” wide use

W 4510-137, if 3/32” wide use W 4520-137.

4.

Apply grease to the bearing journal of the impeller shaft to aid in assembly and slide the bearing into the bearing housing until it contacts the impeller shaft.

5.

Screw hex nut onto hex hd screw and slide flat washer, thrust washer and bearing installation tool housing onto screw.

a.

For units equipped without an oil pump attach assembled tool to the impeller shaft by threading hex hd screw completely into the internal thread of the im peller shaft.

b.

For units equipped with and oil pump (Figure 5), thread bearing installation tool onto the external thread of the impeller shaft. Attach assembled tool to the bearing installation tool by threading hex hd screw completely into the internal thread of the bearing installation tool.

6.

Push the bearing onto the impeller shaft until it seats against the inner retaining ring (or shaft shoulder) by tightening the hex nut against the bearing installation tool housing. It may be necessary to hold the hex hd screw to prevent it from turn ing with the hex nut.

7.

Remove the tool and install the bearing outer retaining ring. Ensure correct retain ing ring is used.

8.

Install the bearing housing cap and gasket. Make sure the slot on the cap lines up with the grease fitting. Install oil pump and gasket (if so equipped). Make sure the drive tang on the oil pump lines with the slot in the impeller shaft.

9.

Fill the bearing housing chamber with a medium consistency ball and roller bearing grease (such as Amoco Super Permalube) until the grease comes out of the lube relief fitting. Check that lubrication seal has not leaked.

Outboard Bearing Installation (without Lube Pump)

Prior to 4/21/2006

Outboard Bearing Installation (with Lube Pump)

Prior to 4/21/2006

Apply grease to bearing journal of shaft.

Flat Washer

Bearing Housing

Bearing

Flinger Retaining Ring

(Mechanical seal pumps) or V-ring Flinger

(Packing Pumps)

Apply grease to bearing journal of shaft.

Bearing

Bearing Housing


(Mechanical seal equipped pumps)

Flat Washer

Hex Hd Screw

(Coarse Thread)

Hex Nut

(Fine Thread)

Hex Hd Screw

(Fine Thread)

Thrust Washer

Bearing Installation Tool Housing

Grease Fitting

Lube Relief Fitting

Hex Nut

(Coarse Thread)

Thrust Washer

Inner Bearing

Retaining Ring

(Mechanical Seal

Equipped Pumps Only)


Bearing Installation Tool


IL2025

Grease Fitting

Lube Relief Fitting

Flinger

Retaining Ring

(Mechanical seal pumps) or

V-Ring Flinger

(Packing Pumps)


IL2002


Outboard Bearing Installation (After 4/21/2006)

1.

Packed Pumps: Install v-ring flinger on impeller shaft. Mechanical Seal Pumps:

Install (flinger) retaining ring on impeller shaft.

2.

Install new shield seal in bearing housing and reinstall bearing housing on pump.

3.

Install inner bearing retaining rings. (Note: Inner retaining ring on shaft is not

used on pumps with packing).

4.

Apply grease to the bearing journal of the impeller shaft to aid in assembly and slide the bearing into the bearing housing until it contacts the impeller shaft.

5.

Screw hex nut onto hex hd screw and slide flat washer, thrust washer and bearing installation tool housing onto screw.

6.

Push the bearing onto the impeller shaft until it seats against the inner retaining ring (or shaft shoulder) by tightening the hex nut against the bearing installation tool housing. It may be necessary to hold the hex hd screw to prevent it from turn ing with the hex nut.

7.

Remove the tool and install the bearing outer retaining rings.

8.

Install plug in outside of bearing housing.

9.

Note that bearing is sealed and does not required external lubrication.

Outboard Bearing Installation (after 4/21/2006)

Apply grease to bearing journal of shaft

Bearing Housing

Bearing

Flat Washer

Hex Nut

(Fine Thread)

Hex Hd Screw

(Fine Thread)

Thrust Washer


Shield

Flinger Retaining Ring

(Mechanical seal pumps) or V-ring Flinger

(Packing Pumps)

Note: This ring is used on pumps with

Mechanical seals only, not used on pumps with packing, these shafts have a machined shoulder.

Inner Bearing Retaining Rings

IL2718


*Cotter Pin, 1/8 x 1-3/4 in.

(*Before 4/20/98)

*Castle Nut

Hex Hd Screw,

3/8-16 x 1 in.

Lock Washer,

3/8 in.

End Yoke Removal/Installation on Drive End

(Front Drive with Tachometer)

**Self-Locking Nut (Torque to 275-325 LB-FT)

Do not reuse. Apply lubricating oil to the threads before moving. Apply anti-seize to the threads before installing a new self-locking nut.

(**After 4/20/98)

End Yoke with U-bolts


Tachometer Gear Housing


O-ring, 3-1/4 x 3-1/2 in.

Spring Pin, 3/16 x 1/2 in.

Tachometer Drive Gear

Tachometer Gear Spacer

Ball Bearing

Retaining Ring

Bearing Housing


CAUTION


Bushing

Tachometer Driven Gear

Tachometer Sleeve



Hex Hd Screw,

1/2-13 x 1-1/4 in.



V-ring Flinger (Both Packing and

Mechanical Seal Pumps)

Impeller Shaft

Lubrication Fitting

1/8 NPT



IL1225

Page 24 of 61

End Yoke Removal / Installation on Drive End

(Front or Rear Drive without

Tachometer)

Impeller Shaft

(Packing Configuration Shown)

V-ring Flinger (Both Packing and Mechanical Seal Pumps)

Hex Nut, 1/2-20


Lubrication Fitting, 1/8 NPT


Lock Washer, 1/2 in.


Bearing Housing

Gasket

Bearing Spacer

Ball Bearing


CAUTION


Oil Seal Housing


End Yoke with U-bolts


Hex Hd Screw,

1/2-20 x 1-3/4 in.


IL1233

Hex Hd Screw, 3/8-16 x 1 in.

*Cotter Pin, 1/8 x 1-3/4”

(*Before 4/20/98)



*Castle Nut

**Self-Locking Nut (Torque to 275-325 LB-FT)

Do not reuse. Apply lubricating oil to the threads before moving. Apply anti-seize to the threads before installing a new self-locking nut.

(**After 4/20/98)

Page 25 of 61

Seal Housing Removal / Installation

(Pumps with Mechanical Seals)

Seal Chamber Cover

O-ring, 3 x 3-1/4 in.

Throttle Bushing (Iron Pumps Only)

Mechanical Seal

Throttle Bushing (Iron Pumps Only)

Seal Housing

Mechanical Seal

Stationary Ring


O-ring

Seal Housing Gasket

Seal Housing

Gasket

(6) Hex Hd or Socket Hd Screws, 1/4-20 x 1 in. (After 1993)

(4) Socket Hd Screws (Prior to 1993)

(4) Lock Washers (Prior to 1988)

(4) Plain Washers (Used 1988-1993)

Dowel Pin, 1/4 x 1/2 in.

Impeller Shaft


IL 1224/1283

Page 26 of 61

Seal Housing Removal / Installation

(Pumps with Packing)

Flat Brass Washer, 5/16 in.

Stud, 5/16-18 x 1-5/8 in.

Gland

Unbalanced Nut, 5/16-18

NOTE: Remove gland before removing seal housing from impeller shaft.

NOTE: Install lantern ring, packing, gland, studs, washers and nuts in seal housing before installing on shaft (See Page 40).

Lantern Ring


Seal Housing


*

Braided Flexible Graphite Packing (BFG)

11/32 in. thick

*

Be sure to stagger joints 90_.

Coat the inside of the seal housing with Never-Seezr or equivalent.

Dowel Pin,

1/4 x 1/2 in.

Impeller Shaft


IL1220

Page 27 of 61

Impeller Removal

Wear Ring

Lock Ring

Impeller

Retaining Ring

Impeller Shaft

1.

Remove wear rings and retaining rings.

2.

Press impellers toward shaft center and remove lock rings.

Square Key,

5/16 x 1-3/8 in.

CAUTION

Lock ring halfs are a matched set. Do not mix.

3.

Remove impellers and keys.

4.

Remove interstage seal.

Retaining Ring

Retaining Ring Removal Tool

Part No. 62917

IL1198

Interstage Seal

Retaining Ring

Impeller

Lock Ring

Wear Ring

IL1221


Interstage Seal and Seal Housing and Cooling Line Check

(Mechanical Seal)

These parts seldom need replacing if handled properly during disassembly and reassembly.

Interstage Seal - If the total clearance between the interstage seal and the impeller shaft is greater than 0.015 in., the interstage seal should be replaced.

Seal Housing

Seal Housing - If the total clearance between the seal housing and the im peller shaft is greater than 0.020 in., the seal housing should be replaced.

Check both seal housings.

Cooling Lines - Ensure that cooling lines are not plugged and are free of debris. A flexible tool must be used in cleaning out cooling lines due to offset in seal housing hole.

Interstage Seal

Seal Housing

Impeller Shaft


Hose Assembly

IL1310

Page 29 of 61

Interstage Seal and Seal Housing and Cooling Line Check

(Packing)

These parts seldom need replacing if handled properly during disassembly and reassembly.

Interstage Seal - If the total clearance between the interstage seal and the impeller shaft is greater than 0.015 in., the interstage seal should be replaced.

Packing Housing

Seal Housing - If the total clearance between the seal housing and the im peller shaft is greater than 0.020 in., the seal housing should be replaced.

Check both seal housings.

Cooling Lines - Ensure that cooling lines are not plugged and are free of debris. A flexible tool must be used in cleaning out cooling lines due to offset in seal housing hole.

Interstage Seal

Packing Housing

Impeller Shaft


Hose Assembly

IL1311

Page 30 of 61

Install Undersize Wear Rings

1.

Check wear rings and impeller hubs for deep grooves or scratches.

2.

If inspections shows that the wear ring clearances are excessive

(diametral clearance in excess of .025 inches), or if the impeller hubs are scored or grooved, use the dimensions in the tables to rework the hubs.

3.

The diametral clearance is determined by averaging the results of four measurements taken at 90

_ increments as follows: a.

Clean and remove small burrs and other protrusions from the wear ring inner diameters and the impeller hubs.

b.

Position each wear ring on the impeller hub on which it was used.

c.

Hold the wear ring firmly against one side of the hub and measure total clearance on the opposite side using a feeler gauge.

4.

Flame plated impeller hub wear ring clearance is usually restored by installing a replacement wear ring with the same dimensions as the original wear ring since most wear occurs on the wear ring, not the impeller hub. Flame plated impellers are the numbers with the

``T'' suffix.

5.

Non-plated impeller hub wear ring clearance is restored by turning impeller hubs and installing undersize wear rings.

6.

Wear rings are available 0.025, 0.050 or 0.075 inches undersize.

The tables give the original hub dimension for each impeller and the rework dimensions for each degree of undersize.

IMPELLERS

71537/71538 or

71537-T/71538-T

1-1/8 in.

Rework Depth

4-3/8

Eye Dia

Hub Dia

See Table

IL1273

Original Hub Dia

Non-plated 5.500 (Min)

Flame Plated 5.494 (Min)

Original

Wear Ring No.

72472

Reworked

Hub Dia

5.476/5.473

5.451/5.448

5.426/5.423

New Wear

Ring No.

72472-25

72472-50

72472-75


Install Undersize Wear Rings - Continued

IMPELLERS

71796/71797 or

71796-T/71797-T

1-3/16 in.

Rework Depth

IMPELLERS

71649-T/71650-T

1.250

Rework Depth

.719

Rework Depth

5

Eye Dia

Hub Dia

See Table

A

Dia

B

Dia

Original Hub Dia

Non-plated 5.498 (Min)

Flame Plated 5.494 (Min)

Original Wear

Ring No.

72403

Reworked

Hub Dia

5.476/5.473

5.451/5.448

5.426/5.423

New Wear

Ring No.

72403-25

72403-50

72403-75

IL1292

Original

Min. Hub Dia

Original Wear

Ring No.

A - 6.368

B - 6.426

72407

Reworked

Hub Dia A

6.350/6.348

6.325/6.323

6.300/6.298

Reworked

Hub Dia B

6.407/6.405

6.382/6.380

6.357/6.355

New Wear

Ring No.

72407-25

72407-50

72407-75


Impeller Shaft

Impeller / Wear Ring Installation

Interstage Seal

Second Stage Impeller

First Stage Impeller

Wear Ring

Wear Ring

Lock Ring

Lock Ring

Square Key

1.

Press one impeller over square key on shaft far enough to allow the installation of lock ring.

2.

Install lock ring and press impeller back over the lock ring.

NOTE: Be sure of impeller is correct. See page 31 for

impeller rotation.

CAUTION

Lock ring halfs are a matched set. Do not mix.

3.

Install retaining ring, see page 31 for installation tool.

4.

Install interstage seal.

5.

Repeat process for other impeller.

6.

Install wear rings.


Retaining Rings

Square Key

IL1275

Page 33 of 61

Impeller / Wear Ring Installation Continued

Apply a dab of grease to tool to hold retaining ring in place.

Retaining Ring Installation Tool

Part Number 62918

IL1998

ROTATION

Stripping Edge

Pump Body (Volute)

Eye of Impeller (Intake)

Impeller Vanes

Discharge

IL1150


Installing Impeller Shaft Assembly into Pump

(Transmission Mounted Directly to the Rear of the Pump and Rear Driven Direct Drive Pumps)


IL1274

Clean body grooves and bores thoroughly.

Coat seal housings and areas of the body and cover where seal housings are located with Never-Seezr or equivalent.

NOTE: After reassembling pump, performance test per NFPA 1911, before the truck is placed back in service.

Make sure dowel pin is seated in volute cover.

Apply a pea sized drop of

100% silicone RTV sealant at each of the gasket and

O-ring intersection locations

(4 per seal housing). Apply silicone prior to gasket installation.

Make sure gasket fits tight againt seal housing.

Page 35 of 61

Installing Impeller Shaft Assembly into Pump

(Transmission Mounted Directly to the Front of the Pump and Front Driven Direct Drive Pumps)


IL1274

Clean body grooves and bores thoroughly.

Coat seal housings and areas of the body and cover where seal housings are located with Never-Seezr or equivalent.

NOTE: After reassembling pump, performance test per NFPA 1911, before the truck is placed back in service.

Make sure dowel pin is seated in volute cover.

Apply a pea sized drop of

100% silicone RTV sealant at each of the gasket and

O-ring intersection locations

(4 per seal housing). Apply silicone prior to gasket installation.

Make sure gasket fits tight againt seal housing.

Page 36 of 61

Ref No.

B17

B21

B30

B91

B110

B130

B131

Description

Socket Hd, 5/8-11 x 3-1/4 in.

Hex Hd, 1/2-13 x 1 in.

Dowel Pin, 7/16 x 1-1/4 in.

Socket Hd, 1/2-13 x 4-3/4

Socket Hd, 1/2-13 x 1-1/2 in.

Socket Hd, 1/2-13 x 1-1/2 in.

Socket Hd, 1/2-13 x 3-1/2 in.

Qty Torque

2

7

4

3

1

20

2

105LB/FT

105LB/FT

Installing Body Hardware


Note: Bearing housing and impeller shaft for a transmission mounted to the rear of the pump shown

Page 37 of 61

Mechanical Seal Removal

(Without Disassembling the Pump)

1.

Replacing the mechanical seal will be easier when using the special tools designed by Waterous Company. These tools may be purchased from Waterous Company or fabricated by the user.

K956

K628

Outboard bearing removal/installation tools

Mechanical seal removal/installation tools

Parts of Kit K

628

Mechanical Seal Removal / Installation Tools

Remove Spacer, it is Used on CM

Models Only

REMOVAL TOOL

P/N 72385

TOOL PROTECTION SLEEVE/INSTALLATION TOOL

(Use as a cover to protect removal tool threads when not in use)

P/N 62896 PART OF 72385

IMPELLER SHAFT BRUSH

P/N V 2633

INSTALLATION

SLEEVE

P/N 52280

2.

Whenever a mechanical seal requires replacement, the Waterous Service Department strongly recommends replacing both seals; out board bearing and drive end. NOTE: Always replace the outboard seal and bearing assembly first.


Remove Seal Chamber

Cover Gasket and Discard

Remove Stationary

Ring and Discard


IL3149



Mechanical Seal

(See next page for removal)

O-ring (After 1993)

Square Gasket (Prior to 1993)


Brush (P/N V 2633)

(6) Hex Hd or Socket Hd Screws, 1/4-20 x 1 in. (After 1993)

(4) Socket Hd Screws (Prior to 1993)

(4) Lock Washers (Prior to 1988)

(4) Plain Washers (Used from 1988 to 1993)

IL1276

Remove Throttle Bushing and Discard (Iron Pumps Only,

Not Used on Bronze Pumps)

3.

Clean the impeller shaft, using the impeller shaft brush (P/N V2633)/.

4.

Remove the screws (and washers if applicable) that attach the seal chamber cover to the seal housing and remove the cover.

5.

Clean the impeller shaft again to remove any debris that may remain.

6.

Remove the stationary ring from the seal chamber cover by clamping the protruding diameter of the stationary ring in a vise, then pulling the seal chamber cover away from the vise.

7.

Remove throttle bushing and discard.

8.

Discard the O-ring from seal chamber cover. Clean seal chamber cov er.

Page 39 of 61



Remove Spacer

Before Using

Remove

Spacer Before

Using

IL1376

9. Attach the mechanical seal removal tool to the pump body using two of the mounting holes in the body and the screws and nuts from the bear ing housing. The plate must be flush with the pump body, but tighten screws hand-tight only.

10. Turn the hex head on the removal tool clockwise until it touches seal, then 1 inch to 1-1/4 inch further (the primary ring in the mechanical seal may break from the force).

11. Turn the hex head on the removal tool counterclockwise to remove the seal.

12. Remove the tool and the seal.

13. Remove spring retainer and spring if they do not come out with the seal. Clean seal chamber and impeller shaft.

14. Clean the sealing surface behind the seal chamber cover on the seal housing.

CAUTION

Remove spacer between removal tool and mounting plate before using. The spacer is used on two-stage CM models.


Mechanical Seal Installation - Continued

CAUTION

The entire mechanical seal installation procedure shall be completed without interruption. Delays may cause seal bellows to seat improperly.

Whenever a mechanical seal requires replacement, the Waterous Service Department strongly recommends replacing both seals; outboard bearing and drive end.

Note: Always replace the seal and bearing on outboard end first.

1.

Inspect the new primary ring and stationary ring sealing surfaces. These sur faces should be “mirror smooth” and without scratches. To identify the sta tionary ring sealing surface examine the outside diameter of the ring. There is a chamfer towards the backside and the o-ring is close to the back.

spring retainer makes contact with shaft shoulder. Continue pushing the seal until the spring is fully compressed. Remove the installation tool slowly allowing the spring to relax. Remove the protection sleeve from the shaft (outboard end only).

CAUTION

Try not to touch the “mirror smooth” surfaces. If surfaces are touched clean surface with denatured alcohol and a soft cloth.

CAUTION

Do not get lubricant on the sealing surfaces on the stationary ring or primary ring. If surfaces get lubricant on them clean with a soft cloth and denatured alcohol.

CAUTION

The mechanical seal primary and stationary rings are made of brittle material. The material can be cracked or chipped. Extra care must be taken when handling these rings.

2.

Sub-Assemble seal chamber cover. See Figure 1. Install a new throttle bushing in the seal chamber cover. (A throttle bushing is not used on bronze pumps.) Install new stationary ring with new O-ring in the seal chamber cov er, the mirror smooth seal surface should be visible, the chamfered O.D.

edge should seat on the throttle bushing. Install new seal chamber cover

O-ring gasket in the seal chamber cover.

CAUTION

The throttle bushing must be seated peroperly to avoid misalignment of the mating surfaces of the mechanical seal.

3.

Install seals. See Figures 2 and 3.

a.

On the outboard end of the pump, install the installation sleeve on the shaft which will allow the seal to slip over the shaft shoulder. Failure to use the installation sleeve may cause damage to the seal. Liberally coat shaft and sleeve with lubricant (supplied with kit) before installing the mechani cal seal.

b.

Place spring retainer and spring on the shaft. Coat inside of mechanical seal bellows with lubricant and push seal on with installation tool until the

Note: If Waterous Mechanical Seal Lubricant part no. 52608 is not available, P80 rubber lubricant, straight dish soap or glycerin may be substituted.

4.

Install seal chamber cover. See Figure 4.

a.

Be sure the stationary ring, O-ring, throttle bushing and O-ring gasket are installed in seal chamber cover (See Step 2).

b.

Install the seal chamber cover on the shaft and slowly push on with installation tool. The seal chamber cover will guide the mechanical seal into place. When the cover contacts the pump body, attach with the screws previously removed during disassembly.

Note: Before proceeding, both replacement seals (outboard and drive end) and the outboard bearing should be installed. As recommended earlier, both seals should be replaced at the same time. Outboard end seal and bearing assembly should be completed first.

5.

Turn impeller shaft by hand at least two revolutions in both a clockwise and counterclockwise direction to seat seals.

6.

Hydrostatically test pump at 150 P.S.I.G. Observe impeller shaft at throttle bushing and intersection of the seal chamber cover with pump body split line for leaks. Turn impeller shaft by hand while retaining the hydrostatic pres sure to see if there is leakage between the throttle bushing and impeller shaft. If leakage persists, after one or two minutes of rotation (10 to 12 turns) disassemble and inspect.


Figure 1. Seal Chamber Cover Sub-Assembly

1. Install new throttle bushing (iron Pumps Only)

2. Install new seal stationary ring.

3. Install new gasket or O-ring.

Mechanical Seal Installation - Continued

Throttle Bushing

Figure 3. Transmission End Seal Installation

Mechanical Seal consists of:

- Spring Retainer

- Spring

- Bellows

- Seal (primary ring)

Nose End

Stationary Ring

Gasket or O-ring

IL1276

Figure 2. Outboard Bearing End Seal Installation

Shaft Shoulder

Installation Sleeve

IL3148

Installation Tool

Figure 4. Seal Chamber Cover Installation

O-ring Gasket

(After 1993)

Square Gasket

(Prior to 1993)

Blunt End

Seal Chamber Cover

Mounting Screws

(6) used after 1993

(4) used Prior to 1993

IL1384

Installation Tool

(Use the end with the machined nose to push seal).


IL1914

Installation Tool

(Use the blunt end of tool to push the cover.)

Page 42 of 61

Packing - Braided Flexible Graphite (BFG)

Waterous uses a braided graphite fiber, with reinforced flexible graphite yarns and high purity graphite filament yarns that appear on the corners as well as throughout the body of the packing. The graphite reinforcement allows the flexible graphite yarns to provide greater tensile strength.

This type of packing reduces the frictional heat created between the shaft and the I.D. of the packing. By dissipating the heat through the cross section of the packing, the heat is transferred to the packing gland and the seal housing.

Packing Removal

!

WARNING

Truck movement hazard.

May cause serious personal injury.

Stop engine, set the parking brake and chock the wheels before going under truck to remove packing.

1.

Remove the unbalanced nuts, flat washers and packing gland halves from one end of the pump.

2.

Engage the pump per appropriate operating instructions. Operate the pump gradually increasing the discharge pressure until the packing is forced out of the seal housing. Pressure in excess of 300 psi (20.7 bar) may be required.

CAUTION

Pump overheating hazard.

May cause damage to the pump.

Circulate enough water through the pump to prevent overheating. Do not pressurize the pump over the rated maximum discharge pressure of the pump.

!

WARNING


Heat is dissipated through the cross-section of the packing, transferring the heat to the packing gland and pump body.

3.

If all the packing is not forced out, it may be necessary to remove the re maining packing by hand, using a pick or similar device. Waterous has a packing removal tool (P/N 5782) available for this purpose.

4.

Replace packing per instructions below, repeating the procedure for the opposite end of the pump.

Packing Removal

Tool

IL1931


Packing Installation

1.

Before installing the new packing, be sure that all of the old packing is re moved from the seal housing.

2.

Be sure that the seal housing and the shaft are clean and free of any packing residue.

3.

Lightly lubricate the packing ring I.D. and O.D. with mineral oil, automotive grease or engine oil for installation purposes.

4.

Make sure packing is clean.

5.

Carefully install one ring of packing. With the aid of packing glands, push the packing into the seal housing as far as possible. Repeat this operation with each ring, staggering the joints at least 90

_ apart. Install the packing rings until the top of the last ring is about 1/4 inch from the end of the seal housing (at least 1/8 inch is required for the packing gland nose entrance into the stuffing box).

NOTE: Be sure that the packing joints are staggered at least 90

_

apart.

6.

Install packing glands, nuts and washers. Tighten gland nuts one flat be yond finger tight.

NOTE: The milled slot on the nut should face the gland.

Packing Gland Installa tion

Packing Adjustment

The pump packing is designed and adjusted to drip slightly during operation.

This is to cool and lubricate the packing. It is desirable to adjust the stuffing box to maintain a leakage rate of 10 to 120 drops per minute when operating at a discharge pressure of 150 psi (10.3 bar).

Leakage through the braided flexible graphite (BFG) packing may be at zero or diminish to zero leakage and may not respond to loosening of the packing nuts to restore leakage, see Adjustment Step 3. While the packing gland and stuffing box and pump body may reach high temperatures during this time, the impeller shaft will be protected from heat damage.

CAUTION

Pump overheating hazard.

May cause damage to the pump.

Circulate enough water through the pump to prevent overheating.

!

WARNING

Truck movement hazard.

May cause serious personal injury.

Stop engine, set the parking brake and chock the wheels before going under truck to adjust packing.

1.

Engage pump per appropriate operating instructions. Operate the pump at the capacity pressure shown on the serial plate for ten (10) minutes.

CAUTION

Observe the stuffing box drip rate from the side of the truck.

2.

Observe leakage. Normal leakage is 10-120 drops per minute.

!

WARNING


Heat is dissipated through the cross-section of the packing, transfer ring the heat to the packing gland and pump body.

7.

Adjust packing as required per instructions on the next page.


3.

If drip rate is considered high, stop the engine and tighten the packing gland nuts 1/2 to 1 flat (maximum of 1/6 of a revolution). Make appropriate adjustments starting with 1 flat, when approaching the final adjustment reduce to 1/2 flat. This reduces the possibility of over tightening. Tighten

the gland nuts equally to ensure that the packing gland goes on

straight. Gradually reducing leakage during the first hour of operation will result in a better seal over a longer period of time. Adjust the drip rate on one stuffing box until the appropriate rate is obtained, then proceed to the other end of the pump.

CAUTION

Stopping the leakage entirely at this point will cause the packing to overheat.

4.

Operate the pump at the capacity pressure shown on the serial plate for two (2) minutes to let packing run in, then observe the drip rate.

5.

Repeat steps 3 and 4 until the drop rate is acceptable.

NOTE: After adjusting the packing, the pump must pass the following vacuum test described below.

Vacuum Test

1.

Remove all caps except openings without valves. Close all discharge, in take and drain valves and other similar openings. Operate priming device to create a vacuum of about 22 in. Hg/.735 atmosphere in pump, then stop primer and engine.

2.

Watch the pressure gauge; if vacuum drops more than 10 in. Hg/.334 at mospheres in five (5) minutes, listen for air leaks around the packing gland, gaskets, valves, etc.

3.

Replace gaskets, re-adjust packing, repack or otherwise repair source of trouble.

4.

Repeat test.


Rotary Style - Bottom Mounted Manual Transfer Valve Actuator Removal/Installation (After 2000)

1.

If possible, rotate the transfer valve to the

VOLUME position before removal.

2.

Remove manual assembly by removing spirol pin, 1/8 x 3/4, from U-joint. Then slide entire assembly out from gear case shaft.

3.

Remove transfer valve actuator assembly by removing hex socket head screws,

5/16-18 x 5/8 and (3) lock washers, 5/16.

4.

Extension shaft may come loose from transfer valve actuator. Make sure key,

3/16 x 1-1/4, is in place when reinstalling extension shaft. This will ensure proper alignment.

5.

For repair of the transfer valve actuator subassembly, refer to form F-1031, Sec tion 2315, Transfer Valve Actuator Over

haul Instructions.

6.

When reinstalling transfer valve actuator, make sure extension shaft is turned to the volume position. To find out if actuator is in the volume position, check under mounting bracket for a stamped arrow with the letter “V” for volume. The arrow indicates the direction in which the exten sion shaft must be fully rotated to be in volume position. Turn opposite way to be in pressure position. Pump mode should also be in volume position to ensure that extension shaft and groove pin from transfer valve ball will properly align when reinstalling actuator to pump. Use align ment marks as shown on attached page,

“Bottom View of Transfer Valve Ball in

Volume Position.”

NOTE: The gear case shaft must be used to turn the extension shaft.

Encoder Ground

Wire Location

Prior to 1/7/08

Mounting Bracket

Stamped Arrow

(Under Mounting Bracket)

Key, 3/16 x 1-1/4

Gear Case

Shaft

Encoder Ground

Wire Location

After 1/7/08

Lock Washer, 5/16

Socket Head Screw

5/16-18 x 5/8

Spirol Pin,

1/8 x 3/4

U-joint

Extension Shaft

Groove Pin

IL1971


Rotary Style - Bottom Mounted Electric Transfer Valve Actuator Removal/Installation (After 2000)

1.



2.

If transfer valve actuator is equipped with optional manual override, remove this first by removing spirol pin, 1/8 x 3/4, from

U-joint. Then slide entire assembly out from gear motor shaft.

3.

Remove transfer valve actuator assembly by removing socket head screws, 5/16-18 x 5/8 and (3) lock washers, 5/16 and (3) lock washers, 5/16.

4.

Extension shaft may come loose from transfer valve actuator. Make sure key,

3/16 x 1-1/4 (3/16 x 3/4 on actuators built prior to 4/21/06), is in place when reinstal ling extension shaft. This will insure proper alignment.

5.

For repair of the transfer valve actuator subassembly, refer to form F-1031, Sec tion 2315, Transfer Valve Overhaul

Instructions.

6.

When reinstalling transfer valve actuator, make sure extension shaft is turned to the volume position. To find out if actuator is in the volume position, check under mounting bracket for a stamped arrow with the letter “V” for volume. The arrow indi cates the direction in which the extension shaft must be fully rotated to be in volume position. Turn opposite way to be in pres sure position. Pump mode should also be in volume position to ensure that exten sion shaft and groove pin from transfer valve ball will properly align when reinstal ling actuator to pump. Use alignment marks as shown on attached page, “Bot tom View of Transfer Valve Ball in Volume

Position.”

NOTE: The gear motor shaft must be used to turn the extension shaft.

Encoder Ground

Wire Location

Prior to 1/7/08

Stamped Arrow


Key, 3/16 x 1-1/4

Encoder Ground

Wire Location

After 1/7/08

Lock Washer, 5/16


5/16-18 x 5/8

Spirol Pin,

1/8 x 3/4

U-joint

Gear Motor

Shaft


Extension Shaft

Groove Pin

IL1972


Rotary Style - Top Mounted Manual Transfer Valve Actuator Removal/Installation (After 2000)

Hex Head Screw

3/8-16 x 5/8

Lock Washer, 3/8


5/16-18 x 5/8



Spirol Pin, 1/8 x 3/4

U-joint

Extension Shaft

IL1973

Gear Case Shaft

Stamped Arrow


Key, 3/16 x 1-1/4

1.



2.

Remove manual assembly by removing spi rol pin, 1/8 x 3/4, from U-joint. Then slide entire assembly out from gear case shaft.

3.

Remove transfer valve actuator assembly by removing (1) hex head screw, 3/8-16 x 5/8,

(2) socket head screws, 5/16-18 x 5/8 and

(3) lock washers, 3/8.

4.

Extension shaft may come loose from trans fer valve actuator. Make sure key, 3/16 x

1-1/4, is in place when reinstalling extension shaft. This will ensure proper alignment.

5.

For repair of the transfer valve actuator sub assembly, refer to form F-1031, Section

2315, Transfer Valve Overhaul Instructions.

6.

When reinstalling transfer valve actuator, make sure extension shaft is turned to the volume position. To find out if actuator is in the volume position, check under mounting bracket for a stamped arrow with the letter

“V” for volume. The arrow indicates the di rection in which the extension shaft must be fully rotated to be in volume position. Turn opposite way to be in pressure position.

Pump mode should also be in volume posi tion to ensure that extension shaft and groove pin from transfer valve ball will prop erly align when reinstalling actuator to pump. Use alignment marks as shown on attached page, “Bottom View of Transfer

Valve Ball in Volume Position.”

NOTE: The gear case shaft must be used to turn the extension shaft.


Rotary Style - Top Mounted Electric Transfer Valve Actuator Removal/Installation (After 2000)

Hex Head Screw

3/8-16 x 5/8



5/16-18 x 5/8



Spirol Pin, 1/8 x 3/4

U-joint

Extension Shaft

IL1974

Gear Motor Shaft

Stamped Arrow


Key, 3/16 x 1-1/4

1.



2.

If transfer valve actuator is equipped with optional manual override, remove this first by removing spirol pin, 1/8 x 3/4, from Ujoint. Then slide entire assembly out from gear motor shaft.

3.

Remove transfer valve actuator assembly by removing (1) hex head screw, 3/8-16 x 5/8,

(2) hex socket head screws, 3/8-16 x 5/8 and (3) lock washers, 3/8.

4.

Extension shaft may come loose from trans fer valve actuator. Make sure key, 3/16 x

1-1/4, is in place when reinstalling extension shaft. This will ensure proper alignment.

5.

For repair of the transfer valve actuator sub assembly, refer to form F-1031, Section

2315, Transfer Valve Overhaul Instructions.

6.

When reinstalling transfer valve actuator, make sure extension shaft is turned to the volume position. To find out if actuator is in the volume position, check under mounting bracket for a stamped arrow with the letter

“V” for volume. The arrow indicates the di rection in which the extension shaft must be fully rotated to be in volume position. Turn opposite way to be in pressure position.

Pump mode should also be in volume posi tion to ensure that extension shaft and groove pin from transfer valve ball will prop erly align when reinstalling actuator to pump. Use alignment marks as shown on attached page, “Bottom View of Transfer

Valve Ball in Volume Position.”

NOTE: The gear motor shaft must be used to turn the extension shaft.



Transfer Valve Removal/Replacement for Rotary Style Actuator (After 2000)

IL1975

Socket Head Screw,

5/16-18 x 3/4 (4)

Hex Head Screw,

1/2-13 x 1 (3)

NOTE: The transfer valve only needs to be re moved and disassembled if it needs to be re paired.

There is repair kit available for replacing the seals in the transfer valve.

1.

Remove the (3) hex head screws, 1/2-13 x 1 that attach the transfer valve cover to the pump body. Do not remove the (4) socket head screws, 5/16-18 x 3/4 until the transfer valve has been removed from the pump assembly.

2.

Use jacking screw holes to remove cover/trans fer valve assembly from the body assembly.

Transfer Valve Cover


Page 50 of 61

Transfer Valve Removal / Installation for Rotary Style Actuator (After 2000)

NOTE: The transfer valve only needs to be removed and disassembled if it needs to be repaired or updated.

O-ring, 1-5/8 x 1-7/8

Stem Bushing

(Can Be Removed With

Punch From Top Of Body)

O-ring, 1-1/8 x 1-3/8

Groove Pin, 5/16 x 1-1/4

Wave Spring

Transfer Valve Housing

Transfer Valve Seal

O-ring, 3-1/8 x 3-1/2

Socket Hd Screw,

5/16-18 x 3/4


Dowel Pin, 1/4 x 3/4

Transfer Valve Ball, Rotary Actuator

Groove Pin, 5/16 x 1-1/4

O-ring, 1-1/8 x 1-3/8

Stem Bushing

O-ring, 1-5/8 x 1-7/8

O-ring, 5 x 5-1/4

Gasket

Transfer Valve Cover, Rotary Actuator

Hex Head Screw,

1/2-13 x 1

IL1976


View Of Assembled Transfer Valve without Transfer Valve Cover for Rotary Style Actuator (After 2000)



Mounting Side

IL1977

When reassembling transfer valve, make sure cast stops on transfer valve ball are located on transfer valve cover mounting side. This will ensure that transfer valve ball is not assembled upside down.

Page 52 of 61

Bottom View Transfer Valve in Volume Position for Rotary Style Actuator (After 2000)


Assemble transfer valve ball in the Volume

Position as shown. Stamped arrows with the letter “V” on the transfer ball and transfer valve cover must be aligned to be in Volume Position. This is to ensure that the transfer valve ball is in alignment with the extension shaft when reinstalling the transfer valve actuator to pump.

IL2072

Page 53 of 61

Reciprocating Actuator Removal/Installation - Bottom Mounted Manual Transfer Valve (Prior to 2000)


Hex Nut, 3/8-24

Spring Housing

Spring

Ball Joint, 3/8-24

Flat Washer, 1/2 in.

Control Arm Assembly

Pivot Pin

Cotter Pin, 1/8 x 1 in.

Roll Pin, 1/8 x 11/16 in.

Clevis Pin, 1/4 x 1-1/4 in.

1.

Remove control arm assembly by re moving ball joint, 1/8 x 1 in. cotter pin and flat washer. Be careful not to lose spring when removing arm.

2.

Check to make sure sector gear and transfer valve stem are marked to aid in proper reassembly.

3.

Remove sector gear by driving out 1/4 x 1-3/4 in. groove pin.

Cotter Pin, 3/32 x 1/2 in.

Sector Gear

Groove Pin,

1/4 x 1-3/4 in.

IL1301


Reciprocating Actuator Removal/Installation - Bottom Mounted Electric Transfer Valve (Prior to 2000)

Plain Washer, 3/8 in.

Cotter Pin, 1/8x 1 in.

Actuator Assembly

Valve Operating Arm

Pivot Pin

Plain Washer, 5/8 in.

Sector Gear

Groove Pin,

1/4 x 1-3/4 in.

Switch Seals

1.

Disconnect actuator assembly from operating arm by removing 3/32 x 3/4 in. cotter pin and

3/8 in. plain washer.

2.

Swing aside the actuator. It may be neces sary to remove the override from the end of the actuator, (if so equipped) by removing 1/4 x 1-1/8 in. roll pin and universal joint.

3.

Remove operating arm from the transfer valve cover by removing 1/8 x 1 in. cotter pin and 5/8 in. plain washers.

4.

Check to make sure sector gear and transfer valve stem are marked to aid in proper reas sembly.

5.

Remove sector gear by driving out 1/4 x

1-3/4 in. groove pin.

6.

Remove switch seal and disconnect switch assembly.


Roll Pin,

1/4 x 1-1/8 in.


Universal Joint

IL1302

Page 55 of 61

Reciprocating Actuator Removal/Installation - Top Mounted Manual Transfer Valve (Prior to 2000)


Sector Gear

Cotter Pin, 1/8x 1 in.

Hex Hd Screw,

3/8-16 x 1-1/4 in.

Plate Assembly

Control Arm Assembly

Ball Joint


Hex Nut, 3/8-24

Groove Pin, 1/4 x 1-3/4 in.

Clevis Pin, 1/4 x 1-1/4 in.

1.

Remove control arm assembly by removing ball joint and 1/8 x 1 in. cotter pin and flat washer. Be careful not to lose spring when removing arm assembly.

2.

Check to make sure sector gear and exten sion shaft are marked to aid in proper reas sembly.

3.

Remove 1/4 x 1-3/4 groove pin and sector gear from extension shaft.


Spring

Spring Housing

Extension Shaft

IL1299


Reciprocating Actuator Removal/Installation - Top Mounted Electric Transfer Valve (Prior to 2000)

See Next Page for Installation

Flat Washer,

1/2 in.

Hex Hd Screw,

5/16-18 x 2 in.


Roll Pin,

1/4 x 1-1/8 in.

Hex Hd Screw,

3/8-16 x 1-1/4 in.

Plate Assembly

Actuator Assembly

Universal Joint

Valve Operating Arm Assembly


Hex Jam Nut, 5/16-18

Groove Pin,

1/4 x 1-3/4 in.

Sector Gear

Hex Hd Screw,

3/8-16 x 1-1/2 in.

1.

Disconnect actuator assembly from operating arm by removing 5/16-18 hex jam nut, 2 flat washers and

5/16-18 x 2 in. hex hd screw.

Switch

Assembly

2.

Swing aside the actuator. It may be necessary to remove the override from the end of the actuator, (if so equipped) by removing the 1/4 x

1-1/8 in roll pin and universal joint.

Switch Seal

Cotter Pin, 1/8 x 1 in.

Extension Shaft

3.

Remove operating arm by removing

1/8 x 1 in. cotter pin and 1/2 in. flat washer.

4.

Mark the sector gear and end of ex tension shaft to aid in proper reas sembly.

5.

Drive out 1/4 x 1-3/4 in. groove pin and remove sector gear.

IL1298


Continued on Next Page

Page 57 of 61

Reciprocating Actuator Installation, Top Mounted Electric Actuator (Prior to 2000) - Continued

1.

Install Grade 5 hex hd screw and washers in actuator as shown.

2.

Thread jam nut onto hex hd screw. Do not tighten. Thread only as far as needed to provide 1/32 in. clearance between brass washer and actuator.

3.

Thread hex hd screw into valve operating arm up to jam nut. Tight en jam nut against valve operating arm.

4.

Check for actuator free play. If actuator does not pivot freely on hex hd screw, remove and provde more clearance between brass washer and actuator by adjusting jam nut. Repeat steps 3 & 4.

5.

Connect motor to power supply.

6.

Connect Manual Override, if required.

IL2137


Transfer Valve Removal / Installation for Reciprocating Actuator (Prior to 2000)

NOTE: The transfer valve only needs to be removed and disassembled if it needs to be repaired.

There is a repair kit available for replacing the seals in the transfer valve.

1.

Remove the three 1/2-13 x 1 in. hex head screws that attach the transfer valve cover to the pump body. Do not remove the four 5/16-18 x 3/4 in. socket head screws.

2.

Use the two jacking screw holes to remove the transfer valve from the pump body.

See page 49 for correct orientation of sector gear and arm.

See page 50 for connecting top mounted actuator to valve operating arm.

Socket Head Screw,

5/16-18 x 3/4 in. (4)


Hex Head Screw,

1/2-13 x 1 in. (3)


Top Mounted

Transfer Valve

IL1294


Bottom Mounted

Transfer Valve


Page 59 of 61

Transfer Valve Removal / Installation for Reciprocating Actuators (Prior to 2000)

Top View of Assembled Transfer Valve

NOTE: Locate transfer valve ball stops in position shown.

IL1240


Manual Transfer Valve

IL1241

Electric Transfer Valve

IL1242

Page 60 of 61

Transfer Valve Repair for Reciprocating Actuator (Prior to 2000)

NOTE: The transfer valve only needs to be removed and disassembled if it needs to be repaired or updated.

O-ring, 1-5/8 x 1-7/8

Stem Bushing

(Can Be Removed With

Punch From Top Of Body)

O-ring, 1-1/8 x 1-3/8

Wave Spring



Transfer Valve Seal

O-ring, 3-1/8 x 3-1/2

Socket Hd Screw,

5/16-18 x 3/4


Dowel Pin, 1/4 x 3/4

Transfer Valve Ball, Reciprocating Actuator

Groove Pin, 1/4 x 1-3/4

O-ring, 1-1/8 x 1-3/8

Gasket

Stem Bushing

O-ring, 1-5/8 x 1-7/8

O-ring, 5 x 5-1/4

Dowel Pin, 1/4 x 3/4

Transfer Valve Cover, Reciprocating Actuator

Hex Head Screw,

1/2-13 x 1

IL1244

Page 61 of 61

Waterous CM, CMU Fire pump Overhaul Instructions

Assistant Bot

CM/CMU Series Overhaul Instructions

CM/CMU Series Fire Pumps

Overhaul Instructions

F-1031

4212

06/30/95

12/17/12

Table of Contents

Visit us at www.waterousco.com

Safety Information

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

Table 1: Complete Disassembly of Transmission Mounted Pumps

(For Transmissions Mounted Direcly to the Rear of the Pump)

Table 2: Complete Disassembly of Transmission Mounted Pumps

(For Transmissions Mounted Direcly to the Front of the Pump)

Table 3: Complete Disassembly of Direct Drive Pumps

Table 4: Replacement of Packing / Mechanical Seal Without Disassembly the Pump

Table 5: Removal / Replacement of Transfer Valve

Tools and Equipment

Preliminary Testing

Cleaning

Pump Bodies, Impellers and Transfer Valves

General Overhaul Information

Bearings, Gaskets, Seals and O-rings

Impeller Shafts

Installing Ball Bearings

Installing Body Gaskets

End Yoke and Companion Flange Nuts

Transmission Removal / Installation

(Transmission Mounted Directly to the Rear of the Pump)

Transmission Removal / Installation

(Transmission Mounted Directly to the Front of the Pump)

Intake Adapter Removal / Installation

Removal of Impeller Shaft Assembly

Transmissions Mounted Directly to the Rear of the Pump and Rear Driven Direct Drive Pumps

Removal of Impeller Shaft Assembly

Transmissions Mounted Directly to the Front of the Pump and Rear Driven Direct Drive Pumps

Outboard Bearing Removal / Installation - Prior to 4/21/2006

(Transmission Mounted Pumps with Mechanical Seals or Direct Drive Pumps without Tachometer with Mechanical Seals)

(Reference Pages 16, 17 and 19)

Outboard Bearing Removal / Installation - After 4/21/2006

(Transmission Mounted Pumps with Mechanical Seals)

(Reference Pages 18 and 20)

Outboard Bearing Removal / Installation (Prior to 4/21/06)

(Transmission Mounted Pumps with Packing or Direct Drive Pumps without Tachometer with Packing)

(Reference Pages 16, 17 and 19)

Outboard Bearing Removal / Installation (After 4/21/06)

(Transmission Mounted Pumps with Packing)

(Reference Pages 18 and 20)

Outboard Bearing Removal / Installation

(Direct Drive Pumps - Front Drive with Tachometer)

Outboard Bearing Removal (Prior to 4/21/2006)

CAUTION

Outboard Bearing Removal (without Lube pump, Prior to 4/21/2006)

Outboard Bearing Removal with Lube Pump (Prior to 4/21/2006)

Outboard Bearing Removal (After 4/21/2006)

CAUTION

Outboard Bearing Removal (After to 4/21/2006)

Outboard Bearing Installation (Prior to 4/21/2006)

Outboard Bearing Installation (without Lube Pump)

Prior to 4/21/2006

Outboard Bearing Installation (with Lube Pump)

Prior to 4/21/2006

Outboard Bearing Installation (After 4/21/2006)

Outboard Bearing Installation (after 4/21/2006)

End Yoke Removal/Installation on Drive End

(Front Drive with Tachometer)

End Yoke Removal / Installation on Drive End

(Front or Rear Drive without

Tachometer)

Seal Housing Removal / Installation

(Pumps with Mechanical Seals)

Seal Housing Removal / Installation

Packing Gland Installa tion