Principals of Operation - Inspection & Troubleshooting ..
3
CS Series Operation and Maintenance ...............................
12
Priming Systems Operation & Maintenance ......................
36
CS/CSU Series Overhaul Instructions ................................
42
C10 Chain Drive Transmission Overhaul Instructions ......
85
CS Series Assembly Service Parts List .............................. 120
CS Series Impeller Shaft Assemblies For Waterous
Single and Two Stage Fire Pumps ...................................... 129
Auxiliary Fittings Dimensional Drawings ........................... 144
C10 Transmission Assembly Service Parts List................ 179
Pneumatic Shift ..................................................................... 209
Vacuum Activated (VAP) Priming Valve and Piping .......... 214
Models VPO & VPOS Priming Pumps ................................. 219
Intake Fitting Dimensional Drawing .................................... 227
Discharge Fittings Dimensional Drawings ......................... 248
Fire Pumps Maintenance Chart ........................................... 258
1
1
1
Document Number
Issue Date
Rev. Date
A−884
10/91
11/98
Fire Pump Owners Manual
Important Notice − Please Read
The manuals supplied with your Waterous equipment contain:
w
Warranty Information
Warranty information contains the Conditional Warranty for Waterous Pumps.
•
Instructions
Instructions contain information on the operation, maintenance, and overhaul of your Waterous fire pump, transmission or power take−off.
•
‘‘Computer Printout’’ Service Parts Lists
‘‘Computer printout’’ service parts lists show your order, serial, assembly, and part numbers,
along with the model name and part descriptions.
•
‘‘Printed’’ Service Parts Lists
“Printed” service parts lists show exploded diagrams of a particular assembly along with part
descriptions.
These manuals pertain to the complete unit as it was shipped from Waterous. Changes made by others after shipment
may affect the applicability of the information in these manuals. Contact the apparatus manufacturer or Waterous
Company if you have questions.
The manual is divided into sections according to the major components plus accessories and options supplied with
the unit. Each section contains operation, maintenance and overhaul instructions, where applicable, plus parts illustrations and accompanying computer generated parts lists. The parts lists give the piece part numbers for all of the
piece parts used, plus the description and quantity used. The reference number, where applicable, appearing on the
parts list corresponds to the reference number on the illustration.
To find a given part number for ordering, refer to the appropriate service parts list illustration to find the part needed.
Note the reference number shown on the illustration for the part, and find that reference number in the reference number column of the computer generated list and note the complete part number for the part needed, including all letters,
numbers and dashes, as shown in the part number column.
Ordering Parts
1. Check the serial numbers listed at the top of the computer generated service parts list against the numbers on
the serial plates on the components for which the repairs are needed.
2. Check to make sure you have found the correct and complete number for all parts needed for repair.
3. Furnish all applicable serial numbers and part numbers when placing the order for repair parts.
NOTE: If parts are ordered by part number only and appropriate serial numbers are not furnished, Waterous cannot be held responsible for delays caused by incorrect parts orders.
125 Hardman Avenue South, South St. Paul, Minnesota 55075−2456 USA
Page 1
(651) 450−5000 FAX (651) 450−5090
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
1
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
0101
B 1
0102
B 4
B 5
B 6
B 7
B 8
B 10
B 11
B 12
B 13
B 14
B 15
B 16
B 17
B 18
B 19
B 20
B 21
B 26
0104
B 4
B 27
B 28
B 30
B 34
0105
B 39
B 40
B 41
0110
S 2
S 3
S 7
S 10
S 11
S 12
S 14
S 16
S 17
S 34
82790-1D
R82789-1
82790-2A
W 1008-20HT
72984
51665
52108
W 3716-4UH
W 1508-24
W 1508-64
W 1508-76
W 9006-4
W89002-B
W 6504-S
W 6506-S
W 6508-S
W 6608-B
W 6304-G
W 6004-24G
W 5014-20
K 1042
82790-3A
W 1008-20HT
82761
82762
6787
W 1012-32HT
82790-4K
62981
52946
W37108-4
81966-3P
73023
W16307-SZZ
62975
W 5008-8
82051
W 4510-162SM
W 4905-44SS
W 1008-20HT
W 4108
W 4520-137HTCA
BODY ASSY ANGLE COMPENSATED CS
BODY SUBASSY ANGLE COMP CSU (SI)
BODY ASSY CS
SCREW HEX HEAD 1/2-13 X 1-1/4 FIRE
GASKET MOLDED CS/CSU
GASKET CM56 (SI)
GASKET DISCHARGE FLANGE CM (SI)
O-RING 1 X 1-1/4 HYD (SI)
SCREW SOCKET HEAD 1/2-13 X 1-1/2 W
SCREW SOCKET HEAD 1/2-13 X 4 FIRE
SCREW SOCKET HEAD 1/2-13 X 4-3/4 CM77
SCREW DRIVE #6 X 1/4 FIRE (SI)
PLUG PIPE 1/8 HEX HEAD BRASS FIRE
PLUG PIPE 1/4 STEEL FIRE
PLUG PIPE 3/8 STEEL FIRE
PLUG PIPE 1/2 STEEL FIRE
PLUG PIPE HEADLESS 1/2 BRASS 604
TEE PIPE 1/4 CH3
NIPPLE PIPE 1/4 X 1-1/2 PB11G
PIN DOWEL .4377 X 1-1/4 FIRE (SI)
GASKET & O-RING KIT CS04
BODY ASSY CS
SCREW HEX HEAD 1/2-13 X 1-1/4 FIRE
ADAPTER INTAKE UNIVERSAL RH CM/CS
ADAPTER INTAKE UNIVERSAL LH CM/CS
GASKET INTAKE FITTING CM/CS
SCREW HEX HEAD 3/4-10 X 2 FIRE
BODY ASSY CS
VALVE CHECK CM93/CS93 (SI)
BEARING PLAIN TFE CS04
O-RING 6-3/4 X 7 TSBV
IMPELLER SHAFT ASSY CS
HOUSING BEARING CM/CS
BEARING BALL SINGLE ROW CM/CS
COVER SEAL HOUSING CM93/CS93
PIN DOWEL .2502 X 1/2 CM
SHAFT IMPELLER CS
RING RETAINING FIRE (SI)
KEY SQUARE .313 X 2-3/4 CS
SCREW HEX HEAD 1/2-13 X 1-1/4 FIRE
WASHER LOCK 1/2 FIRE
RING RETAINING CM/CS
QUANTITY
________
1
1
1
16
2
4
3
4
8
4
4
2
4
9
3
4
1
1
1
2
1
1
32
1
1
2
16
1
1
1
1
1
1
1
2
2
1
2
1
4
4
2
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
2
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
QUANTITY
________
S 37
S 39
S 65
S 66
S 74
S 75
S 76
S 95
S 96
S 99
S110
0111
S 4
S 13
0131
Q 1
Q 2
Q 3
Q 4
Q 1
Q 5
Q 8
0134
0137
0139
H 8
H 22
H 23
H 34
H 1
H 2
H 3
H 4
H 4
H 5
H 6
H 6
H 7
H 42
H 29
H 30
H 31
W 1004-16SS
W 3748-4
W 4510-150
52174
W 4500-315CA
V 3577
52993
K 1085
K 789
52507
R81955
81966-4F
81882-T
72474
82507-1F
V 3592
W 7712-G
W 1005-28CA
9339
V 3592
K 1103
K 1083
61403
61403
81871-1E
K 1086
52509
72456
9205-1
72300
62594
62922
V 2715
W20020-4
W 3728-2
52599
W 1005-12
W 4105-CA
K 1000
63334
63355
V 2795
SCREW HEX HEAD 1/4-20 X 1 CM/CS
O-RING 3 X 3-1/4 RELVAL
RING RETAINING KGC
BUSHING THROTTLE CM
RING RETAINING CM/CS
PLUG HOUSING SEAL CM/CS
SHIELD BEARING CM/CS
OUTBOARD END MECH SEAL REPL KIT CM/CS
DRIVE END MECH SEAL REPLACE KIT CM/CS
GASKET SEAL HOUSING CM/CS
HOUSING SUBASSY CM93/CS93
IMPELLER SHAFT ASSY CS
IMPELLER CSU
RING WEAR STANDARD CSU93
PRIMING VALVE ASSEMBLY VAP
FITTING TUBE COMP 3/4 TUBE X 3/4NPT FIRE
ELBOW STREET 45 DEG 3/4 GALV PRIVAL
SCREW HEX HEAD 5/16-18 X 1-3/4 FIRE (SI)
VALVE SUBASSEMBLY PRIMING VAP
FITTING TUBE COMP 3/4 TUBE X 3/4NPT FIRE
TUBE REPAIR KIT PRIMING VAP
VALVE REPAIR KIT PRIMING VAP
SCREEN INTAKE 6 ZINC FIRE
SCREEN INTAKE 6 ZINC FIRE
PNEUMATIC SHIFT ASSY PNUSFT
PUSH BUTTON SWITCH REPLACEMENT
GASKET CY
BRACKET SHIFT SWITCH PNUSFT
PNEUMATIC SHIFT SUBASSY PNUSFT
BODY PNEUMATIC SHIFT PNUSFT
END CAP PNEUMATIC SHIFT PNUSFT
PISTON PNEUMATIC SHIFT PNUSFT
RING QUAD 1-1/4X1-1/2 (SI)PNUSFT
RING QUAD 1-1/4 X 1-1/2 FIRE
O-RING 1-3/4 X 1-7/8 PNUSFT
SCREW 5/16-18X.75 W/THREAD SEAL PNUSFT
SCREW HEX HEAD 5/16-18 X 3/4 FIRE
WASHER LOCK 5/16 FIRE
PNEUMATIC SHIFT REPAIR KIT PNUSFT
PANEL ASSY CONTROL ELSHFT
PANEL ASSY CONTROL PNUSFT
VALVE AIR CONTROL 3 POSITION PNUSFT (SI)
12
2
1
2
2
1
1
1
1
4
1
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
2
1
1
1
2
1
2
2
2
4
4
4
1
1
1
1
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
3
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
H 41
H 44
H 45
0155
0156
0157
0158
0159
0165
T 52
T 53
T 69
T 93
T131
T 9
T 27
T 28
T 37
T 38
T 39
T 40
T 41
T 41
T 41
T 46
T 47
T 48
T 49
T 50
T 51
T 53
T 58
T 59
T 60
T 61
T 62
T 69
T 71
T 72
T 75
T 80
T 86
K
AIR CONTROL VALVE REPAIR KIT PNUSFT
PACKET FASTENER CONTROL PANEL (SI)
PACKET FASTENER CONTROL PANEL (SI)
OPERATORS MANUAL (CD) (SI)
PLATE SERIAL PANEL FIRE (SI)
PLATE SERIAL PUMP CM (SI)
PLATE SERIAL PUMP CM (SI)
CRATE SHIPPING STD CM/CS
TRANSMISSION ASSY C10
SCREW HEX HEAD 12-1.75 X 30MM TA
WASHER LOCK 12MM TG100
NUT HEX 12-1.75MM C100
SCREW HEX HEAD 12-1.75 X 45MM C100
PIN DOWEL .3752 X 1 FIRE
WASHER LOCK 10MM C10
BREATHER 1/2 FIRE
CASE SUBASSY C100 (SI)
PIN PIVOT 5/8X2-3/4 Y
ARM LOCKING MSGC
O-RING 1/4 X 3/8 RELVAL
SHOE SHIFTER CM (SI)
SHIM COUPLING SHAFT C100
SHIM COUPLING SHAFT C100
SHIM COUPLING SHAFT C100
SHAFT SHIFT Y
GEAR SECTOR PNUSFT
SPACER SECTOR Y
O-RING 7/8 X 1 Y
BEARING SLEEVE MSGC (SI)
PIN SPIROL HEAVY 5/16 X 1-3/8 FIRE
WASHER LOCK 12MM TG100
PLUG HEX HEAD Y
HOUSING SPRING MSGC
PIN SPIROL HEAVY 1/4 X 1-1/4 FIRE
SPRING SHIFT LOCK CM
ARM SHIFT CM68
NUT HEX 12-1.75MM C100
SCREW HEX HEAD 12-1.75 X 60MM TC10
STUD M12-1.75 X 35MM C100
SHOE SHIFT C10
FORK SHIFT C10
SCREW ADJUSTING MSGC
794
52964-2
52964-1
MANUALCD
52906
52905
52905
70877
82897-1C
Y10012-30
Y39012
Y30012
Y10012-45
W 5012-16
Y39010
V 1168
82253
62049
62557
W 3704-2
51639
52824-10
52824-5
52824-7
62184
62811
51698
W 3714-2
51694
W33010-22SM
Y39012
V 3195
50912
W33008-20SM
5066
61023-2
Y30012
Y10012-60
Y47012-35SSC
63410
73121
50915
QUANTITY
________
*
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
2
1
2
1
1
4
2
2
2
1
2
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
4
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
T 87
T112
T112
T134
T136
T154
T173
T190
T237
T238
0166
T 83
T108
T 5
T 18
T 26
T 53
T 65
T 67
T 69
T 71
T 99
T 99
T103
T240
0167
T 2
T 3
T 4
T 6
T 7
T 9
T 11
T 13
T 15
T 42
T 43
T 44
T 94
T135
T141
T182
51640
51777
53014
V 2329
Y10010-20
Y10012-35
62798
52635
W75006-28
W79005
82897-4K
V 2062
W33002-4SS
82664
51706-94
71578
Y39012
82889-5
63000-4
Y30012
Y10012-60
71647-1
71647-2
W 5016-24
Y10012-40
82897-2B
52594
W16306
72969
V 2002
51672
Y39010
82816
82417
W16212
82404
V 3160
82665
V 3181
Y10010-25
K 1043
W 3776-4
RETAINER ADJUSTING SCREW MSGC
BEARING SLEEVE Y (SI)
BEARING SLEEVE C10 (SI)
PLUG SIGHT Y
SCREW HEX HEAD 10-1.5 X 20MM TA
SCREW HEX HEAD 12-1.75 X 35MM C10
LEVER SHIFT PNUSFT
SLEEVE BEARING Y
SCREW SHLDER SOC HEAD 3/8 X 1-3/4 Y
LOCKNUT FLEX TOP 5/16-18 Y
TRANSMISSION ASSY C10
PIN SET CONNECTING Y (SI)
PIN SPIROL HEAVY 1/16 X 1/4 Y
SPROCKET DRIVE 59T Y
CHAIN 94 PITCH Y (SI)
SPROCKET DRIVEN 26T Y
WASHER LOCK 12MM TG100
CAP TRANSMISSION C10
HOSE ASSY 5.5 TC10
NUT HEX 12-1.75MM C100
SCREW HEX HEAD 12-1.75 X 60MM TC10
SPACER BROWN 0.010 Y
SPACER WHITE 0.025 Y
PIN DOWEL .5002 X 1-1/2 YB
SCREW HEX HEAD 12-1.75 X 40MM C100
TRANSMISSION ASSY C10
SPACER COUPLING SHAFT YX
BEARING BALL SINGLE ROW MSGC
COLLAR SHIFT Y (SI)
BEARING NEEDLE YB
WASHER THRUST Y
WASHER LOCK 10MM C10
HOUSING DRIVE SHAFT C10
SHAFT DRIVE C100
BEARING BALL SINGLE ROW Y (SI)
HOUSING CPLG SHAFT Y
NUT SELFLOCK 1-1/4 Y (SI)
SHAFT COUPLING 2.35 IN. Y (SI)
WASHER PLAIN 1-1/4 HT Y
SCREW HEX HEAD 10-1.5 X 25MM CP2L
GASKET & SHIM REPAIR KIT C10
O-RING 4-3/4 X 5 DIVAL
QUANTITY
________
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
8
1
1
2
2
1
1
2
6
1
1
1
1
2
1
12
1
1
3
1
2
1
2
12
1
1
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
5
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
T187
T230
T244
T245
0168
T 9
T 19
T 23
T 24
T 25
T 29
T 31
T 32
T 33
T 95
T120
T135
T138
T241
T244
T244
T246
T248
0169
0226
0240
0241
0243
0244
0246
0380
0381
0382
0999
6102
K 12
K 1
K 2
K 3
K 4
K 5
K 23
W 3956-438
52780
Y12010-25
W 3784-4
82897-3A
Y39010
V 2411
61201
51065
W16307
52925
73108
W
07
N
07
51676
72218
Y10010-25
52540
V 3416
Y12010-25
Y12010-25SS
W 4905-37
W 3752-3
V 2837
WARRANTY5
82419-1
82421-1
82420-1
82434-27
82434-19
82430-22
82433-2
82432-1
82513
82890-1A
9319
52844
V 3199
63266
R72952
RV 3203
K 971
OIL SEAL 3-1/2 X 4-3/8 YX
SPACER C100
SCREW SKT HEAD 10-1.5 X 25MM C10
O-RING 5-1/4 X 5-1/2 FIRE
TRANSMISSION ASSY C10
WASHER LOCK 10MM C10
OIL SEAL 1-7/8 X 2-3/4 Y
HOUSING OIL SEAL CM68
GASKET MSGC
BEARING BALL SINGLE ROW MSGC (SI)
SPACER CXC10
COVER BEARING C10
WASHER BEARING LOCK FIRE
NUT BEARING LOCK MSGC
SPACER BEARING Y
SHAFT DRIVEN Y
SCREW HEX HEAD 10-1.5 X 25MM CP2L
BOOT SEALING Y W K
SPRING WAVE C10
SCREW SKT HEAD 10-1.5 X 25MM C10
SCREW SKT HEAD 10-1.5 X 25MM E600
KEY SQUARE .313 X 2-5/16 CM (SI)
O-RING 3-1/4 X 3-7/16 C10
YOKE END 1710 SERIES YX
FIVE YEAR WARRANTY FIRE
ROUTE ASSEMBLE CM BODY
ROUTE ASSEMBLE CM/CS IMPELLER SHAFT
ROUTE ASSEMBLE SEPARABLE TRANS TO PUMP
ROUTE ASSEM SEPARABLE C10
ROUTE ASSEM VPB VPE HHE PRIMING PUMP
ROUTE CM/CS TESTS (NEW TEST LINE)
ROUTE CRATE CM/CS PUMP
ROUTE PAINT CM/CS PUMP
ROUTE PUMP QUEUE TIME
PRIMING PUMP ASSY 12V VPO/VPOS
PRIMER SUBASSY 12V VPO
VANE VPO (SI)
BEARING FLANGED VPO
ROTOR ASSEMBLY VPO
ADAPTER SUBASSY VPO
MOTOR SUBASSY, 12V VPO
KIT REPAIR PRIMER PUMP SOLENOID
QUANTITY
________
2
1
12
1
1
8
1
1
1
2
1
1
1
1
1
1
4
1
1
8
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
1
1
1
PP0001-1
WATEROUS COMPANY
SERVICE PARTS LIST
ORDER NO:
P120162
PAGE:
DATE:
6
3/29/07
CUSTOMER: CRIMSON FIRE
SERIAL NUMBER:
ASSY NUMBER:
8827345
CSUC10B MIDSHIP SINGLE STAGE FIRE PUMP
*********************************************
* WHEN ORDERING PARTS FURNISH SERIAL NUMBER *
*********************************************
SEQ
_______
NO.
ITEM
___________
NUMBER
D
_____________________
E S C R I P T I O N
K 6
K 7
K 8
K 9
K 10
K 21
K 22
K 24
K 23
K 13
K 14
K 15
K 16
K 17
K 18
K 19
K 28
K 20
K 29
6105
6126
6130
6151
6155
6188
6239
6256
6257
W 3710-3
W 3762-4
W 5006-12SS
W 6602
R82604
W 1504-16SS
W78004-SS
V 1371
K 971
72841
72941
Y10010-20
Y39010
W 1505-16SS
W78005-SS
K 962
73046
63331-12
52964-1
82163
72569-A
82163
72569-A
71442-22
71600-8
52042-2A
51754-A
51754-AA
O-RING 5/8 X 13/16 604
O-RING 3-7/8 X 4-1/8 FFDVAL
PIN DOWEL .1877 X .750 VPO
PLUG PIPE HEADLESS 1/8 STEEL FIRE (SI)
HOUSING SUBASSY VPO
SCREW SOCKET HEAD 1/4-20 X 1 PB18G
WASHER LOCK HI-COLLAR 1/4 VPO
CLAMP WIRE FIRE
KIT REPAIR PRIMER PUMP SOLENOID
BRACKET TOP VPO
BRACKET BOTTOM Y VPO
SCREW HEX HEAD 10-1.5 X 20MM TA
WASHER LOCK 10MM C10
SCREW SOCKET HEAD 5/16-18 X 1 PB11
WASHER LOCK HI-COLLAR, 5/16 VPO
KIT REPAIR VPO (SI)
CABLE EXTENSION ELECTRIC PRIME PRVPIP
PANEL ASSY CONTROL 12V PRVPIP
PACKET FASTENER CONTROL PANEL (SI)
FITTING INTAKE 6 CM/CS
BLIND FLANGE GROUP 4INRV
FITTING INTAKE 6 CM/CS
BLIND FLANGE GROUP 4INRV
FITTING DISCHARGE CM/CS
FITTING DISCHARGE CM/CS
BLIND FLANGE GROUP CM/CS
SPACER GROUP 1-1/16 CM/CS
SPACER GROUP 1-1/16 (2) CM/CS
QUANTITY
________
*
*
*
*
*
*
*
*
2
1
2
1
1
4
4
1
1
1
1
3
3
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Page 2
2
2
Principles of Operation
Table of Contents
Inspection & Troubleshooting
Form No.
Section
F−1031
1000
Issue Date
Rev. Date
09/19/94 02/07/07
Illustrations
1. Water Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Parallel (Volume) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Series (Pressure) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3
Page 3
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Multi−Stage Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Signs of Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parallel (Volume) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Series (Pressure) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monthly Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Test (Hydrostatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Running Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Annual Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Principals of Operation − Inspection & Troubleshooting
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450−5000
Instructions subject to change without notice.
3
All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
4
Principles of Operation
The two main parts of centrifugal pumps are the impeller(s) and volute(s). The
impeller is powered to rotate within the volute, creating centrifugal force which
hurls the water from the impeller eye outward through the impeller. The volute
is a spiral shaped flow passage surrounding the impeller, which collects the water
from the impeller and guides it to pump discharge. In operation, atmospheric or
other pressure continuously forces water through pump intake passages into the
eye and the rotating impeller forces it outward into the volute and to the pump discharge. Figure 1 shows the path a single drop of water takes through a centrifugal
pump. Pump discharge pressure and capacity can be regulated by adjusting
pump speed, transfer valve setting, discharge valve opening and nozzle size.
ROTATION
Pump Body (Volute)
Water
4
Page 4
Eye of Impeller (Intake)
Impeller Vanes
Discharge
Stripping Edge
Figure 1
Path water takes through pump body and out discharge passageway.
F−1031, Section 1000
Revised: 02/07/07
1150
Page 1 of 7
4
5
Signs of Cavitation
Multi−Stage Pumps
When variations in capacity and pressure are required beyond that which can
conveniently be obtained from a single impeller, then multi−stage series/parallel
pumps are used. These pumps have two or more impellers, each enclosed in
its own volute,which is usually part of a common body. A transfer valve at the outlet of the first stage volute directs the water either to pump discharge or to second
stage intake, depending on how the pump is being used.
1. Sudden pressure or capacity loss.
When the transfer valve is in VOLUME (parallel) position, the water enters each
impeller eye from a common intake and leaves through a common pump discharge. See figure 2. If the transfer valve is turned to PRESSURE (series) position, the first stage pumps its full volume and pressure directly to the second stage
intake, instead of to pump discharge. The second stage then pumps this same
volume of water to pump discharge, but at twice first stage pressure. With the
transfer valve in this position, first stage pressure also closes the flap valves in
the intake passageways which prevents water from bypassing back to first stage
intake. See figure 3.
Reducing pump speed or improving intake conditions will usually eliminate cavitation.
Cavitation
2. Increasing pump speed without corresponding increase in volume or pressure.
3. Excessive pump vibration.
4. A rattling sound resembling gravel going through the pump.
Overheating
Any liquid, at any temperature, forms a vapor over its surface which produces a
certain amount of pressure. This ‘‘vapor pressure” increases as the liquid temperature rises. When the vapor pressure is equal to or greater than the pressure surrounding the liquid, the liquid boils. Vapor pressure is important because of the
way it affects pump operation.
5
Page 5
If the pump runs even for a few minutes completely closed it may heat the water
enough to scald someone when the valve is opened. When operating the pump,
at least one discharge valve should be open slightly to prevent the pump from
overheating. 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.
Each pump is designed to operate within a given speed range, and under a specific set of intake conditions. Operating a pump at excessive speed, too high an intake lift, restricting the intake, or any other factor that causes the pressure on the
liquid to fall below its vapor pressure produces a condition called ‘‘cavitation”.
When this condition exists, the liquid vapor released in the low pressure regions
of the pump forms bubbles. These bubbles are carried into the high pressure sections of the impeller (underneath each vane) where they collapse with considerable force. This may cause pitting near the impeller vane tips.
F−1031, Section 1000
Revised: 02/07/07
Page 2 of 7
5
6
PARALLEL (VOLUME) OPERATION
Second−Stage Impeller
Flap Valve
6
Page 6
Driven Gear or Sprocket
Transfer valve
First−Stage Impeller
86−3−14
Intake
Pressure
Discharge
Pressure
Figure 2
Each impeller pumps half the total volume being delivered, at full discharge pressure.
The transfer valve routes water from first stage impeller directly to pump discharge.
F−1031, Section 1000
Revised: 02/07/07
Page 3 of 7
6
7
SERIES (PRESSURE) OPERATION
Second−Stage Impeller
Flap Valve
7
Page 7
Driven Gear or Sprocket
Transfer valve
First−Stage Impeller
Intake
Pressure
Intermediate
Pressure
86−3−14
Discharge
Pressure
Figure 3
Each impeller pumps all of the volume being delivered. Each impeller develops half the total pump pressure.
The transfer valve routes water from the first stage impeller to second stage intake. First stage pressure also closes the flap valve.
F−1031, Section 1000
Revised: 02/07/07
Page 4 of 7
7
8
Inspection Tests
A regular testing program offers the best means of determining the actual condition of a pump and its accessories, and permits locating problems before they
cause trouble. At a fire, it is usually difficult for the pump operator to observe the
pump closely enough to determine its true condition.
Conduct these tests either every month or annually, as outlined below:
Monthly Tests
I. Vacuum Test
Mechanical Seals − Mechanical seals should not leak. Refer to MAINTENANCE INSTRUCTIONS for the particular pump involved for mechanical
seal maintenance.
3. Transfer Valve (series/parallel pumps only) − With the pump running at idle
speed, switch valve from one position to the other several times to make sure
it operates properly. If the transfer valve is equipped with a grease fitting, lubricate it in accordance with MAINTENANCE INSTRUCTIONS for the pump involved.
4. Shift − Check shift mechanism to make sure it is working properly.
Remove all caps except openings without valves. Close all discharge, intake,
drain valves and other similar openings. Operate priming device to create a vacuum of about 22 in. Hg/.735 atmospheres in pump, then stop primer and engine.
5. Performance − Check pump speed at rated pressure and capacity.
Watch pressure gage; if vacuum drops more than 10 in. Hg/.334 atmospheres in
5 minutes, listen for air leaks around packing glands, gaskets, valves, etc.
6. Accessories − Operate all discharge and intake valves, relief valve, drain
valve and similar accessories to make sure that they all function correctly. If
any power accessories are installed, be sure to operate the overrides (if connected) to make sure they operate properly.
Replace gaskets, repack or otherwise repair source of trouble.
7. Indicating Lights − Check to make sure they are working properly.
II. Pressure Test (Hydrostatic)
Annual Tests
III. Running Test
Run pump for at least 15 minutes from draft, if possible. Drafting is best because
the pump is then more sensitive to defects than when connected to a pressurized
water source. Check the following:
1. Priming Ability − If pump does not prime readily (30 seconds for 1250 GPM
(4731 L/min) or less and 45 seconds for 1500 to 2000 GPM (5678 to 7570
L/min) pumps) stop pump and determine cause. (An additional 15 seconds
may be required if the pump is equipped with a 4 inch or larger front or rear
intake.)
2. Shaft Seal
Packing − Packing should leak a small amount to keep it cool and lubricated.
Refer to MAINTENANCE INSTRUCTIONS for the particular pump involved
for specific leakage rate and packing adjustment.
F−1031, Section 1000
1. At least once a year, test the pumper to determine if it is capable of meeting the requirements outlined in NFPA 1911, Tests of Pumps on F.D. Apparatus. Compare the pump and engine speeds observed in these tests with
those in the acceptance and other previous tests. If the speeds observed
in the latest tests are much higher, the pump probably requires some
repairs.
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Page 8
Connect pump to a hydrant or other pressurized water source. Remove all caps
except openings without valves. Close all discharge, intake, drain valves and
other similar openings. Turn on inlet valve and ‘‘crack” highest discharge valve
on pump to expel air from pump. Close discharge valve. Carefully examine pump
and accessories for leaks. Replace gaskets, tighten joints, repair valves or repack
as necessary to eliminate leaks. (See ‘‘Packing” under running tests below.)
2. Tank to Pump Check Valve − Remove the tank to pump valve and associated piping and inspect check valve for excessive wear and replace if necessary.
!
WARNING
Equipment Hazard. May cause severe injury to hands or arms.
Make sure all equipment is turned off prior to reaching into the intake fitting
to inspect the intake adapter flap valve.
3. Intake Adapter Flap Valves (Side Intakes only) − Reach inside intake fitting
and check the movement of the flap valve. Flap valves should sit securely
in the machined slots of the fitting and open and close smoothly.
Revised: 02/07/07
Page 5 of 7
8
9
Troubleshooting
CONDITION
POSSIBLE CAUSE
SUGGESTED REMEDY
Clean and tighten all intake connections. Make sure intake hoses and gaskets are in good condition.
Use the following procedure to locate air leaks:
1.
Connect intake hose to pump and attach intake cap to end of hose.
2.
Close all pump openings.
3.
Operate primer until vacuum gage indicates 22 in. Hg/.735 atmospheres. (If primer fails to draw specified vacuum, it may be defective, or leaks are too large
for primer to handle.)
4.
Shut off primer. If vacuum drops more than 10 in. Hg/.334 atmospheres in 5 minutes, serious air leaks are indicated. With engine stopped, air leaks are frequently
audible. If leaks cannot be heard, apply engine oil to suspected points and watch for break in film or oil being drawn into pump.
Air leaks
Completely fill water tank (if so equipped). Connect intake hose to hydrant or auxiliary pump. Open one discharge valve and run in water until pump is completely
filled and all air is expelled. Close discharge valve, apply pressure to system and watch for leaks or overflowing water tank. A pressure of 100 psi is sufficient. DO
NOT EXCEED RECOMMENDED PRESSURE.
If pump has not been operated for several weeks, packing may be dried out. Close discharge and drain valves and cap intake openings. Operate primer to build up
a strong vacuum in pump. Run pump slowly and apply oil to impeller shaft near packing gland. Make sure packing is adjusted properly.
Remove all leaves, dirt and other foreign material from intake strainer.
When drafting from shallow water source with mud, sand or gravel bottom, protect intake strainer in one of the following ways:
Dirt on intake strainer
Pump fails to prime or
loses prime
A. Engine and pump
speed too low at full
throttle
F−1031, Section 1000
Suspend intake strainer from a log or other floating object to keep it off the bottom. Anchor float to prevent it from drifting into shallow water.
2.
Remove top from a clean barrel. Sink barrel so open end is below water surface. Place intake strainer inside barrel.
3.
Make an intake box, using fine mesh screen. Suspend intake strainer inside box.
No lubricant in priming tank
With some rotary primers, lubricant is required to maintain a tight rotor seal. Check priming tank oil supply and replenish, if necessary.
Lubricant tubing/check valve
If there is lubricant in the tank, but lubricant does not enter (exit) the primer, the check valve may be stuck (replace) or installed backwards (arrow points towards
primer) or the tubing may be clogged, especially if using a biodegradable lubricant and primer is not operated on a regular basis. Clear clog or replace tubing per
Priming System Installation Instructions.
Defective priming valve
A worn or damaged priming valve may leak and cause pump to lose prime. Consult primer instructions for priming valve repair.
Improper clearance in rotary gear or
vane primer
After prolonged service, wear may increase primer clearance and reduce efficiency. Refer to primer instructions for adjusting primer clearance.
Engine speed too low
Refer to instructions supplied with primer for correct priming speeds. Speeds much higher than those recommended do not accelerate priming, and may actually
damage priming pump.
Bypass line open
If a bypass line is installed between the pump discharge and water tank to prevent pump from overheating with all discharge valves closed, look for a check valve
in the line. If valve is stuck open, clean it, replace it or temporarily block off line until a new valve can be obtained.
Lift too high
Do not attempt lifts exceeding 22 feet (6.7m)except at low altitudes and with equipment in new condition.
End of intake hose not submerged
deep enough
Although intake hose might be immersed enough for priming, pumping large volumes of water may produce whirlpools, which will allow air to be drawn into intake
hose. Whenever possible, place end of intake hose at least two feet below water source.
High point in intake line
If possible, avoid placing any part of intake hose higher than pump inlet. If high point cannot be prevented, close discharge valve as soon as pressure drops, and
prime again. This procedure will usually eliminate air pockets in intake line, but it may have to be repeated several times.
Primer not operated long enough
Refer to operation instructions supplied with primer for required priming time.
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Page 9
Insufficient capacity
1.
Engine requires maintenance. Check engine in accordance with manufacturer’s instructions supplied with truck.
Insufficient engine power
Discharge relief valve set improperly
Engine operated at high altitudes and/or high air temperatures. Engine power decreases with an increase in altitude or air temperature, except for turbo charged
engines. Adjusting carburetor or changing carburetor jets (or injector nozzles) may improve engine performance. Consult with engine manufacturer.
If relief valve is set to relieve below desired operating pressure, water will bypass and reduce capacity. Adjust relief valve in accordance with instructions supplied
with valve.
Revised: 02/07/07
Page 6 of 7
9
10
CONDITION
Insufficient capacity
A. Engine and pump
speed too low at full
throttle
(continued)
Insufficient capacity
B. Engine and pump
speed higher than specified for desired pressure and volume
POSSIBLE CAUSE
Transfer valve set improperly
(Does not apply to single stage
pumps.)
Truck transmission in too high a gear
SUGGESTED REMEDY
Place transfer valve in VOLUME (parallel) position when pumping more than two thirds rated capacity.
When shifting transfer valve, make sure it travels all the way into new position. Failure of transfer valve to move completely into new position will seriously impair
pump efficiency.
Consult vehicle instructions for correct pump gear. Pump usually works best with transmission in direct drive. If truck is equipped with an automatic transmission,
be sure transmission is in pumping gear.
Transfer valve set improperly
(Does not apply to single stage
pumps.)
Place transfer valve in VOLUME (parallel) position when pumping more than two thirds rated capacity.
Pump impeller(s) or wear rings badly
worn
Install undersize wear rings if impeller to wear ring clearance is within limits indicated in MAINTENANCE INSTRUCTIONS. If not, install new impeller(s) and wear
rings.
Intake strainer, intake screens or
impeller vanes fouled with debris
Remove intake strainer and hose, and clear away all debris. Pressure backwash (preferably in parallel or ‘‘volume’’ position) will usually clear impeller vanes
when pump is stopped.
Intake hose defective
On old intake hoses, the inner liner sometimes becomes so rough it causes enough friction loss to prevent pump from drawing capacity. Sometimes, the liner will
separate from the outer wall and collapse when drafting. It is usually impossible to detect liner collapse, even with a light. Try drafting with a new intake hose; if
pump then delivers capacity, it may be assumed that previous hose was defective.
Intake hose too small
When pumping at higher than normal lifts, or at high altitudes, use a larger or additional intake hoses.
Truck transmission in too low a gear
Consult vehicle instructions for correct pumping gear. Pump usually works best with transmission in direct drive. (Check both engine and pump speed, if possible, to be sure transmission is in ‘‘direct’’.)
When shifting transfer valve, make sure it travels all the way into new position. Failure of transfer valve to move completely into new position will seriously impair
pump efficiency.
Insufficient capacity
C. Engine speed higher
than specified for
desired pressure and
volume
Insufficient pressure
Relief Valve Malfunction
A. Pressure not relieved
when discharge valves
are closed
Relief Valve Malfunction
B. Pressure will not return
to original setting after
discharge valves are
reopened
Relief Valve Malfunction
D. Slow response
F−1031, Section 1000
Check pump speed with a tachometer. If pump speed is too low, refer to engine manufacturer’s instructions for method of adjusting engine speed governor.
Pump capacity limits pump pressure
Do not attempt to pump greater volume of water at the desired pressure than the pump is designed to handle. Exceeding pump capacity may cause a reduction
in pressure. Exceeding maximum recommended pump speed will produce cavitation, and will seriously impair pump efficiency.
Flap valve stuck open
When pump is in PRESSURE (series), discharge will bypass to first stage intake. Operate pump at 75 psi/5.2 bar, and rapidly switch transfer valve back and
forth between positions. If this fails, try to reach valve with a stick or wire and work it free.
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Plugged tube lines
Disconnect lines and inspect.
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Sticky main valve
Disassemble and clean. Replace noticeably worn parts.
Incorrect installation
Check all lines to be sure installation instructions have been followed.
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Water surges
(relief valve)
Pressure fluctuation can result from a combination of intake and discharge conditions involving the pump, relief valve and engine. When the elasticity of the
intake and discharge system and the response rate (reaction time) of the engine, pilot valve and relief valve are such that the system never stabilizes, fluctuation
results. With the proper combination of circumstances, fluctuation can occur regardless of the make or type of equipment involved. Changing one or more of
these factors enough to disrupt this timing should eliminate fluctuation.
Plugged filter or line
Clean lines and filter.
Relief Valve Malfunction
C. Fluctuating pressure
In general, the above causes and remedies for low pump capacity will also apply to low pump pressure.
Revised: 02/07/07
10
Page 10
Insufficient pressure
(continued)
Pump speed too low
Page 7 of 7
10
11
11
CS Series Centrifugal
CS Series Centrifugal
Fire Pumps
Fire Pumps
11
Operation and Maintenance
Form
FormNo.
No.
Section
Section
F−1031
F−1031 2115
2115
Issue
IssueDate
Date
Rev.
Rev.Date
Date
12/14/95
12/14/95 10/11/04
05/04/06
Table of Contents
Read through the safety information and
operating instructions carefully before using
your Waterous Fire Pump.
Table of Figures
1. CS Pump with C10 Transmission . . . . . . . . . . . . . . . . . . . . . . .
2. Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Drain Locations, CS Series Pumps . . . . . . . . . . . . . . . . . . . . .
4. Extra Pressure Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Zinc Intake Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Bolt−on Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Threaded Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Packing Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Packing and Gland Installation . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
4
9
10
10
10
11
12
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Impeller Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Extra Pressure Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flame Plated Impellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Monarch Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intake Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tank to Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overheat Protection Manager (OPM) . . . . . . . . . . . . . . . . . 3
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pumping from Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 5
After Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pumping from Hydrant or in Relay . . . . . . . . . . . . . . . . . . . 6
After Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pumping from Draft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
After Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Extra Pressure Stage Operation CSH Pumps Only . . . . . 8
After Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Optional Zinc Intake Screens . . . . . . . . . . . . . . . . . . . 10
Optional Zinc Anodes . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outboard Bearing (Except CSH) . . . . . . . . . . . . . . . . . . . . 11
Inboard Bearing (CSD Pumps Only) . . . . . . . . . . . . . . . . 11
Extra Pressure Stage Bearing (CSH Pumps) . . . . . . . . . 11
Packing − Braided Flexible Graphite (BFG) . . . . . . . . . . 11
Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Packing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Vacuum Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overheat Protection Manager (OPM) . . . . . . . . . . . . . . . . 13
Butterfly Valve (BFV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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.
Page 11
12
12
12
Safety Information
Read through the safety information and operating instructions carefully before using
your Waterous Fire Pump.
! WARNING
! 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.
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
! 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.
Rotating Parts Hazard or Unexpected Truck Movement. May result in serious 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
! 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
someone when the valve is opened. Overheating can
damage the packing, seals and other pump parts. If
the apparatus builder has installed a by−pass system
or other provision designed to prevent overheating,
opening a discharge valve may be unnecessary.
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.
CS Series Operation and Maintenance
F−1031, Section 2115
Rev: 05/04/06
Page 12
Page 1 of 13
13
13
13
Introduction
This instruction contains the information needed for operation and maintenance of CS Series centrifugal pumps. Since there
are several types of transmissions available for these pumps, they are covered in separate instructions.
General Description
The CS Series pumps are single stage centrifugal fire
pumps. They are designed for midship mounting and are
available in capacities ranging from 750 to 2250 gpm
(2850 to 8500 l/m).
A variation of the basic pump is the CSH pump. This two
stage pump has an extra pressure stage designed for
high pressure operation. It is identical to the CS except for
the added stage and piping.
Components
Body Assembly
Impeller Shaft Assembly
This assembly includes the body, cover, intake adapters
and related parts. The body, cover and adapters are either
cast iron or bronze.
This assembly consists of the bronze impeller mounted on
a stainless steel shaft with wear rings, packing or mechanical seal and related parts. The impeller is balanced
and the impeller shaft is supported by ball bearings.
Options
Mechanical Seals
Extra Pressure Stage
A mechanical seal consists of a flat, highly polished
(lapped), spring−fed carbon ring that is sealed to and rotates with the impeller shaft. It presses against a highly
polished (lapped), silicone carbide, stationary ring that is
sealed in the pump body. This seals the shaft and prevents air from entering and water from leaving. A mechanical seal does not leak or drip water, even when pumping.
The extra pressure stage provides extra pressure without
the need of a separate PTO driven pump. When the extra
pressure stage control valve is opened, water enters the
extra pressure stage intake from the main pump discharge, and is discharged at a higher pressure. With the
extra pressure stage in operation, the CSH pump develops pressure up to 500 psi (1900 l/m) for two or more
booster lines. The extra pressure body mounts on the
main body opposite the pump drive end. The impeller is
mounted on the same shaft as the other impeller and rotates whenever the pump is in operation. When the extra
pressure stage is not in use, water from the first stage lubricates and cools the extra pressure stage stuffing box.
Flame−Plated Impellers
Approximately 75% of the pump wear due to pumping
sand, occurs on the impeller hubs. For this reason, the
Waterous Company adopted the policy of offering a flame
plated impeller as an option (standard on CSU pumps).
The flame−plating process consists of adding tungsten
carbide to the surfaces to be protected from wear. This
unique process produces extremely hard, well bonded,
wear−resistant coatings which consistently outwear hard
chrome plating, tool steel and solid tungsten carbide.
Monarch Intake Valve
The Monarch intake valve is a package including an extra
short intake fitting, an intake butterfly valve and an intake
nipple with integral relief valve mounting pad, all designed
to fit behind the pump panel. The Monarch intake valve
also features a provision for a pre−valve relief valve and
choice of manual worm gear, pneumatic or 12 or 24 volt
electric actuator. For operation and maintenance instructions for the Monarch intake valve, see the following instructions:
•
F−1031, Section 2318, Operation, Maintenance and
Installation Instructions for Butterfly Valves
Intake Screens
Zinc die cast screens are normally used in the intake fittings, with brass screens available optionally. Although the
screens are chemically treated (coated) to inhibit corrosion, the water being pumped may still corrode the
screens. Such corrosion is ‘‘sacrificial”; that is, it will help
prevent corrosion in the rest of the pump the same way
the magnesium anodes protect the metal parts of a water
heater.
Anodes
As additional corrosion protection for iron body pumps,
Waterous has available zinc anodes to fit any unused
intake pad, 2−1/2 inch or 3 inch pipe tap in the intake fittings. Anodes provide additional zinc surface to the water
to supplement the zinc intake screens.
•
F−1031, Section 2319, Operation, Maintenance and
Installation Instructions for Butterfly Valve Pneumatic
Actuator
F−1031, Section 2115
Rev: 05/04/06
Page 13
Page 2 of 13
14
14
14
Tank to Pump Valve
Overheat Protection Manager (OPM)
The tank to pump valve is a full−flow 3−1/2 inch diameter
ball valve which is attached directly to the pump.
The Overheat Protection Manager (OPM) acts as a safety
device by releasing hot water to the ground or back to the
water tank from the discharge area of the pump.
Figure 1. CS Pump with C10 Transmission
IL2741
F−1031, Section 2115
Rev: 05/04/06
Page 14
Page 3 of 13
15
15
15
Figure 2. Water Flow Diagram
Impeller
Driven Gear or Sprocket
1213
Intake
Discharge
Figure 3. Drain Locations, CS Series Pump
Forward
Bottom View
4
5
Discharge Pilot Valve
(On apparatus panel)
Drain separately
3
1
8
2
7
6
7
1
8
Discharge Relief Valve Cap
Drain Separately
Discharge Relief Valve
1
2
3
4
5
6
7
8
(Optional both ends)
Manifold Drain Valve
Intake Volutes
Discharge Volute
Crossover Passage
Main Discharge Barrel
Relief Valve Elbow or Adapter
Relief Valve Body
Intake Fittings (Depends on type of Intake fitting)
Mechanical Seal/Packing Chambers
6 2 3
5
4
8 1 7
Manifold Drain Valve Details
Note: If the pump has a foam manifold, it’s drains should be plumbed into a separate drain valve. Do not plumb
into drain valve used for the pump.
F−1031, Section 2115
Rev: 05/04/06
Page 15
Page 4 of 13
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16
Operating Instructions
Transmission Operation
Because of the variety of transmissions available for these pumps, the methods of operating them are not explained in this
section. For information on Waterous transmissions, refer to transmission operation instructions.
Pumping from Water Tank
After Pumping
! 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.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
! 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
someone when the valve is opened. Overheating can
damage the packing, seals and other pump parts. If
the apparatus builder has installed a by−pass system
or other provision designed to prevent overheating,
opening a discharge valve may be unnecessary.
1. Disengage pump drive in accordance with
transmission instructions.
2. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all
drains. Flush entire system with clean, fresh water for
several minutes to remove all traces of impurities.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure the
pump is completely full or completely drained − never
partially full.
! WARNING
CAUTION
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.
If the pump is exposed to freezing temperatures, drain
all water from pump, lines and accessories.
4. Close all drains and install intake and discharge caps.
1. Engage pump in accordance with transmission
instructions.
2. Open valve(s) in piping between water tank and pump
intake and at least one discharge valve.
3. Allow about 30 seconds for water to flow into pump.
NOTE: Priming the pump may be necessary
because of air trapped in piping.
4. Accelerate engine to obtain desired discharge
pressure and capacity.
5. Set relief valves or other pressure governing device to
desired pressure.
NOTE: For extra pressure stage pumping
instructions, see page 8.
F−1031, Section 2115
Rev: 05/04/06
Page 16
Page 5 of 13
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17
Pumping from Hydrant or in Relay
NOTE: Do not attempt to pump more water than is
available from the hydrant or relaying pumper.
Always make sure the intake pressure compound−gage reading stays above zero.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
Some fire departments operate at a minimum
intake pressure of 10 psi (.7 bar) when pumping
from hydrant or in relay to prevent a “soft” intake
hose from collapsing.
NOTE: For extra pressure stage pumping instructions, see page 8.
! 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 even for a few minutes
completely closed it may heat the water enough to
scald someone when the valve is opened. Overheating can damage the packing, seals and other pump
parts.If the apparatus builder has installed a by−pass
system or other provision designed to prevent overheating, opening a discharge valve may be unnecessary.
After Pumping
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
1. Disengage pump drive in accordance with transmission instructions.
2. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all
drains. Flush entire system with clean, fresh water for
several minutes to remove all traces of impurities.
! WARNING
Unexpected Truck Movement. May result in personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure the
pump is completely full or completely drained − never
partially full.
CAUTION
1. Engage pump in accordance with transmission instructions.
2. Open intake, hydrant and other valves as necessary
to allow water to enter the pump.
NOTE: Bleeder valves should be used while filling
a hose connected to an intake with water.
If the pump is exposed to freezing temperatures, drain
all water from pump, lines and accessories.
4. Close all drains and install intake and discharge caps.
3. Open discharge valves and accelerate engine to obtain desired discharge pressure and capacity.
4. Set relief valves or other pressure governing device to
desired pressure.
F−1031, Section 2115
Rev: 05/04/06
Page 17
Page 6 of 13
18
18
18
Pumping from Draft
1. Engage pump in accordance with transmission instructions.
! WARNING
2. Prime the pump (see separate instructions supplied
with primer).
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections, relieve pressure by opening drains.
3. Open discharge valves, and accelerate engine to obtain desired discharge pressure and capacity.
4. Set relief valves or other pressure governing device to
desired pressure.
! WARNING
NOTE: For extra pressure stage pumping instructions, see page 8.
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 even for a few minutes
completely closed it may heat the water enough to
scald someone when the valve is opened. Overheating can damage the packing, seals and other pump
parts. If the apparatus builder has installed a by−pass
system or other provision designed to prevent overheating, opening a discharge valve may be unnecessary.
After Pumping
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
1. Disengage pump drive in accordance with transmission instructions.
! WARNING
2. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all
drains. Flush entire system with clean, fresh water for
several minutes to remove all traces of impurities.
Unexpected Truck Movement. May result in personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure the
pump is completely full or completely drained − never
partially full.
To get full capacity, quick prime and maintain pump efficiency:
CAUTION
a) Position vehicle as near as possible to water supply.
b) Avoid humps and sharp bends in intake hose.
Make sure no part of hose is higher than pump
intake inlet. (Air pockets in intake hose may cause
loss of prime or erratic pump action, and may reduce pump capacity.)
If the pump is exposed to freezing temperatures, drain
all water from pump, lines and accessories.
4. Close all drains and install intake and discharge caps.
c) Make sure all intake connections are tight and
discharge valves are closed.
d) Immerse intake strainer at least two feet below
water surface to prevent pump from drawing air.
(Whirlpools forming above intake strainer indicate
that strainer is too close to surface of water.)
e) Make sure intake strainer is far enough from bottom to prevent sand, gravel and other foreign
matter from being drawn into the pump.
F−1031, Section 2115
Rev: 05/04/06
Page 18
Page 7 of 13
19
19
19
Extra Pressure Stage Operation − CSH Pumps Only
After Pumping
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections, relieve pressure by opening drains.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
! WARNING
1. Disengage pump drive in accordance with
transmission instructions.
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 even for a few minutes
completely closed it may heat the water enough to
scald someone when the valve is opened. Overheating can damage the packing, seals and other pump
parts. If the apparatus builder has installed a by−pass
system or other provision designed to prevent overheating, opening a discharge valve may be unnecessary.
2. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all
drains. Flush entire system with clean, fresh water for
several minutes to remove all traces of impurities.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure the
pump is completely full or completely drained − never
partially full.
CAUTION
If the pump is exposed to freezing temperatures, drain
all water from pump, lines and accessories.
! WARNING
Unexpected Truck Movement. May result in personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
4. Close all drains and install intake and discharge caps.
1. Open (or close) extra pressure stage control valve
and discharge valve(s) slowly (at least 3 seconds).
Engine speed may need to be reduced to ease
manual operation of control valve.
2. Accelerate engine to obtain desired discharge
pressure and capacity.
3. Set relief valves or other pressure governing device to
desired pressure.
F−1031, Section 2115
Rev: 05/04/06
Page 19
Page 8 of 13
20
20
20
Figure 4. Extra Pressure Stage
IL 1422
F−1031, Section 2115
Rev: 05/04/06
Page 20
Page 9 of 13
21
21
21
Maintenance
Corrosion Protection
Figure 6. Bolt−on Anodes
Optional Zinc Intake Screens
Once per month check to make sure the intake screens
are not clogged or damaged. Also check for corrosion, and
replace screens if damage is severe. For the zinc screen
to adequately control corrosion, there must be a strong
electrical contact between the screen and the fitting.
Remove any corrosion, debris or paint from the counter
bore that will insulate the screen from the intake fitting. If
the screen does not fit tightly, adjust the gap of the slot on
the outside diameter of the screen to ensure a tight fit.
NOTE: These screens are die−cast which results in a
slight taper from one side to the other. Install the
screen with the thinner cross−section facing out to
minimize flow restriction.
Figure 5. Zinc Intake Screens
Threaded Anodes
NOTE: The 2−1/2 in. hex is threaded into a bushing
that should remain on the pump. Be sure to restrain
the bushing when removing the 2−1/2 in. hex.
Unscrew the 2−1/2 in. hex from the pump. If the zinc
elements require replacement, unscrew the hex head cap
screw.
NOTE: The screw was installed using thread sealant
so higher force than normal may be necessary to
remove.
Replace one or both elements as necessary. Install the
hex head screw using Loctite 242 (blue) on the screw
threads. Remove any paint or corrosion from the face
around the NPT tap on the pump. Apply thread sealant to
the threads and screw the 2−1/2 in. hex into the pipe tap
until tight.
Optional Zinc Anodes
Twice per year, remove the anodes and check for erosion
of the zinc elements. Replace the zinc elements if more
than half of either of the zinc elements has eroded.
Anodes are normally mounted on the pump intake piping,
but they may also be installed in the discharge piping if no
intake mounting locations were available. Physical mounting of the anode may be via an NPT tap or bolt−on flange
as described below.
Figure 7. Threaded Anodes
NOTE: The zinc must make contact with water to be
effective. Do not paint or use any other coating on the
zinc elements.
Bolt−on Anodes
Unscrew the (4) hex head screws from the pump. If zinc
elements require replacement, unscrew the hex head cap
screw.
NOTE: There is no need to remove the threaded
anode adapter from the anode flange for zinc element
replacement. The screw was installed using thread
sealant so higher force than normal may be necessary
to remove.
Replace one or both elements as necessary. Install the
hex head screw using Loctite 242 (blue) on the screw
threads. Mount the anode assembly back on the fitting.
F−1031, Section 2115
Rev: 05/04/06
Page 21
Page 10 of 13
22
22
22
Lubrication
Outboard Bearing
(All Models Except CSD and CSH)
Extra Pressure Stage Bearing
(CSH Pumps Only)
The outboard bearing is located at the end of the pump
opposite the drive end of pump.
For pumps built prior to 11/13/03: The impeller shaft is
supported at the extra pressure stage by a double row,
ball bearing. A fitting permits lubrication of this bearing.
On pumps built prior to 4/21/2006, add a good quality,
medium consistency, ball bearing grease through the
lubrication fitting until it comes out of the relief fitting.
Add grease after every 100 hours of pump operation, or
every six months, whichever comes first.
A relief groove, cut in the threads of the lubrication fitting allows surplus grease to escape without causing
excessive pressure. Add a good quality, medium
consistency, ball bearing grease until it comes out of the
relief groove of the lubrication fitting. Add grease after
every 100 hours of pump operation, or every six months,
whichever comes first.
On pumps built after 4/21/2006, the outboard bearing
is sealed and requires no lubrication.
Inboard and Outboard Bearing
(CSD Pumps Only)
The inboard bearing is located at the drive end of the
pump. The outboard bearing is located on the end opposite of the drive end.
For pumps built after 11/13/03: Lubrication of bearing
is not required as the bearing is a sealed self−lubricating
design. Note that the pumps upgraded in the field to the
sealed self−lubricating design do not require lubrication.
The lube fitting should be plugged when upgraded.
Add a good quality, medium consistency, ball bearing
grease through the lubrication fitting until it comes out of
the relief fitting. Add grease after every 100 hours of
pump operation, or every six months, whichever comes
first.
Packing − Braided Flexible Graphite (BFG)
Waterous pumps use 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.
CAUTION
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.
! 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.
Packing Removal
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.
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 stuffing box. Pressure in excess of 300 psi (20.7
bar) may be required.
3. If all the packing is not forced out, it may be necessary to remove the remaining packing by hand, using a pick or similar device. Waterous has a packing
removal tool (P/N 5782) available for this purpose.
See Figure 8.
4. Replace packing per instructions below.
! WARNING
Figure 8. Packing Removal Tool
Rotating Parts Hazard or Unexpected Truck Movement. May result in serious 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.
F−1031, Section 2115
IL1931
Rev: 05/04/06
Page 22
Page 11 of 13
23
23
23
Packing Installation
CAUTION
1. Before installing the new packing, be sure that all of
the old packing is removed from the seal housing.
Pump overheating hazard.
May cause damage to the pump.
Circulate enough water through the pump to prevent
overheating.
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.
! WARNING
Truck Movement Hazard. May result in serious personal injury or death.
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). See Figure 9.
Stop the engine, set parking brake and chock the
wheels before going under the truck to adjust packing.
1. Engage pump per appropriate operating instructions.
Operate the pump at 150 psi (10.3 bar) for ten (10)
minutes.
CAUTION
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 beyond finger tight. See Figure 9.
NOTE: The milled slot on the nut should face the
gland.
Observe the stuffing box drip rate from the side of the
truck.
2. Observe leakage. Normal leakage is 10−120 drops
per minute. (Leakage may be at zero or diminished to
zero occasionally).
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.
Figure 9. Packing and Gland Installation
CAUTION
Stopping the leakage entirely at this point will cause
the packing to overheat.
7. Adjust packing as require per instruction below.
4. Operate the pump at 150 psi (10.3 bar) for 10 to 15
minutes to let packing run in, then observe the drip
rate.
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.
F−1031, Section 2115
! 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.
5. Repeat steps 3 and 4 until the drip rate is acceptable.
Rev: 05/04/06
Page 23
NOTE: After adjusting the packing, the pump
must pass the following vacuum test described
below.
Page 12 of 13
24
24
24
Vacuum Test
1. Remove all caps except openings without valves.
Close all discharge, intake 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 atmospheres 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.
Overheat Protection Manager (OPM)
Check the electrical circuit by pressing the test button
located on the panel plate every 100 hours of pump operation or every six months, whichever comes first.
If the light does not flash, the light bulb or flasher may
need replacement (provided all wire connections are
solid).
Butterfly Valve (BFV)
Operate valve once a week for optimal performance.
F−1031, Section 2115
Rev: 05/04/06
Page 24
Page 13 of 13
25
25
25
Operation and Maintenance
C10 Series Transmission
Form No.
Section
F−1031
2208
Issue Date
Rev. Date
09/27/02 11/10/06
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description for Transmissions . . . . . . . . . . .
General Description for Accessories . . . . . . . . . . . . .
Shifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Pump Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Shift Manual Override . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicating Lights Operation . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Shift Troubleshooting Guide . . . . . . . . . . . . . . . . .
Pump Transmission Shift Component Inspection . . . . .
1
2
2
2
3
3
4
5
5
5
5
5
6
9
Illustrations
1. C10 Transmission Mounted on an S100 Series Pump . 2
2. C10 Transmission Mounted on a Midship Pump . . . . . . 2
3. Pneumatic Shift Manual Override . . . . . . . . . . . . . . . . . . 4
C10 Series Transmission
Read through the safety information and
operating instructions carefully before
using your Waterous Fire Pump.
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.
Page 25
26
26
26
Safety Information
Read through the safety information and operating instructions before using your Waterous Fire Pump.
! WARNING
! 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.
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
If the truck attempts to move, reduce engine speed to
idle. Put truck transmission in NEUTRAL and repeat
shifting instructions.
F−1031, Section 2208
REV: 11/10/06
Page 26
Page 1 of 10
27
27
27
Introduction
The Waterous C10 transmission, constructed of high−
strength aluminum transmits power from the truck’s automatic transmission either to the fire pump or to the drive
axle of the truck.
This instruction is divided into four sections:
•
General Description for Transmissions
•
General Description for Accessories
•
Shifting Instructions
•
Maintenance Instructions
General Description for Transmissions
The bearings and drive chain are lubricated by a splash
and passive lubrication system. Lubrication is accomplished when spray from the chain collects in a reservoir
in the top of the case. The lubricant flows out of the reservoir, through a hose and onto the inside surface of the
chain. This ensures all pivoting components of the chain
receive lubrication.
An electronic tachometer connection protrudes from the
tachometer housing at a 45° angle. This tachometer
pick−up senses the drive shaft speed.
The shift mechanism within the transmission consists of a
sliding internally−toothed collar which is always in engagement with an externally−toothed section of the drive
shaft. A fork shifts the collar either to engage it with teeth
on the drive sprocket hub (PUMP) or to engage it with the
teeth on the coupling shaft (ROAD). When in PUMP position, the shift collar transmits power from the drive shaft
through the drive sprocket and the chain to the driven
sprocket. The coupling shaft remains stationary. When in
ROAD position, the shift collar transmits power directly
from the drive shaft through the coupling shaft to the truck
propeller shaft and drive axle(s). In this position, the pump
drive and driven sprockets remain stationary while the
drive shaft rotates.
Three shift indicator lights are furnished. Two are mounted
in the cab and the other is mounted on the operators panel. These lights indicate to the operators that the shift has
been completed into PUMP position and the truck transmission is in pumping gear.
Figure 1. C10 Transmission Mounted on an S100 Pump
Figure 2. C10 Transmission Mounted on a Midship Pump
IL2740
General Description for Accessories
The pneumatic shift assembly permits fast, positive shifting without leaving the cab. A two−position control,
mounted on the instrument panel in the cab activates the
shift unit.
F−1031, Section 2208
The pneumatic shift is equipped with a complete set of
lights that indicate when the shift has been fully completed
to PUMP and the truck transmission is in pumping gear.
REV: 11/10/06
Page 27
Page 2 of 10
28
28
28
Shifting Instructions
Pneumatic Shift
Two series of Allison automatic transmissions are commonly used in fire trucks. Each series is available with the shift
patterns controlled hydraulically or both electronically and
hydraulically. This later type is commonly referred to as the
ATEC transmission.
In each automatic transmission, either the non−ATEC or
the ATEC, certain sequences must occur in proper order
after the pump shift control is moved to either PUMP or
ROAD position.
Split shaft pump transmissions, automatic transmissions
and engines will vary in operation due to manufacturing
tolerances, lubrication temperature, etc. This variance in
each may or may not affect the ease of completing a full
shift into either PUMP or ROAD. Operator training and experience in shifting procedures is a requirement to becoming skilled in a smooth, complete shift into either PUMP or
ROAD.
When the pump shift is activated, the operator may
hear a noise associated with the movement of the shift
unit. This does NOT mean that the shift has been completed.
After the shift to pump operation is completed, the green
PUMP ENGAGED and OK TO PUMP lights in the cab
must be on before leaving the cab to operate the pump
from the operators panel. DO NOT LEAVE THE CAB IF
THE GREEN PUMP ENGAGED AND OK TO PUMP
LIGHTS ARE NOT ON.
Some truck builders may install a manual override for the
electric or pneumatic pump shift. The controls are normally
installed from the pump transmission to the operators panel.
CAUTION
If green PUMP ENGAGED and OK TO PUMP
light are not on, momentarily shift truck transmission from pumping gear (DRIVE) to NEUTRAL,
then REVERSE, then NEUTRAL, then back into
pumping gear (DRIVE). Lights should be on. If
lights are not on, repeat procedure.
7. Increase engine speed above idle and hold for a few
seconds. Watch speedometer to make sure it shows
some value of road speed.
NOTE: Some fire trucks have a speedometer that
will not show a value of road speed in a stationary
position.
! WARNING
If the truck attempts to move, reduce engine
speed to idle. Put truck transmission in NEUTRAL and repeat shifting instructions.
8. After leaving truck cab, block wheels using wheel
chocks.
9. To confirm that the pump is engaged:
S THROTTLE READY light on operator’s panel
is illuminated.
S
Pump discharge pressure registers on gages.
S
Other safety interlocks are activated.
Shift to ROAD as follows:
! WARNING
1. With engine speed at idle, put truck transmission in
NEUTRAL.
2. When speedometer slows to zero, move pump shift
control to ROAD position.
3. Engage truck transmission (DRIVE).
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.
CAUTION
Shift to PUMP as follows:
1. Bring truck to complete stop.
2. Reduce engine to idle speed, put truck transmission
into NEUTRAL.
3. Set truck parking brake.
4. Move pump shift control to PUMP position.
NOTE: Green PUMP ENGAGED light may not illuminate.
5. Shift truck transmission into pumping gear (DRIVE).
CAUTION
6. Green PUMP ENGAGED and OK TO PUMP lights
should be on.
If you hear a loud grinding noise when you attempt
to move the truck, the shift to ROAD has not been
completed. Shift into NEUTRAL, wait for grinding
noise to stop and re−engage truck transmission.
If grinding is a common occurrence after Step 3 is performed, it may be prevented by shifting the truck transmission into NEUTRAL, then to REVERSE, back to NEUTRAL and finally to DRIVE.
4. After shifting the truck transmission to DRIVE, release
the parking brake and move the vehicle forward to confirm a shift to ROAD has been completed.
Shifting truck transmission into pumping gear
(DRIVE) above engine idle speed may cause
damage to the equipment.
F−1031, Section 2208
REV: 11/10/06
Page 28
Page 3 of 10
29
29
29
Pneumatic Shift Manual Override
Two series of Allison automatic transmissions are commonly used in fire trucks. Each series is available with the shift
patterns controlled hydraulically or both electronically and
hydraulically. This later type is commonly referred to as the
ATEC transmission.
In each automatic transmission, either the non−ATEC or
the ATEC, certain sequences must occur in proper order
after the pump shift control is moved to either PUMP or
ROAD position.
Split shaft pump transmissions, automatic transmissions
and engines will vary in operation due to manufacturing
tolerances, lubrication temperature, etc. This variance in
each may or may not affect the ease of completing a full
shift into either PUMP or ROAD. Operator training and experience in shifting procedures is a requirement to becoming skilled in a smooth, complete shift into either PUMP or
ROAD.
When the pump shift is activated, the operator may
hear a noise associated with the movement of the shift
unit. This does NOT mean that the shift has been completed.
After the shift to pump operation is completed, the green
PUMP ENGAGED and OK TO PUMP lights in the cab
must be on before leaving the cab to operate the pump
from the operators panel. DO NOT LEAVE THE CAB IF
THE GREEN PUMP ENGAGED AND OK TO PUMP
LIGHTS ARE NOT ON.
If the vehicle builder has provided a means to manually
override the pneumatic pump shift, the override control
will be located at the operators panel or in the cab. The
override control will consist of a rod to the panel or a
cable or rod mechanism to the inside of the cab. The rod
or cable will be attached to the shift arm on the pump
transmission.
NOTE: This instruction is written based on an override control rod directed to the operators panel from
the short arm of the lever on the pump transmission.
Other rod or cable arrangements may require reversal
of stated action to accomplish the desired shift.
Figure 3. Pneumatic Shift Manual Override
It is recommended that this procedure be performed using
two people; one person in the cab and one at the override
control position.
! 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.
Shift to PUMP as follows:
1. Bring truck to complete stop.
2. Reduce engine to idle speed, put truck transmission in
NEUTRAL.
3. Set truck parking brake.
4. Move in−cab pump shift control into the CENTER
position.
5. Push manual shift control rod in for PUMP position.
6. Move the in−cab pump shift control into the PUMP
position.
7. Green PUMP ENGAGED light should be on.
CAUTION
If green PUMP ENGAGED light is not on, momentarily shift truck transmission into REVERSE
while keeping pressure on the manual shift rod.
Return to NEUTRAL. Green PUMP ENGAGED
light should be on.
8. Shift truck transmission into pumping gear (DRIVE).
CAUTION
Shifting truck transmission into pumping gear
above engine idle speed may cause damage to
the equipment.
9. Green OK TO PUMP light should be on.
Rod or cable to cab
10. Increase engine speed above idle and hold for a few
seconds. Watch speedometer to make sure it shows
some value of road speed.
NOTE: Some fire trucks have a speedometer that will
not show a value of road speed in a stationary position.
! WARNING
If the truck attempts to move, reduce engine
speed to idle. Put truck transmission in NEUTRAL and repeat shifting instructions.
Rod to side of truck
IL1011
If the pump transmission is equipped with an override,
shifting manually is done as follows:
F−1031, Section 2208
11. After leaving truck cab, block wheels using wheel
chocks.
12. To confirm that the pump is engaged:
REV: 11/10/06
Page 29
Page 4 of 10
30
30
S
THROTTLE READY light on operator’s panel
is illuminated.
S
Pump discharge pressure registers on gages.
S
Other safety interlocks are activated.
30
5. Engage truck transmission (DRIVE).
CAUTION
Shift to ROAD as follows:
1. With engine at idle speed, put truck transmission in
NEUTRAL.
2. When speedometer drops to zero, move in−cab pump
shift control into the CENTER position.
3. Pull manual shift rod out for ROAD position.
4. Move the in−cab pump shift control into the ROAD
position.
If you hear a loud grinding noise when you attempt to move the truck, the shift to ROAD has
not been completed. Shift into NEUTRAL, wait for
grinding noise to stop and re−engage truck
transmission, while keeping pressure on the
manual shift control rod.
6. After shifting the truck transmission to DRIVE, release
the parking brake and move the vehicle forward to
confirm a shift to ROAD has been completed.
Maintenance
Indicating Lights Operation
Tachometer Readings
Check the operation of the pump shift indicating lights at
least weekly as follows:
Electric Tachometer:
NOTE: Block wheels with wheel chocks before beginning.
1. With the pump in the ROAD position, truck transmission in NEUTRAL and the parking brake engaged,
ensure that the PUMP ENGAGED and OK TO PUMP
lights in the cab are off.
2. Shift to PUMP following the shifting instructions
section of this document.
a. Ensure that the green PUMP ENGAGED and OK
TO PUMP lights in the cab are on.
b. Ensure that the green THROTTLE READY light
on the operator’s panel is on.
To verify input shaft speed, take a frequency reading from
the tachometer sensor. Multiply frequency reading (Hz) by
1.5 for shaft speed. The impeller shaft speed can be calculated by multiplying the input shaft speed by the ratio of
the pump transmission.
Fluid Levels
1. Check fluid level monthly by removing fluid level plug
at rear of case. The fluid should be level with bottom
of hole.
A sight plug is also provided for this purpose, and the fluid
level should be visible thru this plug.
CAUTION
3. Apply the service (foot) brake and release the parking
brake.
a. Ensure that the green OK TO PUMP light in the
cab is off.
b. Ensure that the green THROTTLE READY light
on the operator’s panel is off.
4. Engage the parking brake and shift truck transmission
to NEUTRAL.
a. Ensure that the green OK TO PUMP light in the
cab is off (automatic truck transmission only).
5. Shift to ROAD following the shifting instructions
section of this document.
a. Ensure that the green PUMP ENGAGED and OK
TO PUMP lights in the cab are off.
If fluid level is low, locate source of leak and
repair. If fluid level is high, loosen drain plug until
fluid drops to proper level. If excessive water
drains out, change fluid and determine source of
water leakage, and repair.
NOTE: Fluid temperature should not exceed 250° for
an extended period of time or premature seal wear
and damage may occur.
Fluid can be added thru the fluid level hole or by removing
the breather and adding fluid thru this opening. Any type
of automatic transmission fluid (ATF) can be used.
2. Change fluid twice per year or after each 100 hours of
operation, whichever comes first. Clean the breather
and magnetic drain plug thoroughly whenever the
transmission fluid is changed.
b. Ensure that the green THROTTLE READY light
on the operator’s panel is off.
Amount required if system is drained and refilled
12 quarts (approximately)
Shift Linkage
Periodically check all shift linkage for freedom of movement and clean as necessary.
F−1031, Section 2208
REV: 11/10/06
Page 30
Page 5 of 10
31
31
31
Pump Shift Troubleshooting Guide
It is important to know what to do if you experience shifting problems with your pump. This troubleshooting guide will help
you diagnose, isolate and correct problems as they are encountered.
For problems not covered in this guide, or for additional technical assistance, please contact the Waterous Service
Department.
Problem
Is the chassis
transmission
in DRIVE
(automatic) or
in its pump
gear (Manual)?
No
Possible Cause
Recommended Action
Pneumatic Shift
Electric Shift
Butt−tooth condition
Butt−tooth condition
Place the chassis
transmission in Drive
(automatic) or in its
pumping gear (manual).
Malfunctioning shift
indicating switch or
switch out of
adjustment
Malfunctioning shift
indicating switch or
switch out of
adjustment
Replace or adjust the
shift indicating switch or
bracket.
Manual override
linkage binding
Manual override
linkage binding
Repair or replace to
eliminate binding.
Excessive driveline
torque
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
DRIVE.
−−−−−−−−−−
It may be necessary to
contact the chassis
transmission
manufacturer for
assistance.
Low air pressure to
pneumatic shift unit
(80 psi min.)
−−
Allow air pressure to
build in the system,
repair any leaks in the
system.
Leaking pneumatic
shift unit.
−−
Repair or replace
pneumatic shift unit.
Malfunctioning air
control valve
−−
Repair or replace air
control valve.
−−
No power to shift unit.
Repair as needed to
restore power supply.
−−
Failed shift motor −
check current draw,
should be 20A at
startup and 10A
through the cycle.
Replace the shift motor.
−−
Failed shift unit − unit
has power and draws
correct amperage but
will not activate.
Repair or replace the
electric shift unit.
Pump won’t engage
Excessive driveline
torque
Pump shift control is in the
PUMP position and:
1. No lights or Red light
stays on or flashed (units
built prior to 1991).
or
2. PUMP ENGAGED light
does not come on (units
built 1991 or newer).
F−1031, Section 2208
Yes
REV: 11/10/06
Page 31
Page 6 of 10
32
32
Problem
Is the PUMP
ENGAGED
light on?
Possible Cause
Electric Shift
Manual override
linkage binding.
Manual override
linkage binding.
Repair or replace to
eliminate binding.
Excessive driveline
torque.
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
DRIVE.
−−−−−−−−−−
It may be necessary to
contact the chassis
transmission
manufacturer for
assistance.
Low or no air pressure
to pneumatic shift unit
(80 psi min.)
−−
Allow air pressure to
build in the system,
repair any leaks in the
system.
−−
Weak shift unit or
non−Waterous
supplied shift unit.
Replace shift unit with a
high−torque shift unit
provided by Waterous.
Damage to internal
pump transmission
shifting components.
Damage to internal
pump transmission
shifting components.
See pump transmission
inspection instructions.
Shift indicating switch
is out of adjustment or
its bracket is
damaged.
Malfunctioning shift
indicating switch or
switch out of
adjustment.
Adjust the shift
indicating switch or
replace the bracket.
Damage to internal
pump transmission
shifting components.
Damage to internal
pump transmission
shifting components.
See pump transmission
inspection instructions.
Pump transmission
has not shifted out of
ROAD due to
excessive driveline
torque.
Pump transmission
has not shifted out of
ROAD due to
excessive driveline
torque.
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
DRIVE.
−−−−−−−−−−
It may be necessary to
contact the chassis
transmission
manufacturer for
assistance.
Damage to internal
pump transmission
shifting components.
Damage to internal
pump transmission
shifting components.
See pump transmission
inspection instructions.
Seized fire pump.
Seized fire pump.
Repair fire pump as
necessary.
No
1. The chassis
transmission is in DRIVE
(automatic) or in its
pumping gear (manual).
or
2. The chassis
transmission is in
NEUTRAL
NEUTRAL.
Yes
Chassis engine stalls
after placing the pump
shift control in PUMP
and placing the chassis
transmission in DRIVE
((automatic)) or in its
pumping
i gear ((manual).
l)
No
Yes
F−1031, Section 2208
Recommended Action
Pneumatic Shift
Excessive driveline
torque.
Pump will not engage
and there is a grinding
noise emanating from
the pump transmission.
Pump
p shift control is in the
PUMP position
iti and:
d
32
REV: 11/10/06
Page 32
Page 7 of 10
33
33
Problem
Is the chassis
transmission
in DRIVE
(automatic) or
in its pump
gear (Manual)?
No
PUMP ENGAGED light is
on but OK TO PUMP
light will not illuminate.
(Units built 1991 and
later)
Yes
33
Possible Cause
Recommended Action
Pneumatic Shift
Electric Shift
Chassis transmission
not in the proper gear.
Chassis transmission
not in the proper gear.
Place the chassis
transmission in DRIVE
(automatic) or in its
pumping gear (manual).
Parking brake is not
applied.
Parking brake is not
applied.
Apply the parking brake.
Problem with high
Problem with high
range lockup or safety range lockup or safety
interlock systems.
interlock systems.
Problem with chassis
transmission or
transmission
electronic control unit.
Problem
Pump shift control is in
the ROAD position, but
the PUMP ENGAGED
and/or OK TO PUMP
lights stay on.
Note: Chassis engine may
stall if the chassis
transmission is placed in
DRIVE (automatic) or in its
pumping gear (manual).
F−1031, Section 2208
Is the Pump
transmission
shift arm in
contact with
the shift
indicating
switch?
Problem with chassis
transmission or
transmission
electronic control unit.
Contact the apparatus
manufacturer or
consider
alternative wiring for
high range lockup.
Contact the chassis
transmission
manufacturer for
assistance.
Possible Cause
Recommended Action
Pneumatic Shift
Electric Shift
No
Shift indicating switch
stuck closed.
Shift indicating switch
stuck closed.
Yes
Locking arm assembly Locking arm assembly
is installed backwards is installed backwards
inside pump
inside pump
transmission (the shift transmission (the shift
arm should move
arm should move
away from the shift
away from the shift
indicating switch when indicating switch when
shifting to pump).
shifting to pump).
REV: 11/10/06
Page 33
Replace the shift
indicating switch.
Remove locking arm
assembly and re−install
correctly.
Page 8 of 10
34
34
Problem
Pump shift control is in
the ROAD position and
grinding sounds are
heard emanating from the
pump transmission.
Manual pump shift
override control cannot
be moved by hand
(electric or pneumatic
shift functions p
properly).
p y)
The chassis engine stalls
when the chassis
transmission is placed in
DRIVE (automatic)
after moving the pump
shift control to the ROAD
position.
34
Possible Cause
Electric Shift
Chassis transmission is in
gear when shifting pump.
Chassis transmission is in
gear when shifting pump.
Place the chassis
transmission in NEUTRAL
before shifting pump
transmission.
Butt−tooth condition −
chassis transmission is in
REVERSE.
Butt−tooth condition −
chassis transmission is in
REVERSE.
Place the chassis
transmission in DRIVE after
shifting pump transmission
to ROAD.
Excessive driveline torque
and/or rotation.
Damage to pump
transmission shifting
components.
Damage to pump
transmission shifting
components.
See pump transmission
inspection instructions.
Air pressure present on
pneumatic shift piston.
−−
Place the shift air control
valve in the center position.
(Note: There is no center
position on units built prior
to 1994).
−−
Electric shift still engaged
with shift arm.
Operate the electric shift to
disengage control.
Binding or malfunctioning
manual shift linkage.
Binding or malfunctioning
manual shift linkage.
Repair or replace to
eliminate linkage binding.
Shift indicating switch stuck
closed.
Shift indicating switch stuck
closed.
Replace the shift indicating
switch.
Problem with chassis
transmission or
transmission electronic
control unit.
Problem with chassis
transmission or
transmission electronic
control unit.
Contact chassis
transmission manufacturer
for assistance.
e. Manually align the shift teeth by actuating the
pump transmission shift arm and rotating the drive
shaft until the shift collar is engaged in the PUMP
position.
The following procedures should be followed when a
problem with the pump transmission shift components is
suspected:
f.
1. Perform a shift force test on the pump transmission.
a. Place the chassis transmission in NEUTRAL and
shut off the engine.
b. Set the apparatus parking brake.
Remove any manual override linkage from the
pump transmission shift arm.
d. Remove the pneumatic or electric shift unit (if so
equipped) from the pump transmission.
F−1031, Section 2208
Ensure the driveline is not
rotating before shifting to
ROAD.
−−−−−−−−−−
It may be necessary to
contact the chassis
transmission manufacturer
for assistance.
Excessive driveline torque
and/or rotation.
Pump Transmission Shift Component
Inspection
c.
Recommended Action
Pneumatic Shift
Pull on the long side of the shift arm to shift the
pump transmission between ROAD and PUMP
using a pull scale to measure the force required in
pounds. The force required to shift the pump
transmission should not exceed 18 pounds.
2. Drain the lubricant from the pump transmission and
examine it for metal particles appearing in quantity
and/or size which may indicate excessive wear to internal components. Also check the magnetic drain
plug and the sump screen on the lube pump intake
line (if so equipped) for debris. If there is little or no
debris refill with clean lubricant and retest. If the problem persists or if large quantities or sizes of debris are
found proceed to step 3.
REV: 11/10/06
Page 34
Page 9 of 10
35
35
35
c.
3. Remove the lower section of the pump transmission
according to the pump transmission overhaul instructions.
4. Inspect the pump transmission shift components, including:
a. Check for damage to the shift fork and the shift
shoes.
b. Check for damage to the shift shaft, locking arm
assembly and sector gear.
Check for damage to the engaging teeth on the
drive sprocket, coupling shaft and shift collar.
Note: it will be necessary to manually actuate the
shift arm to inspect all of the teeth. Some binding
may normally occur when actuating the shift arm
with the lower case section removed). Minor burrs
found on the teeth of the shift collar, drive sprocket, or coupling shaft may be filed clean. If excessive damage is found the component(s) should be
replaced.
d. Check to make sure that all bearings turn freely.
5. Contact Waterous to order any replacement parts or
for further assistance.
F−1031, Section 2208
REV: 11/10/06
Page 35
Page 10 of 10
36
36
36
Operation & Maintenance
Priming Systems
Form No.
Section
F−1031
2405
Issue Date
Rev. Date
04/11/06 07/14/06
Table of Contents
IL2759
Illustrations
1. Priming Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Rotary Vane Priming Pump . . . . . . . . . . . . . . . . . . . . . 2
3. Model VPOS Priming Pump . . . . . . . . . . . . . . . . . . . . 2
4. Priming Valve, Vacuum Activated (VAP) . . . . . . . . . . 2
Principals of Operation . . . . . . . . . . . . . . . . . . . . .
Optional Priming Lubricant . . . . . . . . . . . . . . . . . . . .
Pumping from Draft . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Vane Priming Pump − VPO and VPOS . . .
Priming Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Instructions . . . . . . . . . . . . . . . . . . . . . .
Models VPO, VPOS (Electric Operation) . . . . . . . .
Manual Hand Primer . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Instructions . . . . . . . . . . . . . . . . . . .
Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Clearance Adjustment . . . . . . . . . . . . . . . . . .
Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Suggestions . . . . . . . . . . . . . . . . . . . . . . . .
Models VPO and VPOS . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
5
5. Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Wiring Diagram − Models VPO and VPOS . . . . . . . . 5
Tables
1. Priming Motor Power Supply Wire . . . . . . . . . 5
Priming Systems Operation & Maintenance
All content in this instruction is property of the Waterous Company. Instructions subject to change without
Read through the installation instructions
carefully before installing your Priming
System.
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.
Page 36
37
37
37
Principles of Operation
Before any centrifugal pump can be operated, it must be
primed. Priming is the process of replacing air in the
intake lines and portions of the pump with water. If the
pump is to be operated from draft, priming must be done
by means of a positive displacement pump, or some other
device for creating a partial vacuum. Also, when pumping
from a water tank, priming will be accomplished more
quickly and positively if a priming device is used. Priming
will occur naturally when pumping from hydrants or in
relay, because inlet water pressure is high enough to force
air out of the pump and intake lines, providing a discharge
line is opened to permit the air to escape.
A Waterous priming system consists of a priming pump
and a priming valve. The priming pump draws air out of
the centrifugal pump through the priming valve. The priming valve must be open when priming the pump and then
closed when the pump is fully primed (pumping water with
all air removed).
Optional Priming Lubricant
Lubricant may be used to help seal and lubricate the priming pump.
Pumping from Draft
To obtain a quick prime & maintain pump performance:
d.) Always use an intake strainer or screen.
a.) Position pump as near as possible to water supply.
e.) Immerse intake strainer at least two feet below water
surface to prevent pump from drawing air. (Whirlpools
forming above intake strainer indicate that strainer is
too close to surface of water.)
b.) Avoid humps or sharp bends in intake hose. Make
sure no part of hose is higher than pump intake inlet.
(Air pockets in intake hose may cause loss of prime or
erratic pump action and may reduce pump capacity.)
c.) Make sure all intake connections are tight and discharge valves are closed.
f.) Make sure intake strainer is far enough from bottom to
prevent pumping sand, gravel or other foreign matter.
Figure 1. Priming System
Optional Priming Lubricant
Priming
Valve
Highest
point on
Pump Intake
Check Valve
(1−3 PSI cracking pressure)
Priming
Pump
NOTE: If pump fails to prime or loses
prime, refer to the troubleshooting
guide in form F−1031, Section 1000.
F−1031, Section 2405
IL2130
The priming pump should discharge
to atmosphere and be positioned to
allow for drainage.
Rev: 07/14/06
Page 37
Page 1 of 5
38
38
38
Rotary Vane Priming Pump − VPO, VPOS Models
Rotary vane priming pumps are available separately
mounted (model VPOS) or transmission mounted (model
VPO). The VPO and VPOS models are driven by an electric motor. The VPO and VPOS models each contain one
eccentric rotor with four vanes that slide in and out of the
rotor.
Figure 2. Rotary Vane Priming Pump
As the rotor turns, air is drawn from the priming valve inlet
due to the vacuum created behind the priming pump. As
the priming pump evacuates the air from the lines and the
main pump, atmospheric pressure forces water into the
pump.
An optional lubricant tank is available for use with VPO/
VPOS models to provide additional lubrication and sealing.
Figure 3. Model VPOS Priming Pump
Inlet From Priming Valve
Motor Ground Post
from DPL82082
This electric motor driven rotary vane primer is used for
separately mounted applications. With the priming valve, it
forms a complete, dependable priming system.
IL2067
Outlet to Atmosphere
Priming Valve
The priming valve consists of a stainless steel valve stem,
spring and pressure disk in a plastic valve body. A rubber
disk forms the seat for the valve stem and also forms a
seal between the priming valve inlet and the pump body. A
rubber diaphragm forms a seal which allows the valve to
open and close while isolating the interior of the priming
valve from atmospheric pressure
The priming valve is attached directly to the pump body on
CM and CS models. A bronze adapter allows the priming
valve to be installed on all other pumps and also facilitates
remote mounting of the valve.
The priming valve opens automatically during pump priming. When the valve is open, it allows air to flow from the
various pump passages to the priming pump. Once the
pump is primed, the priming valve closes automatically
when the primer is deactivated.
Figure 4. Priming Valve, Vacuum Activated (VAP)
F−1031, Section 2405
Rev: 07/14/06
Page 38
Page 2 of 5
39
39
39
Operating Instructions
Models VPO, VPOS (Electric Operation)
1. Close discharge valves, drain valves and all other
openings.
CAUTION
Operating the priming pump for more than one minute continuously may damage the electric motor
and/or motor solenoid.
2. Make sure all intake connections are tight.
3. Operate priming pump until it discharges a solid
stream of water through its discharge outlet.
NOTE: If priming pump does not prime main pump
and discharge a steady stream of water within 30
seconds (1250 gpm or smaller) or 45 seconds
(1500 gpm or larger), stop pump and determine
cause of problem. (An additional 15 seconds may
be required if the truck is equipped with a 4 inch
or larger front or rear intake pipe.)
4. After main pump is primed, release valve control.
NOTE: The motor and solenoid are NOT rated for
continuous duty. If possible, allow primer to be
OFF for a minimum of one minute between uses.
Manual (Hand) Primer
1. Close discharge valve(s), drain valves and all other
openings.
2. Make sure all intake connections are tight.
3. Open priming valve.
4. Start main pump and immediately begin pumping the
primer handle (to minimize time the pumps runs dry)
until water begins exiting the primer outlet.
5. Close priming valve and open main pump discharge
valve(s).
Maintenance Instructions
Priming Pump
Testing
During operation of VPO model with optional lubricant
tank, lubricant from the priming tank lubricates the priming
pump. The priming pump should be operated weekly
to cycle fresh lubricant through the primer. This cycling
is of particular importance when using biodegradable lubricant, since the biodegradable properties allow it to break
down quickly and lose its lubricating qualities. On rotary
vane primers only, an orifice is in the lubricant line where it
enters the priming pump head, to prevent excessive
amounts of lubricant entering the pump and reducing its
performance. Make sure clean lubricant is used in the
priming tank and make sure the orifice is always open.
Priming Valve
After long service, normal wear of the wave spring and
seals may prevent air sealing of the valve. Replace wave
spring and seals if any signs of leakage are discovered. A
repair kit is available from the Waterous Company.
Priming Tank
A vent hole is located in the elbow on top of the priming
tank to break the syphon and stop the flow of lubricant
after priming. The hole should be kept open at all times,
but do not enlarge it.
Once a month, perform the following vacuum test.
Remove all caps except openings without valves. Close all
discharge, intake, drain valves and other similar openings.
Operate priming device to create a vacuum of about 22 in.
Hg in pump, then stop primer and engine.
Watch pressure gage; if vacuum drops more than 10 in.
Hg in 5 minutes, listen for air leaks around packing glands,
gaskets, valves, etc.
Replace gaskets, repack or otherwise repair source of
trouble.
Rotor Clearance Adjustment
All Waterous priming pumps are factory tested and will
draw a minimum of 22 In. Hg vacuum. After prolonged
service, the rotor to pump clearance may increase because of wear, resulting in lower vacuum.
On VPO models, if maximum vacuum falls below 22 In.
Hg., inspect primer for wear of the housing, vanes, rotor
and seals. Replace as needed.
Vanes
Refill priming tank as needed with lubricant.
If dispensing priming lubricant into the environment, always
use a biodegradable or non−toxic lubricant. Biodegradable /
non−toxic Prime−Safet is available from Waterous.
Use of rotary vane primers will cause vane wear. If wear is
excessive, vacuum levels will decrease. Periodic replacement of vanes and seals is required to maintain acceptable vacuum levels. Contact Waterous service for replacement kits.
NOTE: If 30 weight motor oil is used, it is recommended that a catch pan be used under the primer to
collect the used oil so it can be disposed of properly.
F−1031, Section 2405
Rev: 07/14/06
Page 39
Page 3 of 5
40
40
40
Service Suggestions
Models VPO and VPOS
If the priming system fails to operate properly, refer to the
troubleshooting guide in F−1031, Section 1000 for the
possible cause and suggested remedy. If the cause of the
failure cannot be determined using the troubleshooting
guide, the following Service Suggestions should help locate the cause of the malfunction. Go through each step in
sequence to check out all the components of the priming
system, or until the cause of the malfunction is located.
7. Check for primer motor function in the following manner:
a.) With the motor disassembled from the priming
pump, manually rotate the motor shaft to make sure
it turns freely. If it does not, replace the motor.
b.) Using the correct battery (12V or 24V) for the application, attach a ground cable (6 AWG or heavier)
from the negative, “−”, battery terminal to the ground
post on the primer motor (see Figure 3 or 5). Connect the positive, “+”, battery terminal to the solenoid “HOT” terminal, again using a 6 AWG or heavier cable.
1. Make sure battery is properly charged. If battery is in
low state of charge, it may be difficult to operate the
priming pump at proper speed.
2. Check all wiring to the priming pump and valve for
loose terminals, damaged insulation, or broken wire
strands − especially near terminals.
! WARNING
Solenoid Motor Testing Hazard. Improper wiring
may cause the jumper wire to become very hot,
resulting in burns to fingers or hands.
To prevent the jumper wire from overheating on 24V
motors, DO NOT place the jumper wire on the solenoid ground terminal (small terminal with wire attached).
3. Check that the correct cable size is used (see Table 1
and Table 2).
4. Check for proper grounding of the motor. On VPO
models, there is a ground stud on the side of the motor that should be connected with a ground cable to
the truck chassis.
5. If priming pump still does not operate, remove priming
motor. Step 6 will help troubleshoot the priming pump,
and step 7 will help troubleshoot the motor.
a.) VPO models − There are two cast parts that make
up the priming pump, the part attached to the motor
should not be removed from the motor.
6.
For proper function of the priming system, always follow
the Maintenance Instructions section of this document.
The following are possible priming pump−related causes
of low vacuum levels or a non−functioning priming pump:
c.) Check for motor solenoid function by connecting a
jumper between center (small) and hot terminals of
solenoid (see Figure 5); the motor should run. Disconnect the jumper. If the motor ran with the jumper
installed, go to step 8.
Figure 5. Solenoid
Center (Small)
Terminal (24V Motor)
Center (Small)
Terminal (12V Motor)
a.) VPO primers are made of corrosion−resistant materials, but abrasives passing through the primer
can damage the corrosion resistant surfaces.
Clean the priming pump surfaces to remove corrosion, or replace worn parts.
b.) Stuck or broken vanes. If primer is not used regularly, corrosion and/or the breakdown of biodegradable lubricants can cause vanes to stick; foreign objects can enter the primer and cause a
vane to break; or sand can damage the rotor and
inside walls of the primer, not allowing the vanes
to slide freely. Clean the inside of the primer and
replace vanes or worn parts as needed.
c.) Inside walls of primer damaged from sandy water. A
tight fit between the vanes and smooth primer walls
are required for high vacuum levels. Damage to this
smooth surface (and smooth vane edges) causes a
loss of the required tight fit. Replacement of damaged parts is usually required.
F−1031, Section 2405
Rev: 07/14/06
Page 40
Solenoid
“COLD”
Terminal
Solenoid
“HOT”
Terminal
Solenoid
Buss Bar
Motor “HOT”
Post
CAUTION
Wherever jumper wire is used, do not leave the
wire connected after making the desired test.
Failure to disconnect the jumper before proceeding with subsequent tests may cause serious
damage to the electrical equipment.
Page 4 of 5
41
41
d.) If motor does not run, temporarily place a heavy
jumper (6 AWG or heavier) firmly across hot and
cold terminals of solenoid. If the motor then runs,
check that the buss bar connections are tight. If
connections are good, the solenoid is probably
defective and should be replaced.
e.) If priming motor still does not run, connect a
heavy jumper directly between positive “+”, battery
terminal and “HOT“ post of motor.
41
8. If the priming motor operated with jumper connected
between center (small) and hot terminals of solenoid,
control switch or switch wiring may be defective. To
check switch, connect a jumper to its terminals. If
priming motor operates with switch bypassed, switch
is defective and should be replaced. If priming motor
does not operate with switch bypassed, check wiring
from switch to solenoid.
f.) If motor does not run, replace or rebuild it. If motor
does run with jumper connected, check cable
between battery and priming motor solenoid.
Table 1. Priming Motor Power Supply Wire (Not Furnished by Waterous
Minimum wire size (AWG) for a 5% voltage drop across one leg of the circuit.
Amps
70
75
80
90
100
125
150
175
200
225
250
275
300
325
350
5
12
10
10
10
10
8
8
8
6
6
6
6
4
4
4
(10% total voltage drop if ground wire leg of circuit is equal in length to power wire leg)
Length, ft
10
15
20
25
30
35
40
45
8
6
6
4
4
2
2
2
8
6
4
4
4
2
2
2
8
6
4
4
2
2
2
2
8
6
4
4
2
2
2
1
6
4
4
2
2
2
1
1
6
4
2
2
1
1
1/0
1/0
4
4
2
1
1
1/0
2/0
2/0
4
2
2
1
1/0
2/0
2/0
3/0
4
2
1
1/0
2/0
2/0
3/0
3/0
4
2
1
1/0
2/0
3/0
3/0
4/0
2
1
1/0
2/0
3/0
3/0
4/0
4/0
2
1
1/0
2/0
3/0
4/0
4/0
2 @ 2/0
2
1
2/0
3/0
3/0
4/0
2 @ 2/0
2 @ 2/0
2
1/0
2/0
3/0
4/0
4/0
2 @ 2/0
2 @ 2/0
2
1/0
2/0
3/0
4/0
2 @ 2/0
2 @ 2/0
2 @ 3/0
50
2
1
1
1
1/0
2/0
3/0
3/0
4/0
4/0
2 @ 2/0
2 @ 2/0
2 @ 3/0
2 @ 3/0
2 @ 3/0
Figure 6. Wiring Diagram − Models VPO and VPOS Priming Pumps
No.
Description
1 . . . . . Normally Open Priming Pump Switch on Panel
2 . . . . . Motor Solenoid
3 . . . . . Priming Pump Motor
4 . . . . . Dual Batteries
5 . . . . . Selector Switch
F−1031, Section 2405
Rev: 07/14/06
Page 41
Page 5 of 5
42
CS/CSU Series Overhaul Instructions
Overhaul Instructions
CS/CSU Series Fire Pumps
Form No.
Section
F−1031
4211
Issue Date
Rev. Date
06/30/95 01/03/07
Table of Contents
Mechanical Seal Removal . . . . . . . . . . . . . . . .
Mechanical Seal Installation . . . . . . . . . . . . . . .
Packing − Braided Flexible Graphite (BFG) . .
Packing Removal . . . . . . . . . . . . . . . . . . . . . . . .
Packing Installation . . . . . . . . . . . . . . . . . . . . . .
Packing Adjustment . . . . . . . . . . . . . . . . . . . . . .
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
37
39
39
40
40
41
42
Page 42
IL2740
Safety Information . . . . . . . . . . . . . . . . . Index A
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contents − Complete Disassembly of
Transmission Mounted Pumps . . . . . . . . . . . . . 2
Contents − Complete Disassembly of
Direct Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . 3
Contents − Replacement of Packing/Mech.
Seal without Disassembling the Pump . . . . . . . 4
General Overhaul Information . . . . . . . . . . . . 5
Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . 5
Preliminary Testing . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Bodies and Impellers . . . . . . . . . . . . . . . . 5
Bearings, Gaskets, Seals and O−rings . . . . . . . 5
Impeller Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing Ball Bearings . . . . . . . . . . . . . . . . . . . . 5
Body Molded Gaskets . . . . . . . . . . . . . . . . . . . . . 5
Transmission Removal / Installation . . . . . . . . . 6
Intake Adapter Removal / Installation . . . . . . . . 7
Removal of Impeller Shaft Assembly . . . . . . . . 8
Outboard Bearing Removal / Installation . . . . . 9
End Yoke Removal / Installation on Drive End 18
Seal Housing Removal / Installation . . . . . . . . 21
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . 23
Seal Housing and Cooling Line Check −
Mech. Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Seal Housing and Cooling Line Check −
Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installing Undersize Wear Rings . . . . . . . . . . . 26
Impeller / Wear Ring Installation . . . . . . . . . . . 28
CS ’93 Body Gasket Installation . . . . . . . . . . . 30
Installing Impeller Shaft Assembly into Pump 31
Installing Body Hardware . . . . . . . . . . . . . . . . . 33
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450−5000
Instructions subject to change without notice.
42
All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
43
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.
!
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
Rotating Parts Hazard or Unexpected Truck Movement. May result in
serious 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 someone when the valve is opened. Overheating can damage the packing,
seals and other pump parts. If the apparatus builder has installed a by−
pass system or other provision designed to prevent overheating, opening
a discharge valve may be unnecessary.
F−1031, Section 4211
WARNING
43
Page 43
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
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.
Rev: 01/03/07
Index A
43
44
Contents
Refer to the following tables for overhaul operations required based on the type of overhaul you are performing and type of pump drive you have:
Type of Overhaul
Pump Drive
See Table
On Page
Transmission Mounted Directly to the Pump
1
2
Complete Disassembly of 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)
2
3
Either Listed Above
3
4
Replacement of Packing or Mechanical Seal without
Disassembling the Pump
F−1031, Section 4211
Description
Outboard Bearing Removal − Prior to 4/21/2006 (without lube pump)
Outboard Bearing Removal − Prior to 4/21/2006 (with lube pump)
Outboard Bearing Removal − After 4/21/2006
Outboard Bearing Installation − Prior to 4/21/2006 (without lube pump)
Outboard Bearing Installation − Prior to 4/21/2006 (with lube pump)
Outboard Bearing Installation − After 4/21/2006
Packing Removal Tool
Packing Gland Installation
Rev: 01/03/07
Page
14
15
16
17
17
18
39
40
44
Page 44
Figure Number
1
2
3
4
5
6
7
8
Page 1 of 41
44
45
Contents
Table 1. Complete Disassembly of Transmission Mounted Pumps
See Page
Overhaul Operation
Detail Operation
Pumps with
Mechanical Seals
Pumps with
Packing
General Information
−
5
5
Removing Transmission
−
6
6
Removing Intake Adapters
−
7
7
Removing Impeller Shaft Assembly
−
8
8
Prior to 4/21/2006
9
11
After 4/21/2006
Outboard Bearing Removal
Disassembly of Impeller Shaft Components
12
21
22
Impeller Removal
23
23
Seal Housing Check
24
25
Installing Undersize Wear Rings
26, 27
26, 27
Impeller/Wear Ring Installation
28, 29
28, 29
Seal Housing Installation
21
22
Mechanical Seal Installation
36, 37
−
Packing Installation
−
40
9
11
Outboard Bearing Installation
Attaching Transmission to Pump
F−1031, Section 4211
Prior to 4/21/2006
10
12
Installing Impeller Shaft Assembly
30, 31, 32
30, 31, 32
Installing Body Hardware
33
33
−
6
6
Rev: 01/03/07
After 4/21/2006
45
Page 45
Re−Assembly of Impeller Shaft Components
10
Seal Housing Removal
Page 2 of 41
45
46
Contents
Table 2. Complete Disassembly of Direct Drive Pumps
See Page
Overhaul Operation
Detail Operation
Pumps with
Mechanical Seals
Pumps with
Packing
General Information
−
5
5
Removing Intake Adapters
−
7
7
Removing Impeller Shaft Assembly
−
Disassembly of Impeller Shaft Components
8
8
Front or Rear Drive w/o Tachometer
9
11
Front Drive w/Tachometer
13
13
Front Drive w/Tachometer
19
19
Front or Rear Drive without
Tachometer
20
20
Seal Housing Removal
21
22
Outboard Bearing Removal
End Yoke Removal on Drive End
Disassembly of Impeller Shaft Components
Re−Assembly of Impeller Shaft Components
Re−Assembly of Impeller Shaft Components
F−1031, Section 4211
23
23
24
25
Installing Undersize Wear Rings
26, 27
26, 27
Impeller/Wear Ring Installation
28, 29
28, 29
Seal Housing Installation
21
22
Mechanical Seal Installation
37, 38
−
Packing Installation
−
40
Front or Rear Drive w/o Tachometer
9
11
Front Drive w/Tachometer
13
13
Front Drive w/Tachometer
19
19
Front or Rear Drive without
Tachometer
20
20
Installing Impeller Shaft Assembly
30, 31, 32
30, 31, 32
Installing Body Hardware
33
33
Outboard Bearing Installation
End Yoke Installation on Drive End
Rev: 01/03/07
46
Page 46
Re−Assembly of Impeller Shaft Components
Impeller Removal
Seal Housing Check
Page 3 of 41
46
47
Contents
Table 3. Replacement of Packing/Mechanical Seal without Disassembling the Pump.
Pump Driven By
Type of Seal
Operation
See Page
General Information
5
Transmission Removal
6
Outboard Bearing Removal
10, 16
34, 35, 36
Seal Installation
Transmission Mounted Directly to the Pump
Outboard Bearing Installation
Packing
Rev: 01/03/07
After 4/21/2006
10, 18
6
Packing Removal
39
Packing Installation
40
Packing Adjustment
40
General Information
5
Outboard Bearing Removal
14, 15, 16
Front Drive with Tachometer
19
Front or Rear Drive without
Tachometer
20
Seal Removal
34, 35, 36
Seal Installation
37, 38
Outboard Bearing Installation
17, 18
End Yoke Installation on Drive End
Packing
9, 17
Front Drive with Tachometer
19
Front or Rear Drive without
Tachometer
20
Packing Removal
39
Packing Installation
40
47
Page 47
Mechanical Seals
(Pump is driven by a remotely mounted transmission or P.T.O. The pump is turned by an end yoke on
the impeller shaft)
37, 38
Prior to 4/21/2006
Transmission Installation
End Yoke Removal on Drive End
F−1031, Section 4211
9, 14, 15
After 4/21/2006
Seal Removal
Mechanical Seals
Direct Drive
Prior to 4/21/2006
Page 4 of 41
47
48
General Overhaul Information
Tools and Equipment
Bearings, Gaskets, Seals and O−rings
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.
Parts of this nature are frequently damaged during removal or disassembly. In addition, they sometimes deteriorate or lose their effectiveness because of age or misuse. Replacing these parts whenever overhauling a
pump is a good policy.
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 available from the apparatus manufacturer or the Waterous Company. These
special items are not absolutely necessary, but they will make the mechanic’s work much easier.
Impeller Shafts
Examine shaft for severe scratches, grooves or corrosion − especially under 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 usually permissible if they are not sharp or too deep. Even slight longitudinal
scratches will cause leaks and should be removed.
Installing Ball Bearings
Cleaning
Gaskets
The continued satisfactory operation of a pump depends to a great extent
upon the cleanliness of its internal parts. Sand, dirt or other abrasive material 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.
CS ’04 Pumps (Pumps built after March, 2005)
Page 48
Pump Bodies and Impellers
Flush out these components and related parts with clean water and
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.
F−1031, Section 4211
48
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. Excessive
speed, for instance, indicates that impellers and/or wear rings are probably
worn.
Most Waterous pumps are designed so that ball bearings fit tightly on their
shafts and have relatively loose fits in the bearing housings. When mounting 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.
Preliminary Testing
For ease of installation, the CS pump uses a body molded gasket design.
The molded gasket, made of nitrile rubber, fits into a channel in the pump
body.
CS ’93 Pumps (Pumps built from 1994 to March, 2005)
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.
Rev: 01/03/07
Page 5 of 41
48
49
Transmission Removal / Installation
Pump
Transmission
49
Page 49
IL1211
1. Remove the four cap screws and lock washers that attach the transmission to the pump.
Jacking Screw Holes
2. Use the jacking screw holes to separate the transmission from the pump body.
3. Support transmission and pull straight back from pump.
F−1031, Section 4211
Rev: 01/03/07
Page 6 of 41
49
50
Intake Adapter Removal / Installation
Hex Hd Screw,
3/4−10 x 2 in.
Torque to
160−180 Ft−Lbs
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 adapters need to be replaced.
Hex Hd Screw
Discharge Flange
Gasket
Gasket
Discharge Flange
Gasket
Intake Adapter, RH
50
Page 50
Intake Flange Gasket
Hex Hd Screw,
3/4−10 x 2 in.
Torque to
160−180 Ft−Lbs
Plain Bearing, TFE
Tank Intake Adapter
(or Valve)
O−ring
6−3/4 x 7 in.
Intake Adapter, LH
Intake Flange Gasket
Gasket
Optional
Tank To Pump
Check Valve
Hex Hd Screw,
1/2−13 x 1−1/4 in.
IL2460
Hex Hd Screw
F−1031, Section 4211
Rev: 01/03/07
Page 7 of 41
50
51
Removal of Impeller Shaft Assembly
Volute Body
IL1273
51
Page 51
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).
Bearing Housing
Jacking Screw Hole
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 remain in the volute cover.
Volute Cover
Jacking Screw Hole
O−ring
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 molded gasket material from the two
pump halves and O−rings.
O−rings
IL2459
F−1031, Section 4211
Rev: 01/03/07
Page 8 of 41
51
52
Outboard Bearing Removal / Installation − Before 4/21/2006
(Transmission Mounted Pumps with Mechanical Seals or
Direct Drive Pumps without Tachometer with Mechanical Seals)
(Reference Pages 14, 15 and 17)
Pipe Plug, 1/4 in.
Retaining Ring, 1−17/64
NOTE: If groove width on shaft is
1/16” wide, use W 4510−137, 3/32”
wide, use W 4520−137.
Ball Bearing
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
To prevent seal from pushing out
of housing, do not use power
grease gun.
Hex Hd Screw,
3/8−16 x 1 in.
Bearing Housing
52
Page 52
Lock Washer, 3/8 in.
Lubrication Seal
Bearing Housing Cap
Gasket
Retaining Ring, 1−3/8
(Flinger Ring)
Make sure slot lines up with
lube fitting when reassembling.
Retaining Ring, 1−17/64
NOTE: If groove width on shaft is
1/16” wide, use W 4510−137, 3/32”
wide, use W 4520−137.
Hex Hd Screw,
1/2−13 x 1−1/4 in.
Lock Washer, 1/2 in.
Lubrication Relief Fitting
Lubrication Fitting, 1/8 in.
IL1223
Seal Housing Assembly
F−1031, Section 4211
Rev: 01/03/07
Page 9 of 41
52
53
Outboard Bearing Removal / Installation − After 4/21/2006
Hex Hd Screw,
1/2−13 x 1−1/4 in.
(Transmission Mounted Pumps with Mechanical Seals)
(Reference Pages 16 and 18)
Lock Washer, 1/2 in.
Retaining Ring,
.093 in. Thick
Bearing Housing Plug
Bearing Housing
Bearing Shield
Retaining Ring,
.093 in. Thick
53
Page 53
Retaining Ring,
.109 in. Thick
Retaining Ring,
(Flinger Ring)
.062 in. Thick
Ball Bearing
Retaining Ring,
.109 in. Thick
IL2730
Seal Housing Assembly
F−1031, Section 4211
Rev: 01/03/07
Page 10 of 41
53
54
Outboard Bearing Removal / Installation (Prior to 4/21/06)
(Transmission Mounted Pumps with Packing or
Direct Drive Pumps without Tachometer with Packing)
(Reference Pages 14, 15 and 17)
Pipe Plug, 1/4 in.
V−Ring Flinger Installation
Retaining Ring, 1−17/64
NOTE: If groove width on shaft is
1/16” wide, use W 4510−137, 3/32”
wide, use W 4520−137.
Ball Bearing
Make sure flat side is facing away from bearing
housing when reassembled on shaft.
Hex Hd Screw,
3/8−16 x 1 in.
Bearing Housing
54
Page 54
Lock Washer, 3/8 in.
Lubrication Seal
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.
Gasket
V−Ring Flinger
Hex Hd Screw,
1/2−13 x 1−1/4 in.
Lock Washer, 1/2 in.
CAUTION
CAUTION
Lubrication Relief Fitting
To prevent seal from pushing out
of housing, do not use power
grease gun.
Lubrication Fitting, 1/8 in.
IL1219
Seal Housing Assembly
F−1031, Section 4211
Rev: 01/03/07
Page 11 of 41
54
55
Outboard Bearing Removal / Installation (After 4/21/06)
Hex Hd Screw,
1/2−13 x 1−1/4 in.
(Transmission Mounted Pumps with Packing)
(Reference Pages 16 and 18)
V−Ring Flinger Installation
Lock Washer, 1/2 in.
Make sure flat side is facing away from bearing
housing when reassembled on shaft.
Bearing Housing Plug
Bearing Housing
55
Page 55
Bearing Shield
Retaining Ring,
.109 in. Thick
V−Ring Flinger
Make sure flat side
faces away from the
bearing housing when
installed on the shaft.
Retaining Ring,
.093 in. Thick
Sealed Ball Bearing
Retaining Ring,
.109 in. Thick
IL2731
Seal Housing Assembly
F−1031, Section 4211
Rev: 01/03/07
Page 12 of 41
55
56
Outboard Bearing Removal / Installation
(Direct Drive Pumps − Front Drive with Tachometer)
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.
V−Ring Flinger
CAUTION
CAUTION
Bearing Spacer
To prevent seal from pushing out
of housing, do not use power
grease gun.
Bearing Seal
Ball Bearing
Lubrication Relief Fitting
56
Page 56
Bearing Housing
Impeller Shaft
Jacking Screw
Holes
V−Ring Flinger Installation
IL1227
Lock Washer, 1/2 in.
Hex Nut, 1/2−20
IL1291
Lubrication Fitting, 1/8 NPT
Make sure flat side is facing away from bearing
housing when reassembled on shaft.
F−1031, Section 4211
Hex Hd Screw, 1/2−20 x 1−3/4 in.
Rev: 01/03/07
Page 13 of 41
56
57
Outboard Bearing Removal (Prior to 4/21/2006)
(See Figures 1 & 2)
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 oil pump − See Figure 2).
CAUTION
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 retaining 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.
8. Remove inner bearing retaining ring from impeller shaft. (Note: Inner retaining 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.
Figure 1. Outboard Bearing Removal (without oil pump, Prior to 4/21/2006)
CAUTION
CAUTION
Remove outer retaining ring before installing puller.
Hex Hd Screw 3/8−16 x 3 (Coarse Thread)
57
Page 57
Hub puller screw,
tighten screw to pull
bearing off shaft
Bearing Housing
CAUTION
CAUTION
Do not damage internal thread of
impeller shaft.
Hub puller bar
Lubrication Seal
Inner Retaining Ring
(Mechanical seal equipped
pumps only)
Hub puller bar, attach to bearing
housing in place of bearing
housing cap
F−1031, Section 4211
Hex Hd Screw,
3/8−16 x 3
(Coarse Thread)
Rev: 01/03/07
Apply grease to
center of shaft
IL2026
Page 14 of 41
57
58
Outboard Bearing Removal with Lube Pump (Prior to 4/21/2006)
Figure 2. Outboard Bearing Removal (when equipped with oil pump, prior to 4/21/2006)
Hex Hd Screw, 3/8−16 x 3
(Coarse Thread)
CAUTION
CAUTION
Remove outer retaining ring before installing puller.
Bearing Housing
CAUTION
Do not damage external thread
of impeller shaft.
58
Page 58
Hub puller bar
Lubrication Seal
Hub puller screw,
tighten screw to pull
bearing off shaft
Inner Retaining Ring
(Mechanical seal equipped pumps only)
Hub puller bar, attach to bearing housing
in place of bearing housing cap
Bearing
Removal Tool
Hex Hd Screw,
3/8−16 x 3 (Coarse Thread)
F−1031, Section 4211
Rev: 01/03/07
Apply grease to pilot in
bearing removal tool
IL2003
Page 15 of 41
58
59
Outboard Bearing Removal (After 4/21/2006)
(See Figure 3)
1.
2.
3.
4.
Remove plug from bearing housing.
Remove the bearing outer retaining rings from the impeller shaft.
Remove (4) hex hd screws attaching the bearing housing to the pump
body.
Install hub puller bar. (Use bearing removal tool if removing outboard bearing on units equipped with oil pump − See Figure 2).
5.
6.
7.
Tighten hub puller screw, causing the bearing housing to pull the bearing
off of the end of the impeller shaft.
Remove inner bearing retaining rings from impeller shaft and bearing
housing. (Note: Inner retaining ring on shaft is not used on pumps
with packing).
Remove bearing from bearing housing.
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.
Figure 3. Outboard Bearing Removal (After 4/21/2006)
CAUTION
CAUTION
Remove outer retaining rings before installing puller.
Hex Hd Screw 3/8−16 x 3 (Coarse Thread)
59
Page 59
Hub puller screw,
tighten screw to pull
bearing off shaft
Bearing Housing
Inner Retaining Rings
Note: This ring is used on pumps with
Mechanical seals CAUTION
only, not used on
pumps with packing, these shafts have
a machined shoulder.
CAUTION
Hub puller bar
Do not damage internal thread of
impeller shaft.
Shield
Apply grease to
center of shaft
Hub puller bar, attach to bearing
housing in place of bearing housing cap
F−1031, Section 4211
Hex Hd Screw,
3/8−16 x 3 (Coarse Thread)
Rev: 01/03/07
IL2717
Page 16 of 41
59
60
Outboard Bearing Installation (Prior to 4/21/2006)
1.
2.
3.
4.
5.
Packed Pumps: Install v−ring flinger on impeller shaft. Mechanical Seal Pumps:
Install (flinger) retaining ring on impeller shaft.
Install new lubrication seal in bearing housing and reinstall bearing housing on
pump.
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.
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.
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 (Figure 4), attach assembled tool to
the impeller shaft by threading hex hd screw completely into the internal
thread of the impeller shaft.
b.
6.
7.
8.
9.
Figure 4. Outboard Bearing Installation (without oil pump)
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.
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 turning with the hex nut.
Remove the tool and install the bearing outer retaining ring. Ensure correct retaining ring is used.
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.
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.
Figure 5. Outboard Bearing Installation (when equipped with oil pump)
Prior to 4/21/2006
Prior to 4/21/2006
Apply grease to bearing journal of shaft.
Apply grease to bearing journal of shaft.
Bearing
Flinger Retaining Ring
(Mechanical seal pumps)
or V−ring Flinger
(Packing Pumps)
Bearing
Flat Washer
Flat Washer
Hex Hd Screw
(Coarse Thread)
Hex Nut
(Fine Thread)
Hex Nut
(Coarse Thread)
Hex Hd Screw
(Fine Thread)
Thrust Washer
Bearing Installation Tool Housing
Grease Fitting
Lube Relief Fitting
F−1031, Section 4211
Inner Retaining Ring
(Mechanical seal
equipped pumps)
60
Page 60
Bearing Housing
Bearing Housing
Thrust Washer
Inner Bearing
Retaining Ring
Bearing Installation Tool Housing
(Mechanical Seal
Equipped Pumps Only)
Bearing Installation Tool
Lubrication Seal
Grease Fitting
IL2025
Rev: 01/03/07
Lube Relief Fitting
Flinger
Retaining Ring
(Mechanical seal
pumps) or
V−Ring Flinger
(Packing Pumps)
Lubrication Seal
IL2002
Page 17 of 41
60
61
Outboard Bearing Installation (After 4/21/2006)
1.
2.
3.
4.
5.
Packed Pumps: Install v−ring flinger on impeller shaft. Mechanical Seal Pumps:
Install (flinger) retaining ring on impeller shaft.
Install new shield seal in bearing housing and reinstall bearing housing on pump.
Install inner bearing retaining rings. (Note: Inner retaining ring on shaft is not
used on pumps with packing).
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.
Screw hex nut onto hex hd screw and slide flat washer, thrust washer and bearing
installation tool housing onto screw.
6.
7.
8.
9.
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 turning with the hex nut.
Remove the tool and install the bearing outer retaining rings.
Install plug in outside of bearing housing.
Note that bearing is sealed and does not required external lubrication.
Figure 6. Outboard Bearing Installation (after 4/21/2006)
Apply grease to bearing journal of shaft
Bearing Housing
Bearing
Shield
Page 61
Hex Nut
(Fine Thread)
61
Flinger Retaining Ring
(Mechanical seal pumps)
or V−ring Flinger
(Packing Pumps)
Flat Washer
Note: This ring is used on pumps with
Mechanical seals only, not used on
pumps with packing, these shafts have
a machined shoulder.
Hex Hd Screw
(Fine Thread)
Inner Bearing
Retaining Rings
Thrust Washer
Bearing Installation Tool Housing
IL2718
F−1031, Section 4211
Rev: 01/03/07
Page 18 of 41
61
62
End Yoke Removal/Installation on Drive End
(Front Drive with Tachometer)
*Cotter Pin, 1/8 x 1−3/4”
(*Before 4/20/98)
**Self−Locking Nut (Torque to 275−325 LB−FT)
(**After 4/20/98)
End Yoke with U−bolts
Tachometer Gear Housing
Lubrication Relief Fitting
O−ring, 3−1/4 x 3−1/2 in.
Lubrication Seal
Spring Pin, 3/16 x 1/2 in.
Tachometer Drive Gear
*Castle Nut
Tachometer Gear Spacer
Ball Bearing
To prevent seal from pushing out
of housing, do not use power
grease gun.
Retaining Ring
Lock Washer,
3/8 in.
62
Page 62
Hex Hd Screw,
3/8−16 x 1 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.
CAUTION
CAUTION
Bearing Housing
Bushing
Tachometer Driven Gear
Lubrication Seal
Tachometer Sleeve
V−Ring Flinger Installation
Hex Hd Screw,
1/2−13 x 1−1/4 in.
V−ring Flinger (Both Packing and
Mechanical Seal Pumps)
Lock Washer, 1/2 in.
Impeller Shaft
Jacking Screw Holes
Lubrication Fitting
1/8 NPT
Make sure flat side is facing away from bearing
housing when reassembled on shaft.
F−1031, Section 4211
Rev: 01/03/07
IL1225
Page 19 of 41
62
63
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)
Lubrication Seal
Bearing Housing
Gasket
Bearing Spacer
Ball Bearing
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
CAUTION
To prevent seal from pushing out
of housing, do not use power
grease gun.
Oil Seal Housing
63
Page 63
Hex Nut, 1/2−20
Lubrication Seal
Jacking Screw Holes
Lubrication Fitting, 1/8 NPT
End Yoke with U−bolts
Lubrication Relief Fitting
V−Ring Flinger Installation
Lock Washer, 1/2 in.
Hex Hd Screw,
1/2−20 x 1−3/4 in.
Lock Washer, 3/8 in.
Hex Hd Screw, 3/8−16 x 1 in.
**Self−Locking Nut
Torque to 275−325 LB−FT
(**After 4/20/98)
*Cotter Pin, 1/8 x 1−3/4”
Make sure flat side is facing away from bearing
housing when reassembled on shaft.
F−1031, Section 4211
(*Before 4/20/98)
*Castle Nut
IL1233
Rev: 01/03/07
Page 20 of 41
63
64
Seal Housing Removal / Installation
Throttle Bushing (Iron Pumps only)
(Pumps with Mechanical Seals)
Seal Chamber Cover
O−ring, 3 x 3−1/4 in.
Throttle Bushing (Iron Pumps only)
Mechanical Seal
Mechanical Seal
Stationary Ring
Seal Chamber Cover
Seal Housing
O−ring
Page 64
Seal Housing Gasket
64
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) Lockwashers (Prior to 1988)
(4) Plain Washers (Used 1988−1993)
Dowel Pin, 1/4 x 1/2 in.
Impeller Shaft
IL 1224/1283
F−1031, Section 4211
Rev: 01/03/07
Page 21 of 41
64
65
Seal Housing Removal / Installation
(Pumps with Packing)
NOTE: Install lantern ring, packing,
gland, studs, washers and nuts in seal
housing before installing on shaft (See
Page 35).
Flat Brass Washer, 5/16 in.
Stud, 5/16−18 x 1−5/8 in.
Gland
Lantern Ring
Seal Housing Gasket
Unbalanced Nut, 5/16−18
Seal Housing
65
Page 65
Seal Housing Gasket
* Braided Flexible Graphite Packing (BFG)
11/32 in. thick
Impeller Shaft
* 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.
IL1220
F−1031, Section 4211
Rev: 01/03/07
Page 22 of 41
65
66
Impeller Removal
Wear Ring
Retaining Ring
Impeller Shaft
66
Page 66
Impeller
Retaining Ring
Square Key,
5/16 x 2−3/4 in.
Wear Ring
1. Remove wear rings and retaining rings.
IL1288
2. Remove impeller and key.
F−1031, Section 4211
Rev: 01/03/07
Page 23 of 41
66
67
Seal Housing and Cooling Line Check
(Mechanical Seal)
Seal Housing − If the total clearance between the seal housing and the impeller
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 the cooling lines due to offset in seal
housing hole.
Seal Housing
Seal Housing
67
Page 67
IL1312
Impeller Shaft
F−1031, Section 4211
Rev: 01/03/07
Page 24 of 41
67
68
Seal Housing and Cooling Line Check
(Packing)
Seal Housing − If the total clearance between the seal housing and the impeller
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.
Packing Housing
Packing Housing
68
Page 68
Impeller Shaft
IL1313
F−1031, Section 4211
Rev: 01/03/07
Page 25 of 41
68
69
Installing Undersize Wear Rings
1. Check wear rings and impeller hubs for deep grooves or scratches.
IMPELLER
71651−T / 81882−T
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.
1.187
Rework Depth
3. The diametral clearance is determined by averaging the results of four
measurements taken at 90° increments as follows:
.719
Rework Depth
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.
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.
A
Dia
B
Dia
5. Non−plated impeller hub wear ring clearance is restored by turning impeller hubs and installing undersize wear rings.
69
Page 69
10−1/2 DIA
c.
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.
1304
Original Hub Dia
A − 6.370 (Min)
B − 6.426 (Min)
F−1031, Section 4211
Rev: 01/03/07
Original Wear
Ring No.
Reworked
Hub Dia A
Reworked
Hub Dia B
New Wear
Ring No.
72474
6.350/6.348
6.325/6.323
6.300/6.298
6.407/6.405
6.382/6.380
6.357/6.355
72474−25
72474−50
72474−75
Page 26 of 41
69
70
Installing Undersize Wear Rings
(Continued)
IMPELLER
71799 or 71799−T
IMPELLERS
81357 or 81357−T
1.19 inch
Rework Depth
4−3/8
Eye Dia
10−1/2 DIA
5
Eye Dia
Hub Dia
See Table
Hub Dia
See Table
70
Page 70
10−1/2 DIA
1.093 inch
Rework Depth
1305
1303
Original Hub Dia
Non−plated
5.498 (Min)
Flame Plated 5.494 (Min)
F−1031, Section 4211
Original Wear
Ring No.
Reworked
Hub Dia
New Wear
Ring No.
72409
5.476/5.473
5.451/5.448
5.426/5.423
72409−25
72409−50
72409−75
Rev: 01/03/07
Original Hub Dia
Non−plated
5.311 (Min)
Flame Plated 5.307 (Min)
Original Wear
Ring No.
Reworked
Hub Dia
New Wear
Ring No.
72430
5.288/5.286
5.263/5.261
5.238/5.236
72430−25
72430−50
72430−75
Page 27 of 41
70
71
Impeller / Wear Ring Installation
Impeller
Wear Ring
Wear Ring
Retaining Ring
Retaining Ring
Impeller Shaft
Square Key
71
Page 71
IL1290
1. Install impeller over square key on shaft. Make sure the position
of the impeller is not reversed. Be sure rotation of impeller is
correct, see page 25 for impeller rotation.
2. Install retaining rings
3. Install wear rings.
F−1031, Section 4211
Rev: 01/03/07
Page 28 of 41
71
72
Impeller / Wear Ring Installation
(Continued)
Pump Body (Volute)
ROTATION
Eye of Impeller (Intake)
Discharge
72
Page 72
Stripping Edge
Stripping Edge
Impeller Vanes
Discharge
F−1031, Section 4211
Rev: 01/03/07
Page 29 of 41
72
73
CS ’93 Body Gasket Installation when the Pump Body is Disassembled
(Pumps without Separate Seal Housings)
The mechanical seals should be installed in the pump after the impeller shaft has
been installed and the body halves are bolted together. Before bolting body
halves together, pay special attention to the body gasket in the seal cover area
on both ends of the pump as follows:
S
The seal chamber cover seal (square cross−section rubber ring) can seal into
gaps at the pump body split line a maximum of 1/16 inch deep. The sealing
capability depends on gap width, seal hardness, etc.
S
The pump body gasket should come as close as possible to being flush (without protruding) with the edge of the pump body at the seal chamber cover
sealing surface. It is recommended that the gasket be within 1/32 inch of the
edge of the pump body. This applies to both ends of the pump.
Lathe−cut Gaskets
73
Page 73
Gasket
Make sure dowel
pin is seated in
volute cover.
IL2453
Make sure gasket fits tight against
seal housing. Apply a pea sized
drop of 100% silicone RTV sealant
at each of the body gasket and
lathe−cut gaskets intersection locations (4 per seal housing).
Pump Cover
F−1031, Section 4211
Rev: 01/03/07
Page 30 of 41
73
74
Installing Impeller Shaft Assembly into Pump
(CS ’04 Molded Body Gasket)
Step 1
Clean all bores and grooves in the pump body and cover thouroughly.
Step 3
Install molded body gaskets and O−rings as directed in diagram below.
Step 2
Apply silicone to areas identified in diagram below.
Pump Cover
Molded body gaskets
(two required).
Lightly brush the
gasket channels with
a food grade grease.
Gently press gasket
into channel.
74
Page 74
Apply a pea sized
drop of 100% silicon
RTV sealant at the
intersection of the
body gasket groove and
body bore. Apply at
all four locations.
F−1031, Section 4211
Rev: 01/03/07
O−rings (four required).
Lightly brush the
O−rings with a food
grade grease. Gently
press O−rings into the
grooves.
Page 31 of 41
74
75
Installing Impeller Shaft Assembly into Pump
(CS ’04 Molded Body Gasket)
Step 4
1. Coat impeller shaft seal housings and the seal housing bores (in
both the pump body and cover) with Never−Seez or equivilent.
Step 5
1. Apply a pea sized drop of 100% silicone RTV sealant to the four areas
where the molded body gaskets interface with the seal housing gaskets.
2. Install impeller shaft assembly in the pump cover making sure the
dowel pins in the seal housings engage the holes in the pump
cover seal housing bores.
Seal housing gasket
Seal housing
Apply silicone to this area
(all four locations)
Molded body gasket
75
Page 75
IL2451
IL2637
Step 6
Attach pump cover to pump body (see next page for hardware).
NOTE: Reassembled pump should be tested per NFPA 1911 to
verify performance before vehicle is placed back in service.
F−1031, Section 4211
Rev: 01/03/07
Page 32 of 41
75
76
Installing Body Hardware
CS ’93
Ref No.
B10
B11
B14
B18
B40
B59
Description
Hex Hd Screw, 1/2−13 x 4−3/4 in.
Dowel Pin, 7/16 x 1−1/4 in.
Socket Hd, 5/8−11 x 3 in.
Hex Hd Screw, 1/2−13 x 1−1/2 in.
Socket Hd, 1/2−13 x 1−1/2 in.
Socket Hd, 1/2−13 x 4−3/4 in.
CS ’04
Qty
Torque
Ref No.
Qty
Torque
7
2
4
20
20
7
105LB/FT
B10
B11
B12
Socket Hd, 1/2−13 x 1−1/2 in.
Socket Hd, 1/2−13 x 4 in.
Socket Hd, 1/2−13 x 4−3/4 in.
8
4
4
105LB/FT
B21
Dowel Pin, 7/16 x 1−1/4 in.
2
105LB/FT
Description
Torque order not required.
Jacking
Screw Hole
76
Page 76
Jacking
Screw Hole
Jacking
Screw Hole
F−1031, Section 4211
Jacking Screw Hole
Rev: 01/03/07
Page 33 of 41
76
77
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
Outboard bearing removal/installation tools
K628
Mechanical seal removal/installation tools
Parts of kit K 628
Mechanical Seal Removal / Installation Tools
Remove Spacer,
it is Used on CM
Models Only
77
Page 77
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
2. Whenever a mechanical seal requires replacement, the Waterous Service
Department strongly recommends replacing both seals; outboard bearing
F−1031, Section 4211
IMPELLER SHAFT BRUSH
INSTALLATION SLEEVE
P/N V 2633
P/N 52280
and drive end. Note: Always replace the outboard seal and bearing
assembly first.
Rev: 01/03/07
Page 34 of 41
77
78
Mechanical Seal Removal
(Without Disassembling the Pump)
(Continued)
Mechanical Seal
(See next page for removal)
O−ring (After 1993)
Square Gasket (Prior to 1993)
Brush (P/N V 2633)
Seal Chamber Cover
Mechanical Seal
Stationary Ring
IL1180
78
Page 78
(6) Hex Hd or Socket Hd Screws 1/4−20 x 1 in.
(4) Socket Hd Screws (Prior to 1993)
(4) Lockwashers (Only Lockwashers Before 1988)
(4) Plain Washers (Used from 1988 to 1993)
3. Clean the impeller shaft, using the impeller shaft brush.
4. Remove the screws (and washers if applicable) that attach the
seal chamber cover to the seal housing and remove the cover.
Seal Chamber Cover
O−ring or Gasket
Seal Chamber
Cover
5. Clean the impeller shaft again to remove any debree 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.
CAUTION
Throttle Bushing (iron pump only)
IL1276
Seal Chamber Cover
F−1031, Section 4211
Rev: 01/03/07
Throttle bushing is brass and can be damaged if hit with excessive force. If throttle bushing is damaged, replace it.
7. Discard the O−ring from seal chamber cover. Clean seal chamber cover.
Page 35 of 41
78
79
Mechanical Seal Removal
(Without Disassembling the Pump)
(Continued)
Remove
Spacer Before
Using
Remove Spacer
Before Using
79
Page 79
IL1279
IL1376
10. Turn the hex head on the removal tool counterclockwise to remove the
seal.
8. 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 bearing housing. The plate must be flush with the pump body, but tighten
screws hand−tight only.
11. Remove the tool and the seal.
9. 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).
12. Remove spring retainer and spring if they do not come out with the seal.
Clean seal chamber and impeller shaft.
13. 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.
F−1031, Section 4211
Rev: 01/03/07
Page 36 of 41
79
80
Mechanical Seal Installation
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 surfaces
should be “mirror smooth” and without scratches. To identify the stationary 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.
Installation Sleeve
Shaft
Shoulder
CAUTION
Try not to touch the “mirror smooth” surfaces. If surfaces are touched clean
surface with denatured alcohol and a soft cloth.
CAUTION
IL1384
Installation Tool
(Use the end with the machined nose to push seal.)
2.
Outboard Bearing End
Mechanical Seal
consists of:
− Spring Retainer
− Spring
− Bellows
− Seal (primary ring)
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.
3.
Nose End
4.
Installation Tool
IL1280
F−1031, Section 4211
Transmission End
Blunt End
NOTE: If Waterous Mechanical Seal Lubricant part no. 52608 is not available,
P80 rubber lubricant, straight dish soap or glycerin may be substituted.
Check that the throttle bushing is installed 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 cover, 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.
80
Page 80
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.
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 protection
sleeve may cause damage to the seal. Liberally coat shaft and sleeve with lubricant (supplied with kit) before installing the mechanical seal.
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 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).
Rev: 01/03/07
Page 37 of 41
80
81
Mechanical Seal Installation − Continued
5. Be sure the stationary ring, O−ring, throttle bushing and O−ring gasket are
installed in seal chamber cover, see Step 2).
Seal Chamber Cover
Mounting Screws (6)
used After 1993 (4)
used Prior to 1993
O−ring Gasket
(After 1993)
Square Gasket
(Prior to 1993)
6. 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. On pre 93 pumps use both lockwashers and flatwashers.
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.
7. Turn impeller shaft by hand at least two revolutions in both a clockwise
and counterclockwise direction to seat seals.
81
Page 81
8. Hydrostatically test pump at 150 psi (10.3 bar). 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 pressure 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.
IL 1914
Stationary Ring, O−ring
and Throttle Bushing
Installation Tool
(Use the blunt end of tool
to push the cover.)
Seal Chamber Cover Installation
F−1031, Section 4211
Rev: 01/03/07
Page 38 of 41
81
82
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.
!
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.
Packing Removal
WARNING
CAUTION
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.
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.
!
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.
3. If all the packing is not forced out, it may be necessary to remove the remaining packing by hand, using a pick or similar device. Waterous has a
packing removal tool (P/N 5782) available for this purpose, see Figure 7.
82
Page 82
1. Remove the unbalanced nuts, flat washers and packing gland halves from
one end of the pump.
4. Replace packing per instructions below, repeating the procedure for the
opposite end of the pump.
Figure 7. Packing Removal Tool
IL1931
F−1031, Section 4211
Rev: 01/03/07
Page 39 of 41
82
83
Packing Installation
7. Adjust packing as required per instructions on the next page.
1. Before installing the new packing, be sure that all of the old packing is removed from the seal housing.
Packing Adjustment
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), see Figure 8.
NOTE: Be sure that the packing joints are staggered at least 90_
apart.
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.
NOTE: The milled slot on the nut should face the gland.
Figure 8. Packing and Gland Installation
!
WARNING
83
Page 83
6. Install packing glands, nuts and washers. Tighten gland nuts one flat beyond finger tight, see Figure 8.
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
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 4211
Rev: 01/03/07
Page 40 of 41
83
84
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, intake 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 atmospheres 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.
Page 84
F−1031, Section 4211
Rev: 01/03/07
84
4. Repeat test.
Page 41 of 41
84
85
C10 Chain Drive Transmission Overhaul Instructions
Overhaul Instructions
C10 Chain Drive Transmission
Issue Date
F−1031
4314
04/20/06
Rev. Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
19.
20.
21.
22.
23.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Eclipse ES CAFSystem Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Eclipse ES CAFSystem Air Clutch Assembly (Side View) . . . . . . . . . . . . . 2
Supporting Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of End Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of Coupling Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removable Connecting Pin Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Drive Shaft and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Shift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Mid−Section from Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of Driven Shaft Assemblies (Figures 12−18) . . . . . . . . . . . . 7
Coupling Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Shaft Disassembly −
Shift Collar and Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Needle Bearing Removal from Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reassembly of the Driven Shaft (Figures 23−29) . . . . . . . . . . . . . . . . . . . 13
Dowel Pins and Spacer Installation for Extended Drop Cases . . . . . . . . 20
Pivot Pin, Shaft Bushing and Sleeve Bearing Installation . . . . . . . . . . . . 21
Shift Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mid−Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cap and Mid−Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Needle Bearing Installation into Drive Sprocket . . . . . . . . . . . . . . . . . . . . 24
Drive Shaft Installation into Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . 24
Drive Assembly into Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drive Shaft/Housing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Electronic Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installing the Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Connecting Pin Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting Pin Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assembling Items on the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembling Bottom Section to the Cap and Mid−Section . . . . . . . . . . . . 28
Retainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coupling Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Coupling Shaft Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembling Coupling Shaft Housing to Case . . . . . . . . . . . . . . . . . . . . . . 31
End Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
85
Page 85
IL 2742
Section
Illustrations
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Propeller Shaft Disconnect and Accessory Removal . . . . . . . . . . . . . . . . . 1
Eclipse CAFSystem Removal from Transmission . . . . . . . . . . . . . . . . . . . . 1
Eclipse ES CAFSystem Removal from Transmission . . . . . . . . . . . . . . . . . 1
Pump Removal from Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of End Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coupling Shaft Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of the Drive Shaft and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Shift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Mid−Section from Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of Driven Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Separable Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Separable Shaft − Eclipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separable Shaft − Hydraulic Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separable Shaft − Combination Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Separable Shaft − Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
One−Piece Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Eclipse ES Mounted CAFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly of Coupling Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly of Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installing Bearings, Oil Seals and O−rings . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reassembly of the Driven Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Separable Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Separable Shaft − Eclipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Separable Shaft − Hydraulic Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Separable Shaft − Combination Pump . . . . . . . . . . . . . . . . . . . . . . . . . 16
Separable Shaft − Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
One−Piece Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Eclipse ES Mounted CAFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dowel Pins and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Reassembly of the Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reassembly of the Cap and Mid−Section . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reassembly of the Drive Shaft and Drive Shaft Housing . . . . . . . . . . . . . 24
Installing the Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reassembly of the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shift Position Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coupling Shaft and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Coupling Shaft Housing to Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reassembly of Miscellaneous Items and Accessories . . . . . . . . . . . . . . . 32
Eclipse CAFSystem Installation onto Transmission . . . . . . . . . . . . . . . . . 33
Eclipse ES CAFSystem Installation onto Transmission . . . . . . . . . . . . . . 33
Propeller Shaft Connection and Accessory Installation . . . . . . . . . . . . . . . 34
Lubrication and Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Form No.
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450−5000
Instructions subject to change without notice.
85
All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
86
Introduction
This instruction provides the necessary steps required to overhaul the C10 transmission. These instructions are divided into Disassembly and Reassembly
sections. Also, refer to the Service Parts List (SPL documents) furnished with your C10 transmission to aid in further part identification and repair parts ordering.
General Description
The Waterous C10 is a chain driven transmission with a housing
constructed of high−strength aluminum. Drive and driven sprockets are
made of hardened steel and have ground bores. Shafts are made of alloy
steel forgings, hardened and ground to size. A passive lubrication system
eliminates the need for a separate oil pump. The shift mechanism is a
constant−mesh, two−position sliding collar that engages all teeth simultaneously.
Disassembly
Before beginning the disassembly process, drain the fluid from the transmission by removing the drain plug. Note that these instructions apply for out of
chassis overhaul of the unit.
Propeller Shaft Disconnect and Accessory Removal
Shift Unit
Disconnect the propeller shafts.
Remove the pneumatic shift unit from the transmission by removing the
two hex nuts and washers. Note that the adjusting screw retainers are exposed when the shift unit is removed. Special care should be taken to prevent the retainers from falling out of the transmission.
Electrical Connections
Disconnect the tachometer cable, shift wiring and electric shift override
linkage.
86
Page 86
Propeller Shaft Disconnect
Eclipse CAFSystemt Removal from Transmission
4. Loosen tension on the Polychain by turning the Polychain tension
screw, counter clockwise.
5. Remove the Polychain from the air clutch assembly, driven sprocket
and idler sprocket.
6. Remove the four (4) cap screws that attach the transmission to the
pump.
7. Remove the transmission from the pump. Note that the air clutch
assembly will remain on the transmission.
To remove the Eclipse CAFSystem from the transmission, perform the following steps:
1. Remove air connections from the air clutch assembly.
2. Remove the Polychain cover assembly by unscrewing the four (4) hex
nuts.
3. Loosen the 1−29/32” hex screw on the idler sprocket assembly. This releases the idler sprocket assembly for adjustment.
Eclipse ES CAFSystemt Removal from Transmission (See Figure 1)
4. Remove the nylon tube from the air clutch assembly.
5. Loosen the 1−29/32” hex screw on the idler sprocket assembly. This releases the idler sprocket assembly for adjustment.
6. Loosen tension on the Polychain by turning the Polychain tension
screw, counter clockwise.
7. Remove the Polychain from the air clutch assembly, driven sprocket
and idler sprocket.
To remove the Eclipse ES CAFSystem from the transmission, perform the
following steps:
1. Support the Eclipse ES unit with a lifting strap placed under the air
compressor. Two other eyeloops are also provided for lifting (see Figure 1).
2. Remove all electrical and air connections.
3. Remove the Polychain cover assembly by unscrewing the ten (10) hex
hd screws.
F−1031, Section 4314
Rev:
Page 1 of 34
86
87
8. Loosen the set screw that holds the air clutch assembly to the transmission driven shaft. (See Figure 2).
9. Remove the hex head screw that attaches the air clutch assembly to
the anti−rotation bracket (leave grommet attached to anti−rotation
bracket).
10. Remove the air clutch assembly from the transmission.
11. Remove the five (5) hex hd screws that attach the Eclipse ES unit to
transmission.
12. Remove the compressor bracket that supports the Eclipse ES unit to
the transmission.
13. Lift the unit off the transmission.
Figure 1. Eclipse ES CAFSystemt Removal
Figure 2. Eclipse ES − Air Clutch Assembly (Side View)
87
Page 87
F−1031, Section 4314
Rev:
Page 2 of 34
87
88
Pump Removal from Transmission for Separable Impeller Shafts
Refer to the pump overhaul instructions for information on how to remove the pump from the transmission.
Disassembly of the C10 Transmission
The C10 consists of three sections; the cap, the mid−section and the bottom section. The order of disassembly is bottom section, mid−section and
then cap.
Removal of End Yokes
1. Remove the end yokes from the drive and coupling shafts.
2. Remove the lube system hose.
NOTE: Out of chassis overhaul will require supporting the transmission
initially in an upside down position, possibly attaching it direct to an
engine overhaul stand at the face of the cap (fabrication of an adapter
would be required) or using the side mounting pads (see Figure 3).
Figure 3.
Figure 4.
Removal of End Yokes
Cap
Supporting Transmission (CXC10 Shown)
Lube System
Hose Assembly
88
Page 88
Mid Section
Coupling Shaft
Housing
Yoke
Washer
Bottom Section
F−1031, Section 4314
Rev:
Nut
Page 3 of 34
88
89
Coupling Shaft Housing Removal
Removing the Bottom Section
1. Remove the hex head screws and lock washers attaching the coupling
shaft housing to the mid−section.
1. Invert the case.
2. Remove lower cap screws connecting the driveshaft housing to the
bottom section. Loosen cap screws connecting housing to case mid−
section.
3. Remove the cap screws, nuts and lock washers attaching the bottom
section to the mid−section.
4. Drive the four dowel pins out of the bottom section flange.
5. Remove the bottom section from the mid−section.
2. Remove the coupling shaft housing, O−ring and shims. Note that jacking screw holes are provided.
NOTE: The coupling shaft and its associated parts may come with the
housing. If not, pull on the coupling shaft to remove.
Figure 5.
Removal of Coupling Shaft Housing
Figure 6.
Cap Screw
89
Page 89
Shims
Removal of the Bottom Section
Coupling Shaft
Housing
Driveshaft
Housing
Lock Washer
Driveshaft
Hex Hd
Screw
Lock Washer
Hex Nut
Flange
Sealed
by
RTV.
Jacking Screw Holes (2)
Dowel Pins
F−1031, Section 4314
Rev:
Page 4 of 34
89
90
Removal of Chain
Removal of Drive Shaft and Housing
1. Rotate the drive shaft until removeable connecting pin set of the chain
is visible at the drive sprocket. The removable connecting pin set has a
spirol pins on both ends holding it in place (see Figure 7).
Figure 7. Removable Connecting Pin Set
1. Remove the remaining hex head screws and lock washers attaching
the drive shaft housing to the mid−section. The housing, drive shaft,
drive sprocket, shift collar and associated parts can now be removed
as a unit from the mid−section. The shift fork will slip off the shift shaft
when the drive shaft assembly is lifted out.
Chain
Figure 9.
Removal of Drive Shaft and Housing
Spirol Pin
Drive Shaft Assembly
Shift Fork
Driven Sprocket
Connecting Pin Assy
and Connecting Rocker
Connecting Pin Set
Hex Hd Screw
Lock Washer
Drive Sprocket
Drive Shaft Housing
IL2436
90
Page 90
2. Remove the tapped in spirol pin on one end, tap both the connecting
pin assembly and connecting rocker out of the chain links. Disengage
the chain from the drive and driven sprocket and remove from the
case.
Figure 8. Chain Removal
Shift Shaft
Drive Sprocket
IL2790
Chain
Driven Sprocket
F−1031, Section 4314
Rev:
Page 5 of 34
90
91
Figure 10a. Removal of Shift Component − (Internal)
Removal of Shift Components
1. Remove the shift shoe from the locking arm.
2. Slip locking arm off pivot pin.
Shift Shoe
NOTE: The pivot pin and shift shaft bushing (typically pressed into
the bottom section) need only be removed if bent or otherwise damaged.
Locking Arm
Shift Shaft
3. Remove the shoulder screw that attaches the sector gear and shift lever to the shift shaft and remove the sector gear, shift lever and
spacer.
Pivot Pin
4. Reposition mid and cap section assembly on the supports so that the
cap portion is on top or set the assembly on a bench.
5. Remove spirol pin attaching the shift arm to the shift shaft (Figure 10b) if
necessary.
Shoulder Screw
6. Remove the shift arm, shift lock spring and shift shaft.
Shift Lever
(Pneumatic
Only)
Locking Nut
Sector Gear
Page 91
Sector Spacer
91
IL2232
Figure 10b. Removal of Shift Components (External)
Spirol Pin
Shift Arm
Shift Shaft
Spirol Pin
Shift Lock
Spring
IL2546
F−1031, Section 4314
Rev:
Spirol Pin
Spring
Housing
Page 6 of 34
91
92
Removal of Mid−Section from Cap
Disassembly of Driven Shaft Assembly
The cap does not need to be removed from the mid−section unless either
is being replaced. NOTE: Removal will make it easier to handle the assembly during driven shaft removal and reassembly.
Separable Shaft
1. Remove the four cap screws from the bearing cover and the four
socket hd screws from oil seal housing. Remove cover and housing
from cap.
1. Remove cap screws and nuts that attach the cap to the mid−section.
2. Remove cap with driven shaft from the mid−section. Rapping the cap
with a soft hammer will break adhesion with the shims, spacers and
mid−section.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
NOTE: Do not drive the dowels through the flange of the cap deeper
into the mid−section or spacer plates.
3. Under a press, support the assembly on the front (pump flange) face
side of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprockets.
Figure 11. Removal of Mid−Section from Cap
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 12. Driven Shaft Disassembly − Separable Shaft
Cap Screw
Bearing Cover
Lock Washer
O−ring
Wave Spring
Bearing Lock Washer
92
Page 92
Bearing Lock Nut
Ball Bearing
Spacer
Rear
Sprocket
Cap
Front (Pump Flange)
Spacer
Driven Shaft
3. Remove any shims and spacers from the top of the mid−section.
Key
a. The quantity and thickness of shims and spacers depends on transmission model and ratio.
Gasket
IL2744
Oil Seal Housing
Oil Seal
Sealing Boot
F−1031, Section 4314
Ball Bearing
Rev:
Lock Washer
Socket Hd Screw
Page 7 of 34
92
93
Separable Shaft − Eclipse
Separable Shaft − Hydraulic Adapter
1. Remove the four cap screws and four socket hd screws that fasten the
oil seal housings to the cap. Remove housings.
2. Remove the retaining ring and wave spring.
3. Under a press, support the assembly on the front (pump flange) face
of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprockets.
4. Remove the ball bearing, spacer and sprocket from cap.
1. Remove the four cap screws from the hydraulic pump adapter and the
four socket hd screws from the oil seal housing. Remove adapter and
housing from cap.
2. Remove the retaining ring and wave spring.
3. Under a press, support the assembly on the front (pump flange) face
of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprocket.
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 13. Driven Shaft Disassembly − Eclipse
Figure 14. Driven Shaft Disassembly − Hydraulic Adapter
Cap Screw
Oil Seal
Cap Screw
Lock Washer
Lock Washer
Oil Seal Housing
Hydraulic Pump Adapter
O−ring
O−ring
Wave Spring
Wave Spring
Retaining Ring
Retaining Ring
Ball Bearing
Ball Bearing
Spacer
Rear
93
Page 93
Spacer
Oil Seal
Rear
Cap
Sprocket
Cap
Front (Pump Flange)
Sprocket
Spacer
Spacer
Ball Bearing
Driven Shaft
Front (Pump Flange)
Ball Bearing
Driven Shaft
Key
Key
Key
Gasket
Gasket
Oil Seal Housing
Oil Seal
Sealing Boot
F−1031, Section 4314
Oil Seal Housing
Lock Washer
Socket Hd Screw
IL2745
Oil Seal
Sealing Boot
Rev:
Lock Washer
Socket Hd Screw
IL2746
Page 8 of 34
93
94
Separable Shaft − Combination Pump
Separable Shaft − Oil Cooler
1. Remove the four cap screws and four socket hd screws that fasten the
oil seal housings to the cap. Remove housings.
1. Remove the four hex hd screws from the oil pump and the four socket
hd screws from the oil seal housing. Remove oil pump and housing
from cap.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on front (pump flange) face of
the cap and apply a press load to the end of the driven shaft to press
the shaft out of the ball bearing, spacers and sprocket.
4. Remove the ball bearing, spacers and sprocket from cap.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the front (pump flange) face
of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprocket.
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 15. Driven Shaft Disassembly − Combination Pump
Cap Screw
Lock Washer
Oil Seal Housing
Figure 16. Driven Shaft Disassembly − Oil Cooler
Hex Hd Screw
Oil Seal
Lock Washer
Oil Pump
O−ring
Cap Screw
Bearing Lock Nut
Gasket
Bearing Lock Washer
Oil Pump Support Housing
Oil Seal Sleeve
O−ring
Bearing Lock Nut
Ball Bearing
94
Page 94
Wave Spring
Lock Washer
Bearing Lock Washer
Spacer
Wave Spring
Rear
Ball Bearing
Cap
Sprocket
Spacer
Spacer
Front (Pump Flange)
Cap
Ball Bearing
Sprocket
Driven Shaft
Spacer
Key
Key
IL2747
Oil Seal
Front (Pump Flange)
Ball Bearing
Driven Shaft
Gasket
Oil Seal Housing
Rear
Lock Washer
Socket Hd Screw
Oil Seal Housing
Gasket
IL2748
Lock Washer
Sealing Boot
Oil Seal
Sealing Boot
F−1031, Section 4314
Rev:
Socket Hd Screw
Page 9 of 34
94
95
One−Piece Shaft (CG, CX Models)
Eclipse ES Mounted CAFS (CX Models)
1. Remove the four cap screws from the bearing cover and the four
socket hd screws from the oil seal housing. Remove cover and housing from cap.
1. Remove the four cap screws and four socket hd screws that fasten the
oil seal housings to the cap. Remove housings.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the front (pump flange) face
of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprocket.
3. Under a press, support the assembly on the front (pump flange) side of
the case and apply a press load to the end of the driven shaft and
press the shaft out of the ball bearing, spacers and sprocket. Rear ball
bearing and retaining ring will come out with the driven shaft. Remove
from shaft.
4. Remove the ball bearing, spacers and sprocket from cap.
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 17. Driven Shaft Disassembly − One−Piece Shaft (CG, CX)
Figure 18. Driven Shaft Disassembly − Eclipse ES (CX Models)
Bearing Cover
2. Remove the retaining ring and wave spring.
Cap Screw
Lock Washer
Oil Seal
O−ring
Oil Seal Housing
Cap Screw
Lock Washer
O−ring
Bearing Lock Nut
Wave Spring
Bearing Lock Washer
Retaining Ring
Wave Spring
Ball Bearing
95
Page 95
Ball Bearing
Spacer
Spacer
Rear
Rear
Cap
Cap
Sprocket
Front (Pump Flange)
Sprocket
Front (Pump Flange)
Spacer
Double−Row Ball Bearing
Spacer
Double−Row Ball Bearing
Driven Shaft
(Pump Impeller Shaft)
Driven Shaft
(Pump Impeller Shaft)
Gasket
Gasket
Oil Seal Housing
IL2749
Oil Seal
Oil Seal Housing
Lock Washer
Socket Hd Screw
Oil Seal
F−1031, Section 4314
Rev:
Lock Washer
Socket Hd Screw
IL2750
Page 10 of 34
95
96
Disassembly of Coupling Shaft Assembly
Disassembly of Drive Shaft Assembly
1. Press coupling shaft housing off of ball bearings if not previously removed.
1. Slide shift collar from teeth on the drive shaft.
2. Pull outer ball bearing from the shaft.
NOTE: If the transmission is equipped with an electronic tachometer, remove the pick−up from the housing prior to removal of the
driveshaft housing to avoid damage.
3. Remove the spacer and pull inner ball bearing from the shaft. Note that
due to the closeness of the ball bearing to the hub end of the shaft, a
split−plate type puller may be necessary.
2. Press drive shaft housing from drive shaft assembly and press the oil
seal from housing. Discard the oil seal.
4. Tap out pilot bearing if still in coupling shaft by using a punch through
the two access holes in the coupling shaft.
3. Remove the tachometer pulse generator (if equipped) with a suitable
puller (see Figure 21).
Figure 19. Coupling Shaft Disassembly
Figure 20. Drive Shaft Disassembly − Shift Collar Removal and Oil Seal
Shift Collar
Ball Bearing
Shaft Spacer
Drive Shaft Assembly
96
Page 96
Ball Bearing
Coupling Shaft
O−ring
Access Hole (2)
Drive Housing
Pilot Bearing
Oil Seal
F−1031, Section 4314
Rev:
Page 11 of 34
96
97
Figure 22. Needle Bearing Removal from Sprocket
Disassembly of Drive Shaft Assembly Cont’d
4. Remove spacer if applicable.
5. Place shaft and sprocket assembly in an arbor press in a vertical position with the threaded end up and supported on the bottom face of the
sprocket. Press shaft out of drive sprocket assembly. Catch shaft to
avoid damage.
6. Remove needle bearings from the sprocket.
Needle Bearing
Figure 21. Drive Shaft Disassembly
Pilot Bearing
Drive Shaft
Drive Sprocket
Drive Sprocket
Assembly
IL2526
Needle Bearing
Thrust Washer
Check the following:
Ball Bearing
•
Bent shift forks
•
Bent shift shaft
•
Worn shifter shoes
•
Loose shifter shoe studs
97
Page 97
Inspection and Repair
Spacer
•
Damaged locking arm assembly, sector gear or bent pivot pin
Spacer
•
Condition of oil hose
Tach Pulse Generator
•
Worn sprocket teeth
•
Worn flanks on inner chain links
•
Outside guide links of chain not retained by “riveted over” pins
•
Wear on inner faces of outside guide links of chain
•
Badly worn pointing on teeth of drive sprocket, coupling shaft and shift
collar
•
Damaged splines on drive and coupling shafts
Before reassembly, make sure all reusable parts have been cleaned and
are kept free of dirt during reassembly.
F−1031, Section 4314
Rev:
Page 12 of 34
97
98
Reassembly
Guidelines for Installing Ball Bearings, Oil Seals and O−Rings
Installing Ball Bearings
Installing Oil Seals
Keep new ball bearings wrapped until they are to be installed. When pressing the
ball bearing on a shaft or into a bore, coat appropriate surfaces with grease.
Shaft − grease shaft and ball bearing bore.
Bore − grease bore and outside of diameter of ball bearing.
Always apply force to the inner race of a ball bearing when pressing it on a
shaft and to the outer race if pressing into a bore. Press evenly with a piece of
pipe or tube which just clears the shaft.
NOTE: Wherever silicone or sealant is referenced, use Loctite Ultra Blue
RTV Silicone Sealant or equivalent, unless otherwise specified.
Before installing a new oil seal in its housing, apply a thin coat of sealant to
housing oil seal seat. Be sure that the seal, shaft and housing are clean. Always install a seal with the seal lip facing in. Lubricate seal lip with light oil
before installing shaft. Apply force to the outer edge of the seal and press in
evenly.
Installing O−Rings
Grease new O−rings prior to installation. This will aid in the installation as well
as preventing damage to the O−ring.
Reassembly of the Driven Shaft
Figure 23.
Separable Shaft
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Cap Screw
Use high pressure grease to coat the driven shaft.
Press the ball bearing to the shoulder of the driven shaft.
Tap the key into place.
Place high pressure grease in the rear bore of the cap.
Tap the ball bearing into place.
Set the bearing cover on rear face of cap and secure with the cap
screws and lock washers. Hand tighten only at this stage of reassembly.
With the cap resting on the rear face, position the spacer and driven
sprocket inside the cap.
Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
Tap into place until the shaft seats.
Install gasket and oil seal in the oil seal housing.
Install oil seal housing.
Tap lock nut end of driven shaft towards oil seal housing to seat assembly.
Remove the bearing cover and install the O−ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway
in the shaft.
Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
Install wave spring and bearing cover.
Install sealing boot.
Bearing Cover
O−ring
Bearing Lock Nut
Wave Spring
Bearing Lock Washer
Ball Bearing
Spacer
Rear
Sprocket
Cap
Front (Pump Flange)
Spacer
Driven Shaft
Ball Bearing
Key
Gasket
IL2744
Oil Seal Housing
Oil Seal
Sealing Boot
F−1031, Section 4314
Lock Washer
98
Page 98
1.
2.
3.
4.
5.
6.
Reassembly of the Driven Shaft − Separable Shaft
Rev:
Lock Washer
Socket Hd Screw
Page 13 of 34
98
99
Figure 24. Reassembly of the Driven Shaft − Eclipse
Separable Shaft − Eclipse
1. Use high pressure grease to coat the driven shaft.
Cap Screw
2. Press the ball bearing to the shoulder of the driven shaft.
Oil Seal
Lock Washer
3. Tap the key into place.
Oil Seal Housing (A)
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place.
O−ring
6. Set the oil seal housing (A) in cap and secure with the cap screws and
lock washers. Hand tighten only at this stage of reassembly.
Wave Spring
Retaining Ring
7. With the cap resting on the rear face, position the spacers and driven
sprocket inside the cap.
Ball Bearing
8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
Spacer
Rear
Cap
9. Tap into place until the shaft seats.
Sprocket
10. Install gasket and oil seal in the oil seal housing (B).
Front (Pump Flange)
Spacer
11. Install the oil seal housing (B) using four socket hd screws.
Ball Bearing
13. Remove the oil seal housing (A) and install retaining ring
14. Install wave spring , O−ring and oil seal and install oil seal housing (A)
onto cap.
99
Page 99
12. Tap end of driven shaft towards oil seal housing (B) to seat assembly.
Driven Shaft
15. Install sealing boot.
Key
Key
Gasket
Oil Seal Housing (B)
Oil Seal
Sealing Boot
F−1031, Section 4314
Rev:
Lock Washer
Socket Hd Screw
IL2745
Page 14 of 34
99
100
Figure 25. Reassembly of the Driven Shaft − Hydraulic Adapter
Separable Shaft − Hydraulic Adapter
1. Use high pressure grease to coat the driven shaft.
Cap Screw
Lock Washer
2. Press the ball bearing to the shoulder of driven shaft.
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
Oil Seal
Hydraulic Pump Adapter
O−ring
5. Tap the ball bearing into place.
Wave Spring
6. Set the hydraulic pump adapter on cap and secure with cap screws and
lock washers. Hand tighten only at this stage of reassembly.
Retaining Ring
Ball Bearing
7. With the cap resting on its rear face, position the spacers and driven
sprocket inside the cap.
Spacer
8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
Rear
Cap
9. Tap into place until the shaft seats.
10. Install O−ring and oil seal in the oil seal housing.
Sprocket
Front (Pump Flange)
11. Install the oil seal housing.
13. Tap internal splined end of driven shaft towards front face to seat
assembly.
Ball Bearing
100
Page 100
Spacer
12. Remove the hydraulic pump adapter and install retaining ring.
Driven Shaft
14. Install O−ring and oil seal in hydraulic pump adapter.
15. Install wave spring and hydraulic pump adapter.
16. Install sealing boot.
Key
Oil Seal Housing
Oil Seal
Sealing Boot
F−1031, Section 4314
Rev:
Gasket
Lock Washer
Socket Hd Screw
IL2746
Page 15 of 34
100
101
Figure 26. Reassembly of the Driven Shaft − Combination Pump
Separable Shaft − Combination Pump
1. Use high pressure grease to coat the driven shaft.
Cap Screw
Lock Washer
Oil Seal Housing
2. Press the ball bearing to the shoulder on the internal spline end of the
drive shaft.
3. Tap the key into place.
Oil Seal
O−ring
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place.
Bearing Lock Nut
6. Set the oil seal housing (A) on cap and secure with cap screws and
lock washers. Hand tighten only at this stage of reassembly.
Bearing Lock Washer
Oil Seal Sleeve
7. With the cap resting on its rear face, position the spacers and driven
sprocket inside the cap.
Wave Spring
8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
Spacer
Ball Bearing
Rear
Cap
9. Tap into place until the shaft seats.
Sprocket
10. Install gasket and oil seal in the oil seal housing (B).
Spacer
Front (Pump Flange)
Ball Bearing
12. Tap end of driven shaft towards oil seal housing (B) to seat assembly.
101
Page 101
11. Install the oil seal housing (B) using four socket hd screws.
13. Remove the oil seal housing (A) and install oil seal.
Driven Shaft
14. Install wave spring, O−ring and and install oil seal housing (A) onto
cap.
Key
15. Reapply high pressure grease to coat the driven shaft and apply light
oil on the oil seal lip and oil seal sleeve O.D.
Gasket
16. Install oil seal sleeve onto shaft.
Oil Seal Housing
17. Install bearing lock washer and lock nut. Make sure the tang of the
washer aligns with the keyway in the shaft.
IL2747
18. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
19. Install sealing boot.
F−1031, Section 4314
Oil Seal
Lock Washer
Socket Hd Screw
Sealing Boot
Rev:
Page 16 of 34
101
102
Figure 27.
Separable Shaft − Oil Cooler
1. Use high pressure grease to coat the driven shaft.
Reassembly of the Driven Shaft − Oil Cooler
Hex Hd Screw
2. Press the ball bearing to the shoulder of driven shaft.
Lock Washer
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
Oil Pump
Cap Screw
Gasket
5. Tap the ball bearing into place.
6. Set the oil pump support housing on cap and secure with hex head
screws and lock washers. Hand tighten only at this stage of reassembly.
Lock Washer
Oil Pump Support Housing
O−ring
7. With the cap resting on its rear face, position the spacers and driven
sprocket inside the cap.
8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
9. Tap into place until the shaft seats.
Spacer
10. Install gasket and oil seal in the oil seal housing.
Ball Bearing
Rear
Cap
11. Install the oil seal housing.
Sprocket
Spacer
Front (Pump Flange)
13. Tap internal splined end of driven shaft towards front face to seat
assembly.
Ball Bearing
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
Driven Shaft
Key
15. Install O−ring in oil pump adapter.
Gasket
16. Install wave spring, oil pump support housing.
17. Install oil pump and gasket, aligning the tang on the driven shaft with
the slot in the oil pump shaft.
18. Install sealing boot.
F−1031, Section 4314
Oil Seal Housing
Oil Seal
Sealing Boot
Rev:
102
Page 102
12. Remove the oil pump adapter and install the bearing lock washer and
lock nut. Make sure the tang of the washer aligns with the keyway in
the shaft.
IL2748
Lock Washer
Socket Hd Screw
Page 17 of 34
102
103
Figure 28. Reassembly of the Driven Shaft − One−Piece Shaft
(CG, CX Models)
One−Piece Shaft (CG, CX Models)
1.
2.
3.
4.
5.
6.
7.
8.
13.
14.
15.
Bearing Cover
Cap Screw
Lock Washer
O−ring
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Ball Bearing
Spacer
Rear
Cap
Sprocket
Front (Pump Flange)
Spacer
Double−Row Ball Bearing
Driven Shaft
(Pump Impeller Shaft)
103
Page 103
9.
10.
11.
12.
Use high pressure grease to coat the driven shaft.
Press the double−row ball bearing to the shoulder of the driven shaft.
Tap the key into place.
Place high pressure grease in the rear bore of the cap.
Tap the ball bearing into place.
Set the bearing cover on rear face of cap and secure with the cap
screws and lock washers. Hand tighten only at this stage of reassembly.
With the cap resting on the rear face, position the spacers and driven
sprocket inside the cap.
Take the driven shaft, double−row ball bearing and key assembled previously and from the front (pump flange) face of the cap, slide the shaft
through the bore in the cap into the bore of the driven sprocket, spacers
and ball bearing lining up the key in the shaft with the keyway in the
sprocket.
Tap into place until the shaft seats.
Install gasket and oil seal in the oil seal housing.
Install oil seal housing.
Tap lock nut end of driven shaft towards oil seal housing to seat assembly.
Remove the bearing cover and install the O−ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway
in the shaft.
Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
Install wave spring and bearing cover.
Gasket
Oil Seal Housing
IL2749
F−1031, Section 4314
Rev:
Oil Seal
Lock Washer
Socket Hd Screw
Page 18 of 34
103
104
Figure 29.
Eclipse ES Mounted CAFS (CX Models)
Reassembly of the Driven Shaft − Eclipse ES (CX Models)
1. Use high pressure grease to coat the driven shaft.
2. Press the double−row ball bearing to the shoulder of driven shaft.
Oil Seal
3. Tap the key for the driven sprocket into place.
Oil Seal Housing (A)
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place.
Cap Screw
Lock Washer
O−ring
Wave Spring
6. Set the oil seal housing (A) on cap and secure with cap screws and
lock washers. Hand tighten only at this stage of reassembly.
Retaining Ring
Ball Bearing
7. With the cap resting on the rear face, position the spacers and driven
sprocket inside the cap.
Spacer
8. Take the driven shaft, double−row ball bearing and key assembled previously and from the front (pump flange) face of the cap, slide the shaft
through the bore in the cap into the bore of the driven sprocket,
spacers and ball bearing lining up the key in the shaft with the keyway
in the sprocket.
Rear
Cap
9. Tap into place until the shaft seats.
10. Install the oil seal in the oil seal housing (B).
Sprocket
Front (Pump Flange)
Spacer
Double−Row Ball Bearing
12. Tap end of oil seal housing (A) end of driven shaft towards oil seal
housing (B) to seat assembly.
104
Page 104
11. Install the gasket and oil seal housing (B).
Driven Shaft
(Pump Impeller Shaft)
13. Remove the oil seal housing (A) and install the O−ring and oil seal.
14. Install wave spring and oil seal housing (A).
Gasket
Oil Seal Housing (B)
Oil Seal
F−1031, Section 4314
Rev:
Lock Washer
Socket Hd Screw
IL2750
Page 19 of 34
104
105
Dowel Pins and Spacer Installation (Extended Drop Chain Cases)
1.
Place high pressure grease on the dowel pin holes and install into the
cap.
2.
Apply a bead of silicone to the inside of the bolt hole pattern of the cap.
3.
If shims are required, apply bead of silicone inside bolt pattern on
spacer, then lay shims on the spacer or mid−section on B drop (see
Service Parts List SPL82890 for shims).
4.
Position cap on spacer and tap dowel pins into place.
5.
Secure with appropriated hardware (see Service Parts List SPL82890
− C10 Transmission or SPL82821 − Eclipse ES).
Figure 30. Dowel Pins and Spacer Installation (for Extended Drop
Chain Cases − C, D & E Drop)
Cap
Cap Screw
Cap Screw
Silicone
Dowel Pin
Lock
Washer
If shims are
required, install
between cap and
spacer.
105
Page 105
Dowel
Pin
Hex
Nut
Cap
Screw
F−1031, Section 4314
Rev:
Spacer
(Not used with
B drops)
Page 20 of 34
105
106
Reassembly of the Shift Assembly
1.
File and clean sealing surfaces of the mid−section and clean out any
metal chips or shavings.
Shift Assembly
2.
Install pivot pin into the mid−section and apply a small amount of
grease to the O−ring and install on the groove of the pivot pin.
2.
3.
Press the shaft bearing and sleeve bushing into the shift shaft bore.
Make sure the shaft bushing is flush with the pad and there is a 1/8”
gap between the bushing and bearing.
4.
Apply a small amount of grease on the O−ring and install between the
bushing and bearing.
5.
Install spirol pin in mid−section.
6.
Install the spring housing into the spirol pin.
1.
3.
4.
Invert mid−section.
Attach shift arm to shift shaft with spirol pin (see Figure 32).
Install shift lock spirol pin in shift arm.
Grease the shift shaft.
Figure 32. Shift Arm Assembly
Mid−Section
Spirol Pin
Figure 31. Pivot Pin, Shaft Bushing and Sleeve Bearing Installation
Page 106
Pivot Pin
Spring
Housing
O−ring
Shift Lock
Spring
106
Mid−section
Spirol
Pin
Shift
Shaft
Shift Arm
Spirol Pin
Shaft Bushing
O−ring
Shaft Bearing
F−1031, Section 4314
Rev:
Page 21 of 34
106
107
Figure 33. Shift Assembly
Pneumatic Shift
Shift
Shoe
Locking
Arm
Pivot
Pin
IL2195
Shift Shaft
Screw Retainer
Adjusting Screw
Shoulder
Screw
NOTE: Shift mechanism may not shift smoothly until bottom cover is
installed.
13. Install adjusting screws in the mid−section and adjust so the locking
arm is rotatable slightly less than 90_ each direction (see Figure 33).
Locking Nut
14. Install screw retainers. Place a dab of grease on the retainers to hold
them in place until the shift unit or cover can be installed.
Sector Spacer
IL2232
F−1031, Section 4314
107
Page 107
Sector Gear
Shift Lever
5. Slide the shift lever into the sector gear aligning the holes (see Figure 33).
6. Set shift lever/sector gear over the shift shaft opening in the mid−section.
7. Slide shift shaft up through the shift shaft opening, engaging spacer
and shift lever or shift lever/sector gear.
8. Install the shift lock spring into the spring housing (see Figure 32).
9. Engage shift arm spirol pin with the shift lock spring (see Figure 32).
10. Rotate the shift arm to compress the shift lock spring into the housing.
Line up the holes in the shift lever/sector gear and install shoulder
screw and locking nut.
11. Install the locking arm onto the pivot pin (see Figure 33) and mesh the
teeth with the sector gear. Proper alignment is important. The center
tooth space in the sector gear should be centered with the locking arm.
12. Install the shift shoe assembly on the pin of the locking arm.
NOTE: Shift shoe can be installed with the counter bore either up or
down.
15. Check assembly for proper shifting.
IL2249
Rev:
Page 22 of 34
107
108
Reassembly of the Cap and Mid−Section
1. Make sure the face of the mid−section is clean and free of nicks and
burrs.
5. Install cap or cap and spacer to mid−section.
a. Cap only: Position cap on mid−section and tap dowel pins into mid−
section.
2. Clean shims or spacer. If assembly includes a spacer, grease dowel
pin holes in mid−section and install dowel pins. If no spacer is
required, grease dowel pin holes in cap and install dowel pins.
b. Cap with spacer: Position cap assembly on the dowels previously
installed in the mid−section and tap down into place.
3. Apply a bead of silicone inside the bolt hole pattern of the mid−section.
6. Install appropriate hardware.
4. If no spacer is being used and shims are required, install shims on the
mid−section. Apply a bead of silicone inside the bolt hole pattern on
top of shims.
7. Support the mid−section and cap assembly in an upside down position.
Figure 35. Cap and Mid−Section Assembly
Figure 34. Mid−Section Assembly
Hex
Nut
Lock
Washer
Cap Screw
Dowel
Pin
108
Page 108
Lock Washer
Spacer
(D&E Drop Only)
Dowel Pin
Cap
Screw
Mid−Section
IL2790
F−1031, Section 4314
Rev:
Page 23 of 34
108
109
Reassembly of the Drive Shaft and Drive Shaft Housing
Drive Shaft Assembly
7. Install the thrust washer onto the drive shaft.
1. File and clean the sprocket faces and check teeth for burrs.
8. Apply grease and install the ball bearing.
2. Use high pressure grease in the bore of the drive sprocket.
9. If the tachometer option is used, add the tach pulse generator and
spacer required. If no tach is required, install appropriate spacer.
3. Press the needle needle bearings into each end of the bore of the
drive sprocket. Press rounded end of needle bearing into sprocket
bore. Needle bearings should set just below the slots in the sprocket.
NOTE: Drive sprocket assembly should turn freely.
Figure 37. Drive Shaft Installation into Drive Sprocket
Figure 36. Needle Bearing Installation into Drive Sprocket
Pilot Bearing
Drive Shaft
Drive Sprocket
Assembly
Thrust Washer
109
Page 109
Needle Bearing
Spacer
Ball bearing
Drive Sprocket
Spacer
Needle Bearing
Tach Pulse Generator
IL2526
4. Install pilot bearing on end of drive shaft.
5. Use high pressure grease on the drive shaft and press into the drive
sprocket assembly.
6. Check the shift collar (not shown) for proper fit. Do not install at this
time.
F−1031, Section 4314
Rev:
Page 24 of 34
109
110
Drive Shaft Housing Assembly
Drive Shaft/Housing Assembly Installation
1. Apply a light coat of silicone to the housing bore and install the oil seal.
1. Install the drive shaft assembly into the mid−section and onto the shift
shaft. Make sure the shift shoe on the locking arm is mated with the
slot in the fork. The drive shaft housing should be seated.
2. Apply grease to the O−ring and insert into the housing.
3. Use high pressure grease in the bore of the housing and press the
housing onto the drive shaft assembly.
5. Check the shift fork shoes for free movement.
2. Install hex head screws and lock washers to secure the drive housing
to the mid−section. Do not completely tighten. Leave a small gap
between the drive shaft housing and mid−section flange to allow installation of the bottom cover.
6. Grease the shift shoe studs and insert into shift fork.
Figure 39. Drive Shaft/Housing Assembly Installation
4. Add the shift collar onto the drive line.
7. Slide the shift fork onto the shift collar.
Drive Shaft Assembly
Figure 38. Drive Assembly into Drive Housing
Shift Collar
Shift Fork
Shift Shoe Stud
Hex Hd Screw
Lock Washer
Drive Shaft Assembly
Drive Shaft Housing
110
Page 110
Shift Fork
Shift Shoe Stud
O−ring
Drive Shaft Housing
Oil Seal
Shift Shaft
IL2790
F−1031, Section 4314
Rev:
Page 25 of 34
110
111
Figure 40. Optional Electronic Tachometer
Optional Electronic Tachometer
1. Install the O−ring onto the tachometer pick−up.
2. Rotate drive shaft until tach tooth lines up with the tach opening.
3. Install the tachometer pick−up into the drive shaft housing until it contacts the tach pulse generator. Turn back 1/2 turn.
4. Tighten hex nut.
Pick−Up
Hex Nut
O−ring
Drive Shaft Housing
IL2530
Installing the Chain
Wrap the chain around the drive and driven sprockets making sure
everything meshes and then lace the joining ends together using the
connecting pin set (see Figure 41).
2.
Insert the connecting pin rocker partway through the holes in the joining end links being careful of orientation (see Figure 43). The connecting rocker must be on the side of the guide link opposite the joining
end with the connecting rockers wide curved surface towards the center of the hole.
3.
Insert the connecting pin assembly along side the connecting rocker.
The two wide curved surfaces of the connecting pin and connecting
rocker must face each other.
4.
After the connecting pin assembly and connecting rocker have been
pushed all the way through the joining ends of the chain, insert the
spirol pin into the open hole at the end of the connecting pin assembly
(see Figure 43). Make sure the spirol pin overlaps the connecting rocker.
5.
Figure 41. Installing the Chain
Chain
Push to
determine
chain
tension
Driven Sprocket
Connecting Pin Set
Drive Sprocket
Check chain for proper tension. Check deflection half−way between
the drive sprocket and driven sprocket (see chart below for maximum
deflection). Replace chain if deflection is greater than those displayed
in the chart below.
Drop
Max Deflection (In.)
(Both Directions)
B
1.75
C
1.75
D
1.75
E
2.0
F
2.0
F−1031, Section 4314
111
Page 111
1.
IL2431
Rev:
Page 26 of 34
111
112
Figure 42. Connecting Pin Set
Figure 43. Connecting Pin Orientation
Connecting Pin Set
(Spirol pin on opposite
side must be tapped in to
complete installation.)
Connecting Rocker
Joining End of Chain
Chain
IL2432
Spirol Pin
Guide Link
IL2433
112
Page 112
Spirol Pin
Connecting Rocker
Connecting Pin Set
(V 2062)
Connecting Pin Assembly
(Consists of a connecting pin
and tapped−in spirol pins.)
F−1031, Section 4314
The connecting pin set contains one connecting pin
assembly, connecting rocker and two spirol pins.
Rev:
Page 27 of 34
112
113
Reassembly of the Bottom Section to the Cap and Mid−Section
1. Install the shift shaft bushing into the bottom of the case.
4. Tap back the drive shaft assembly to allow for the bottom section
installation.
2. Apply pipe joint compound to the sight plug.
5. Apply silicone around the inside of the bolt hole pattern as shown in
Figure 45.
3. Install the sight and magnetic plugs in the case.
Figure 44. Assembling Items on the Bottom Section
6. Install the bottom section onto the mid−section. Be sure to engage the
shift shaft with shift shaft bushing.
Shift Shaft Bushing
7. Install four dowel pins into place.
Bottom Case
8. Secure the bottom section to the mid−section with fasteners.
(4) Dowel Pins
Figure 45. Assembling Bottom Section to the Cap and Mid−Section
Magnetic
Oil Fill Plug
Dowel Pins
Lock Washer
Magnetic Drain Plug
113
Page 113
Hex Nut
Sight Plug
IL2796
Cap Screw
F−1031, Section 4314
Rev:
Page 28 of 34
113
114
Shift Position Adjustments
2. Adjust as necessary.
1. Check the distance from shift collar to face of coupling shaft housing
bore. Distances should read as follows:
•
ROAD mode: 1−3/8 inches (right adjusting screw)
•
PUMP mode: 2−11/16 inches (left adjusting screw)
3. Install retainers. Apply grease into the slots to help secure retainers.
Figure 46. Retainer Installation
114
Page 114
Adjusting Screw
Pump
Retainer
Road
F−1031, Section 4314
Rev:
Page 29 of 34
114
115
Coupling Shaft and Housing Assembly
Coupling Shaft Assembly
Coupling Shaft Housing Assembly
1. Use high pressure grease and press ball bearing, spacer and ball
bearing onto shaft.
1. Coat the seal outer diameter evenly with sealant. Be sure that the seal,
shaft and housing are clean. Always install a seal with the seal lip facing in. Apply force to the outer edge of the seal and press in evenly.
Figure 47. Coupling Shaft Assembly
2. Use high pressure grease in bore of the coupling housing and press
coupling shaft assembly into place.
Figure 48. Coupling Shaft Housing Assembly
Coupling Shaft
Coupling Shaft Assembly
O−ring
(Install after shimming)
Housing
Page 115
Ball Bearing
115
Shaft Spacer
Ball Bearing
IL2527
Oil Seal
F−1031, Section 4314
Rev:
IL2528
Page 30 of 34
115
116
Figure 49. Assembling Coupling Shaft Housing to Case
Coupling Shaft Housing Assembly to Case Assembly
The driveline assembly was factory shimmed to limit the axial float of the
drive line. If any of the drive line parts have been changed, it may be necessary to change the total thickness of shims between the coupling shaft
housing and the transmission case. Shims are color coded for thickness as
follows:
.005”
Blue
.007”
Natural
.010”
Brown
Breather
The correct thickness of shims can be determined as follows:
Hose Assembly
1. Install coupling shaft and housing assembly with no O−ring or shims
between the housing and case. Lightly tighten the cap screws evenly
and tap the end of the coupling shaft with a soft mallet to force the
drive line all the way forward. Do not overtighten causing bending or
breakage of the coupling shaft housing.
Shims
(.005 − .010”)
Axial float
Lock Washer
3. Remove the coupling shaft assembly from the case after measuring
the gap.
NOTE: Field conditions may make it difficult to determine the correct
amount of shims. If in doubt, add another .005 in. shims. No harm will
result from a small amount of additional axial float but ball bearing
life will be shortened if ball bearings are excessively preloaded.
116
Page 116
2. Measure the gap between the housing and case in several places to
assure a uniform gap and add .005 in. This will be the total thickness
of shims needed to provide the recommended axial float of .005 − .010
in.
Hex Hd Screw
4. Install the correct amount of shims on the coupling shaft housing or if
all original parts are being used, reinstall original shims on coupling
shaft housing.
5. Coat O−ring with grease and install O−ring on housing.
6. Install the coupling shaft housing assembly.
Breather and Hose Assembly Installation
7. Install fasteners.
1. Apply thread sealer to breather and install.
2. Connect hose assembly from the cap to the mid−section.
F−1031, Section 4314
Rev:
Page 31 of 34
116
117
Reassembly of Miscellaneous Items and Accessories
End Yoke Assembly
Shift Accessory Assembly
1. Slide yoke onto the coupling shaft and drive shaft.
2. Secure in place using washers and nuts (500 ft−lbs).
1. Attach the switch to the switch bracket using a seal and locking nut.
Install the cap.
3. Slide yoke on the output shaft.
2. Set the gasket on the mid−section.
4. Secure in place using a nut (300 ft−lbs).
3. Align the shift arm with the piston in the shift unit and install bracket,
gasket and shift unit to the case with lock washers and hex nuts. Note
that the word “TOP” cast into the shift unit.
Figure 50. End Yoke Assembly
4. Test the shift operations as required.
Figure 51. Shift Assembly
117
Page 117
Studs
Grease Oil Seal
Before Installing Yoke
Yoke
Gasket
Bracket
Gasket
Shift Arm
Cap
Washer
Lock
Washer
Locking Nut
Nut
(500 ft−lbs)
Seal
Switch
Hex Nut
Shift Unit
F−1031, Section 4314
Rev:
Page 32 of 34
117
118
Eclipse CAFSystemt Installation onto Transmission
To install the Eclipse CAFSystem onto the transmission, perform the following steps:
4. Install the Polychain onto the air clutch assembly, driven sprocket and
idler sprocket.
5. Attach air connections to the air clutch assembly.
6. Tighten Polychain until taut using the Polychain tensioning screw. Polychain tension may be checked by applying a 10 lb. load to the Polychain, mid−span between drive and driven sprocket. The Polychain
should deflect .250 to .313”.
NOTE: If air clutch was not removed from the transmission during the
overhaul procedure, proceed to step 4.
NOTE: Apply anti−seize to shaft before installing air clutch.
1. Apply Loctite 609 to keyway, install key and align clutch assembly.
Push assembly into place.
7. Tighten the large hex head screw on the idler sprocket.
NOTE: Locate clutch assembly to ensure proper interface
between set screw and its seating hole.
8. Attach the Polychain cover using the four hex nuts and lock washers.
9. See Lubrication and Final Checks section for final polychain adjustment.
2. Lock air clutch assembly into place for final polychain adjustment using
set screw (use Loctite 242).
3. Attach the transmission and air clutch assembly to the pump using four
(4) cap screws.
Eclipse ES CAFSystemt Installation onto transmission (See Figure 1)
6. Lock air clutch assembly into place for final polychain adjustment using
set screw (use Loctite 242).
1. Support the Eclipse ES unit with a lifting strap placed under the air
compressor. Two other eyeloops are provided for lifting (see Figure 1).
7. Install the Polychain onto the air clutch assembly, driven sprocket and
idler sprocket.
2. Lift the unit onto the C10.
8. Connect the nylon tube to the air clutch assembly.
3. Install the compressor bracket that supports the Eclipse ES unit to the
C10.
9. Tighten Polychain until taut using the Polychain tensioning screw. Polychain tension may be checked by applying a 10 lb. load to the Polychain, mid−span between drive and driven sprocket. The Polychain
should deflect .250 to .313”.
4. Install the five (5) hex hd screws that attach the Eclipse ES unit to the
C10.
NOTE: Apply anti−seize to shaft before installing air clutch.
5. Apply Loctite 609 to keyway, install key and align clutch assembly.
Push assembly into place.
NOTE: Locate clutch assembly to ensure proper interface
between set screw and its seating hole.
F−1031, Section 4314
118
Page 118
To install the Eclipse ES CAFSystem onto the C10 transmission, perform
the following steps:
10. Tighten the large hex head screw on the idler sprocket.
11. Reconnect all electrical and air connections.
12. See Lubrication and Final Checks section for final polychain adjustment.
Rev:
Page 33 of 34
118
119
Propeller Shaft Connection and Accessory Installation
Electrical Connections
Drain Valve
Connect the tachometer cable, electric shift wiring and primer motor wiring
as required.
Connect the manifold drain valve.
Propeller Shaft
Primer
Connect the propeller shafts to the drive and coupling shafts
Connect the priming pump and hose to the priming pump.
Pneumatic Shift
•
Connect power supply and truck transmission interfaces.
•
SAE J1402 air brake hose recommended, 1/4” to 3/8”. Connect air lines
from main truck supply.
Lubrication and Final Checks
2. Ensure that the green THROTTLE READY light on the operator’s
panel is off.
d. Engage the parking brake and shift truck transmission to NEUTRAL.
1. Ensure that the green OK TO PUMP light in the cab is off (automatic truck transmission only).
2. Recheck fasteners for tightness.
3. Check for fluid leaks.
4. Recheck for proper operation of shift mechanism and that the shift indicator light system is functioning properly.
e. Shift to ROAD following the shifting instructions section of this document.
Indicating Lights Operation
1. Ensure that the green PUMP ENGAGED and OK TO PUMP
lights in the cab are off.
Check the operation of the pump shift indicating lights at least weekly
as follows:
2. Ensure that the green THROTTLE READY light on the operator’s
panel is off.
NOTE: Block wheels with wheel chocks before beginning.
Eclipse Units Only
a. With the pump in the ROAD position, truck transmission in NEUTRAL
and the parking brake engaged, ensure that the PUMP ENGAGED
and OK TO PUMP lights in the cab are off.
b. Shift to PUMP following the shifting instructions section of this document.
1. Ensure that the green PUMP ENGAGED and OK TO PUMP
lights in the cab are on.
2. Ensure that the green THROTTLE READY light on the operator’s
panel is on.
c.
119
Page 119
1. Fill the transmission through the fluid level hole or by removing the
breather and addling fluid through this opening. Any type of automatic
transmission fluid (ATF) can be used. Capacity is approximately 12
quarts (fill to the bottom of threads of the oil level port).
5. Engage water pump and CAFS per appropriate operating instructions.
Operate system for ten (10) minutes.
6. Check Polychain tension. Apply a 10 lb. load to the Polychain, mid−
span between drive and driven sprocket. The Polychain should deflect
.250 to .313. Adjust tension with Polychain tensioning screw. When
tension is correct, loosen large hex head screw on the idler sprocket
and apply a bead of Loctite 243 Blue to the threads. Tighten hex head
screw.
7. Install the Polychain cover.
Apply the service (foot) brake and release the parking brake.
1. Ensure that the green OK TO PUMP light in the cab is off.
F−1031, Section 4314
Rev:
Page 34 of 34
119
120
Issue Date
Rev. Date
03/02/05
08/16/06
Document Number
SPL82790
CS Series Assembly Service Parts List
(CS’04 Body Style)
Contents:
See Pages
1&2
Intake Adapters
3&4
Tank to Pump Flange Components
5&6
Underside View of Pump
7&8
120
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450−5000
Instructions subject to change without notice.
120
Page 120
Pump Body
121
Pump Body
DESCRIPTION
REF.
NO.
DESCRIPTION
B1
Body/Cover Subassembly
B16
Pipe Plug, 3/8 NPT
B2
Front Discharge Plug
B17
Pipe Plug, 1/2 NPT
B3
O−ring, 3−3/4 x 4 in.
B18
Headless Pipe Plug, 1/2 NPT
B4
Hex Hd Screw, 1/2−13 x 1−1/4 in.
B21
Dowel Pin, 7/16 x 1−1/4 in.
B5
Molded Body Gasket
B22
Priming Valve Pad Blind Flange
B7
Discharge & Crossover Flange Gasket
B23
Repair Pump Serial Plate
B8
O−ring, 1 x 1−1/4 in.
B24
Repair Panel Serial Plate
B9
O−ring, 2−1/8 x 2−3/8 in.
B26
Gasket Repair Kit
B13
Drive Screw, #6 x 1/4 in.
B42
Hex Hd Screw, 5/16−18 x 1 in.
B15
Pipe Plug, 1/4 NPT
B43
Lock Washer, 5/16 in.
121
Page 121
REF.
NO.
SPL82790
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122
122
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CS SERIES FIRE PUMPS
SPL82790
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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123
Intake Adapters
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
B1
Body/Cover Subassembly
B29
Rear Intake Fitting, 5 in.
B4
Hex Hd Screw, 1/2−13 x 1−1/4 in.
B30
Large Intake Fitting Gasket
B6
Intake Adapter Gasket
B31
Rear Intake Fitting Gasket
B7
Discharge & Crossover Flange Gasket
B32
Hex Hd Screw, 1/2−20 x 2 in.
B16
Pipe Plug, 3/8 NPT
B33
Hex Hd Screw, 5/8−11 x 2 in.
B26
Gasket Repair Kit
B34
Hex Hd Screw, 3/4−10 x 2 in.
B27
Large Intake Adapter − RH
B35
Hex Nut, 1/2−20
B28
Large Intake Adapter − LH
123
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124
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CS SERIES FIRE PUMPS
SPL82790
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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125
Tank to Pump Flange Components
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
B1
Body/Cover Subassembly
B37
Adapter, 4 ANSI
B4
Hex Hd Screw, 1/2−13 x 1−1/4 in.
B38
Blind Flange
B26
Gasket Repair Kit
B39
Check Valve
B36
Adapter, 2−1/2 NPT
B40
Plain Bearing, TFE
B36
Adapter, 3 NPT
B41
O−ring, 6−3/4 x 7 in.
125
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126
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CS SERIES FIRE PUMPS
SPL82790
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 6 OF 8
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127
Underside View of Pump
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
B10
Socket Hd Screw, 1/2−13 x 1−1/2 in.
B17
Pipe Plug, 1/2 NPT
B11
Socket Hd Screw, 1/2−13 x 4 in.
B19
Pipe Tee, 1/4 NPT
B12
Socket Hd Screw, 1/2−13 x 4−3/4 in.
B20
Pipe Nipple, 1/4 x 1−1/2 in.
B14
Hex Hd Pipe Plug, 1/8 NPT
B21
Dowel Pin, 7/16 x 1−1/4 in.
B15
Pipe Plug, 1/4 NPT
127
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128
128
Page 128
CS SERIES FIRE PUMPS
SPL82790
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 8 OF 8
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129
Issued:
WATEROUS COMPANY
10/14/93
SOUTH ST. PAUL, MINNESOTA
Revised: 03/23/06
CS Series Impeller Shaft Assemblies
For Waterous Single and Two Stage Fire Pumps
THIS SERVICE PARTS LIST COVERS THE FOLLOWING MODELS:
PUMP
TYPE
SHAFT TYPE
REAR
MECHANICAL SEAL
SEPARABLE
7
4
FRONT
ONE PIECE
10
−
WITH TACHOMETER
FRONT
ONE PIECE
6
5
WITHOUT TACHOMETER
FRONT OR REAR
ONE PIECE
11
12
REAR
ONE PIECE
8
−
FRONT
ONE PIECE
9
−
FRONT OR REAR
ONE PIECE
13
−
CSK, CSUK,
CSPA, CSUPA
CSWB, CSWK
CSYB, CSYC, CSYD, CSYE, CSYF
CSUYB, CSUYC, CSUYD, CSUYE, CSUYF
CSC10B, CSC10C, CSC10D, CSC10E, CSC10F
CSUC10B, CSUC10C, CSUC10D, CSUC10E, CSUC10F
CSD, CSUD
CSHK,
CSHWB, CSHWK,
CSHYB, CSHYC, CSHYD, CSHYE, CSHYF
CSUHYB, CSUHYC, CSUHYD, CSUHYE, CSUHYF
CSHC10B, CSHC10C, CSHC10D, CSHC10E, CSHC10F
CSUHC10B, CSUHC10C, CSUHC10D, CSUHC10E, CSUHC10F
CSHD, CSUHD
SEE PAGE FOR DIAGRAM
PACKING
CSK1
TWO
STAGE
DRIVE
WITH TACHOMETER
WITHOUT TACHOMETER
PLEASE NOTE
WHEN ORDERING PARTS PLEASE SUPPLY PUMP SERIAL NUMBER
129
Page 129
SINGLE
STAGE
PUMP AND TRANSMISSION MODEL
SPL81966
PAGE 1 OF 15
129
130
WATEROUS COMPANY
SOUTH ST. PAUL, MINNESOTA
CS Series Impeller Shaft Assemblies
REF NO.
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
Bearing housing
Ball bearing
Impeller, first stage
Seal housing (not available individually, see S110)
Packing, flexible graphite (Grafoil), solid ring
Packing gland
Seal chamber cover
Key, 5/16 x 1−9/16, 5/16 x 2−5/16 in. or
1/4 x 5/16 x 1−9/16
Dowel pin, 1/4 x 1/2 in.
Impeller shaft
Retaining ring
Wear ring (available in original size or 0.025, 0.050
and 0.075 in. undersize)
Square key, SS, 5/16 x 2−3/4 in.
Lubrication fitting, 1/8 in.
Hex hd screw, 1/2−13 x 1−1/4 in., grade 5
Lock washer, 1/2 in.
Hex castle nut, SS, 3/4−16
Cotter pin, SS, 1/8 x 1 in.
Bearing housing
Extra pressure impeller
Flinger ring
REF NO.
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33
S34
S35
S36
S37
S38
S39
S42
S45
S46
S47
S48
S49
DESCRIPTION
Ball bearing, double row
Retaining ring, SS
Impeller spacer
Packing, soft ring
Flinger grommet
Flinger disc
Outboard bearing housing cap
Gasket
Square head pipe plug, steel, 1/4 in.
Oil seal, 1−5/8 x 2−3/4 in. or 1−7/16 x 2−3/4 in.
(For 1−1/2 x 2−3/4, see Ref. No. S116)
Lube relief fitting, 1/8 in.
Retaining ring
Lock washer, 3/8 in.
Hex hd screw, 3/8−16 x 1 in.
Hex hd screw, SS, 1/4−20 x 1 in.
Tachometer driven gear
O−ring, 3 x 3−1/4 in.
Ball bearing
Hex hd screw, 1/2−20 x 1−3/4 in. or 1/2−20 x 2 in.
Hex nut, 1/2−20
Tachometer drive gear
Tachometer gear spacer
Tachometer gear bushing
130
Page 130
S2
S3
S4
S5
S6
S7
S7
S9
DESCRIPTION
SPL81966
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131
WATEROUS COMPANY
SOUTH ST. PAUL, MINNESOTA
CS Series Impeller Shaft Assemblies
REF NO.
S65
S66
S68
S69
S70
S71
S72
S73
S74
REF NO.
DESCRIPTION
Retaining ring
O−ring, 3−1/4 x 3−1/2 in.
Spring pin, 3/16 x 1/2 in.
Oil seal, 1−23/32 x 2−3/4 in.
End yoke with U−bolts
Shaft nut, 1−20
Cotter pin, 1/8 x 1−3/4 in. (prior to 04/20/98)
Tachometer sleeve
Mechanical seal (not available individually,
see S95 or S96)
Retaining ring
Throttle bushing
Tachometer gear housing (not available individually,
see S111)
Flinger
Bearing housing spacer
Bearing spacer
Packing, flexible graphite (Grafoil), split ring
Bearing seal
Retaining ring
S75
S76
S95
S96
S97
S99
S105
S106
S107
S108
S110
S111
Seal housing plug
Bearing shield
Repair kit, mechanical seal, outboard end
Repair kit, mechanical seal, drive end
Bearing spacer
Seal housing gasket
Lantern ring
Unbalanced nut, 5/16−18
Flat brass washer, 5/16 in.
Stud, 5/16−18 x 1−5/8 in.
Seal housing subassembly (includes S5 and S10)
Tachometer gear housing assembly
(includes S49 and S68)
Packing kit, solid ring
Packing kit, split ring
Oil seal housing
Bearing housing
Oil Seal, 1−1/2 x 2−3/4 (formely S32)
Complete impeller shaft assembly
S112
S113
S114
S115
S116
S500
131
Page 131
S50
S51
S52
S53
S54
S55
S56
S57
S64
DESCRIPTION
SPL81966
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135
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136
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140
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144
Document Number
Issue Date
Rev. Date
DPL 82088
06/13/95
12/15/06
Auxiliary Fittings Dimensional Drawings
Auxiliary Fittings for Intake and Discharge Fitting Pads
Specify Installation of these fittings on main intake and discharge fitting pads to achieve a custom piping configuration.
These fittings are divided into type groups which are referred to on the intake and discharge fitting dimensional drawings. Refer to the table column *install aux fittings* on those
drawings and using the type group specified. Locate and choose additional fittings to be installed on those pads.
Description
See Page
Type 1
Fittings for 2−1/2 in. 4−Bolt Machined Pads
1−3
Type 2
Fittings for 2−1/2 in. NPT Openings
4
Type 3
Fittings for 2 in. NPT Openings
4
Type 4
Fittings for 1−1/2 in. NPT Openings
4
Type 7
Fittings for 3−1/2 in. Discharge Valves (Includes Siamese)
5−7
Type 8
Fittings for 3−1/2 in. 8−Bolt Machined Pads
8−13
Type 9
Fittings for 3 in. NPT Openings
14
Type 11
Fittings for 5 in. Flanged Ends on Intake Fittings
15
Type 12
Fittings for 6 in. Flanged Ends on Intake Fittings
16
Type 13
Fittings for 6 in. Threaded Ends on Intake Fittings
17
Type 14
Fittings for 3 in. Relief Valve Pad
18
Type 15
Fittings for 4 in. Relief Valve Pad
19
Type 16
Fittings for 8591−1 Pant Leg Intake Fitting
19
Type 17
Fittings for 6 in. Flanged Ends on 6−3/4 in. Long Intake Fittings
20−24
Type 18
Fittings for 6 in. Butterfly Valves
25
Type 19
Fittings for Dump Flange on Intake Nipples
26
Type 20
Fittings for Relief Valve Spacers
26
Type 21
Fittings for 6 in. Flanged End on CXN Pumps
27−30
Type 22
Fittings for 6 in. Butterfly Valves on CXN Pumps
31
Type 23
Fittings for 5 in. Threaded Ends on Intake Fittings
32
Type 24
Fittings for 4 in. ANSI Flanges
33
Type 25
Fittings for 3−1/2 in. Front Discharge
34
Printed in U.S.A.
144
Waterous Company Since 1886
Subsidiary of American Cast Iron Pipe Company
144
Page 144
Fitting Type
145
145
Page 145
TYPE 1
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 1 OF 34 REV: 12/15/06
145
146
146
Page 146
TYPE 1
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 2 OF 34 REV: 12/15/06
146
147
147
Page 147
TYPE 1
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 3 OF 34 REV: 12/15/06
147
148
148
Page 148
TYPE 2, 3, 4
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 4 OF 34
REV: 12/15/06
148
149
149
Page 149
TYPE 7
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 5 OF 34 REV: 12/15/06
149
150
150
Page 150
TYPE 7
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 6 OF 34 REV: 12/15/06
150
151
151
Page 151
TYPE 7
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 7 OF 34 REV: 12/15/06
151
152
152
Page 152
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 8 OF 34
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153
153
Page 153
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 9 OF 34
REV: 12/15/06
153
154
154
Page 154
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 10 OF 34 REV: 12/15/06
154
155
155
Page 155
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 11 OF 34
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156
156
Page 156
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 12 OF 34 REV: 12/15/06
156
157
157
Page 157
TYPE 8
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 13 OF 34
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158
158
Page 158
TYPE 9
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 14 OF 34 REV: 12/15/06
158
159
159
Page 159
TYPE 11
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 15 OF 34 REV: 12/15/06
159
160
160
Page 160
TYPE 12
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 16 OF 34 REV: 12/15/06
160
161
161
Page 161
TYPE 13
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 17 OF 34 REV: 12/15/06
161
162
162
Page 162
TYPE 14
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 18 OF 34 REV: 12/15/06
162
163
163
Page 163
TYPE 15 & 16
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 19 OF 34 REV: 12/15/06
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164
164
Page 164
TYPE 17
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 20 OF 34 REV: 12/15/06
164
165
165
Page 165
TYPE 17
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 21 OF 34 REV: 12/15/06
165
166
166
Page 166
TYPE 17
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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167
167
Page 167
TYPE 17
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 23 OF 34 REV: 12/15/06
167
168
168
Page 168
TYPE 17
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 24 OF 34 REV: 12/15/06
168
169
169
Page 169
TYPE 18
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 25 OF 34 REV: 12/15/06
169
170
170
Page 170
TYPE 19 & 20
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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170
171
171
Page 171
TYPE 22
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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172
172
Page 172
TYPE 21
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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173
173
Page 173
TYPE 21
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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174
174
Page 174
TYPE 21
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 30 OF 34 REV: 12/15/06
174
175
175
Page 175
TYPE 21
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 31 OF 34 REV: 12/15/06
175
176
176
Page 176
TYPE 23
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 32 OF 34 REV: 12/15/06
176
177
177
Page 177
TYPE 24
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 33 OF 34 REV: 12/15/06
177
178
178
Page 178
TYPE 25
AUXILIARY FITTINGS
DPL82088
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 34 OF 34 REV: 12/15/06
178
179
Issue Date
Rev. Date
04/20/06
10/31/06
Document Number
SPL82897
C10 Transmission Assembly Service Parts List
Index:
See Page
See Page
CM & CS
Pump
Models
CG & CX
Pump
Models
CMH & CSH
Pump
Models
Viewed from Input Side
2, 3
2, 3
2, 3
Viewed from Output Side
4, 5
4, 5
4, 5
Spacers and Shims
6, 7
6, 7
6, 7
8, 9
8, 9
8, 9
Model C10B
10, 11
10, 11
10, 11
Model C10C
12, 13
12, 13
12, 13
Models C10D,
C10E, C10F
14, 15
14, 15
14, 15
Oil Cooler Option
16, 17
−
−
Input and Output Shaft
18, 19
18, 19
18, 19
Input Shaft Only
20, 21
20, 21
20, 21
Rear Facing Configuration
−
−
−
None
22, 23
−
−
Eclipset CAFS
22, 23
−
−
Hydraulic Pump Adapter
24, 25
−
−
Combination Pump
24, 25
−
−
Oil Cooler
26, 27
−
−
None
−
26, 27
28, 29
Eclipse ESt CAFS
−
28, 29
−
Components
Page 179
Lower Section of Case
Case Assembly
Hardware
Driveline
Pump Impeller Shaft Type
Driven Shaft and
Rear Facing
Configuration
Separable Impeller Shaft
(CM & CS Models)
Non−Separable Impeller
Shaft
(CG & CX Models)
Between Cap and Case
179
See Page
179
180
Case Assembly, Viewed From Input Side of Case
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T65
Case Cap
T11
Drive Shaft Housing
T69
Hex Nut, M12
T23
Oil Seal Housing
T71
Hex Hd Screw, M12 x 60 mm
T24
Gasket
T99
Shim
T27
Breather, 1/2 NPT
T100
Spacer
T28
Chain Case Subassembly
T135
Hex Hd Screw, M10 x 25 mm
T46
Shift Shaft
T136
Hex Hd Screw, M10 x 20 mm
T51
Heavy Spirol Pin, 5/16 x 1−3/8 in.
T141
Gasket and Shim Repair Kit
T53
Lock Washer, M12
T154
Hex Hd Screw, M12 x 35 mm
T58
Magnetic Drain Plug, 3/4−16
T180
Magnetic Tachometer Pickup
T59
Spring Housing
T181
O−ring, 5/8 x 3/4 in.
T60
Heavy Spirol Pin, 1/4 x 1−1/4 in.
T244
Socket Hd Screw, M10 x 25 mm
T61
Shift Lock Spring
T245
O−ring, 5−1/4 x 5−1/2 in.
T62
Shift Arm
180
Page 180
REF.
NO.
SPL82897
PAGE 2 OF 29
REV: 10/31/06
180
181
181
Page 181
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 3 OF 29
REV: 10/31/06
181
182
Case Assembly, Viewed From Output Side of Case
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T72
Threaded Stud, M12 x 35 mm
T28
Chain Case Subassembly
T86
Adjusting Screw
T41
Aluminum Shim
T87
Adjusting Screw Retainer
T42
Bearing Housing
T99
Shim
T53
Lock Washer, M12
T100
Spacer
T55
Shift Cover
T134
Sight Plug
T56
Gasket Cover
T135
Hex Hd Screw, M10 x 25 mm
T58
Magnetic Plug, 3/4−16
T141
Gasket and Shim Repair Kit
T65
Case Cap
T182
O−ring, 4−3/4 x 5 in.
T67
Hose
T249
Hex Hd Screw, M12 x 25 mm
T69
Hex Nut, M12
182
Page 182
REF.
NO.
SPL82897
PAGE 4 OF 29
REV: 10/31/06
182
183
183
Page 183
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 5 OF 29
REV: 10/31/06
183
184
Case Assembly, Spacers and Shims
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T28
Chain Case Subassembly
T99
Shim
T65
Case Cap
T100
Spacer
184
Page 184
SPL82897
PAGE 6 OF 29
REV: 10/31/06
184
185
185
Page 185
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 7 OF 29
REV: 10/31/06
185
186
Case Hardware, Lower Section of Case
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T52
Hex Hd Screw, M12 x 30 mm
T93
Hex Hd Screw, M12 x 45 mm
T53
Lock Washer, M12
T131
Dowel Pin, 3/8 x 1 in.
T69
Hex Nut, M12
186
Page 186
SPL82897
PAGE 8 OF 29
REV: 10/31/06
186
187
187
Page 187
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 9 OF 29
REV: 10/31/06
187
188
Case Hardware, Between Cap and Case, Model C10B
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T53
Lock Washer, M12
T103
Dowel Pin, 1/2 x 1−1/2 in.
T69
Hex Nut, M12
T240
Hex Hd Screw, M12 x 40 mm
T71
Hex Hd Screw, M12 x 60 mm
188
Page 188
SPL82897
PAGE 10 OF 29
REV: 10/31/06
188
189
189
Page 189
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 11 OF 29
REV: 10/31/06
189
190
Case Hardware, Between Cap and Case, Model C10C
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T53
Lock Washer, M12
T73
Flat Extra Thick Washer, 1/2 in.
T68
Hex Hd Screw, M12 x 100 mm
T103
Dowel Pin, 1/2 x 1−1/2 in.
T69
Hex Nut, M12
T70
Hex Hd Screw, M12 x 90 mm
190
Page 190
SPL82897
PAGE 12 OF 29
REV: 10/31/06
190
191
191
Page 191
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 13 OF 29
REV: 10/31/06
191
192
Case Hardware, Between Cap and Case, Models, C10D, C10E, C10F
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T52
Hex Hd Screw, M12 x 30 mm
T103
Dowel Pin, 1/2 x 1−1/2 in.
T53
Lock Washer, M12
T106
Hex Hd Screw, M12 x 50 mm
T69
Hex Nut, M12
192
Page 192
SPL82897
PAGE 14 OF 29
REV: 10/31/06
192
193
193
Page 193
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 15 OF 29
REV: 10/31/06
193
194
Oil Cooler Option
REF.
NO.
DESCRIPTION
REF.
NO.
DESCRIPTION
T57
Street Elbow, 90_, 1/2 in.
T132
Oil Strainer
T66
Straight Adapter, 1/2 in.
T247
Hose
194
Page 194
SPL82897
PAGE 16 OF 29
REV: 10/31/06
194
195
195
Page 195
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 17 OF 29
REV: 10/31/06
195
196
Driveline, Input and Output Shaft
DESCRIPTION
REF.
NO.
DESCRIPTION
T2
Coupling Shaft Spacer
T49
O−ring, 7/8 x 1 in.
T3
Ball Bearing
T50
Sleeve Bearing
T4
Shift Collar
T62
Shift Arm
T5
Drive Sprocket
T75
Shifter Shoe
T6
Needle Bearing
T80
Shift Fork
T7
Thrust Washer
T83
Connecting Pin Set
T10
Tachometer Pulse Generator
T94
Plain Washer, 1−1/4 in.
T13
Drive Shaft
T104
Drive Shaft Spacer
T15
Ball Bearing
T108
Heavy Spilrol Pin, 1/16 x 1/4 in.
T18
Chain
T112
Sleeve
T37
Pivot Pin, 5/8 x 2−3/4 in.
T141
Gasket and Shim Repair Kit
T38
Locking Arm
T173
Shift Lever
T39
O−ring, 1/4 x 3/8 in.
T187
Oil Seal, 3−1/2 x 4−3/8 in.
T40
Shifter Shoe
T190
Sleeve Bearing
T43
Self−Locking Nut, 1−1/4 in.
T230
Drive Shaft Spacer
T44
Coupling Shaft
T237
Shoulder Screw, 3/8 x 1−3/4 in.
T46
Shift Shaft
T238
Lock Nut, 5/16−18
T47
Sector Gear
T48
Sector Spacer
196
Page 196
REF.
NO.
SPL82897
PAGE 18 OF 29
REV: 10/31/06
196
197
197
Page 197
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 19 OF 29
REV: 10/31/06
197
198
Driveline, Input Shaft Only
DESCRIPTION
REF.
NO.
DESCRIPTION
T3
Ball Bearing
T49
O−ring, 7/8 x 1 in.
T4
Shift Collar
T50
Sleeve Bearing
T5
Drive Sprocket
T62
Shift Arm
T6
Needle Bearing
T75
Shifter Shoe
T7
Thrust Washer
T80
Shift Fork
T10
Tachometer Pulse Generator
T83
Connecting Pin Set
T13
Drive Shaft
T94
Plain Washer, 1−1/4 in.
T15
Ball Bearing
T104
Drive Shaft Spacer
T18
Chain
T108
Heavy Spilrol Pin, 1/16 x 1/4 in.
T37
Pivot Pin, 5/8 x 2−3/4 in.
T112
Sleeve
T38
Locking Arm
T141
Gasket and Shim Repair Kit
T39
O−ring, 1/4 x 3/8 in.
T173
Shift Lever
T40
Shifter Shoe
T187
Oil Seal, 3−1/2 x 4−3/8 in.
T43
Self−Locking Nut, 1−1/4 in.
T190
Sleeve Bearing
T46
Shift Shaft
T230
Drive Shaft Spacer
T47
Sector Gear
T237
Shoulder Screw, 3/8 x 1−3/4 in.
T48
Sector Spacer
T238
Lock Nut, 5/16−18
198
Page 198
REF.
NO.
SPL82897
PAGE 20 OF 29
REV: 10/31/06
198
199
199
Page 199
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 21 OF 29
REV: 10/31/06
199
200
Driven Shaft Components
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T120
Driven Shaft
T19
Oil Seal
T135
Hex Hd Screw, M10 x 25 mm
T23
Oil Seal Housing
T138
Boot
T24
Gasket
T183
Ball Bearing
T25
Ball Bearing
T232
Square Key, 5−16 x 1−3/4 in.
T26
Driven Sprocket
T241
Wave Spring
T29
Bearing Spacer
T242
Oil Seal
T31
Oil Seal Housing
T243
Retaining Ring
T32
Bearing Nut Washer
T244
Socket Hd Screw, M10 x 25 mm
T33
Lock Bearing Nut
T246
Square Key, 5/16 x 2−5/16 in.
T65
Case Cap
T248
O−ring, 3−1/4 x 3−7/16 in.
T95
Bearing Spacer
200
Page 200
REF.
NO.
SPL82897
PAGE 22 OF 29
REV: 10/31/06
200
201
201
Page 201
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 23 OF 29
REV: 10/31/06
201
202
Driven Shaft Components
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T120
Driven Shaft
T19
Oil Seal
T135
Hex Hd Screw, M10 x 25 mm
T23
Oil Seal Housing
T138
Boot
T24
Gasket
T169
Hydraulic Adapter or Oil Seal Housing
T25
Ball Bearing
T170
Oil Seal Sleeve
T26
Driven Sprocket
T241
Wave Spring
T29
Bearing Spacer
T242
Oil Seal
T32
Bearing Nut Washer
T243
Retaining Ring
T33
Bearing Lock Nut
T244
Socket Hd Screw, M10 x 25 mm
T65
Case Cap
T246
Square Key, 5/16 x 2−5/16 in.
T95
Bearing Spacer
T248
O−ring, 3−1/4 x 3−7/16 in.
202
Page 202
REF.
NO.
SPL82897
PAGE 24 OF 29
REV: 10/31/06
202
203
203
Page 203
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 25 OF 29
REV: 10/31/06
203
204
Driven Shaft Components
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T65
Case Cap
T19
Oil Seal
T95
Bearing Spacer
T22
Lock Washer, 5/16 in.
T96
Pump Gasket
T23
Oil Seal Housing
T97
Hex Hd Screw, 5/16−18 x 3−1/2 in.
T24
Gasket
T120
Driven Shaft
T25
Ball Bearing
T135
Hex Hd Screw, M10 x 25 mm
T26
Driven Sprocket
T138
Boot
T29
Bearing Spacer
T141
Gasket and Shim Repair Kit
T31
Oil Seal Housing
T183
Ball Bearing
T32
Bearing Nut Washer
T241
Wave Spring
T33
Bearing Lock Nut
T244
Socket Hd Screw, M10 x 25 mm
T34
Lube Pump
T246
Square Key, 5/16 x 2−5/16 in.
T248
O−ring, 3−1/4 x 3−7/16 in.
204
Page 204
REF.
NO.
SPL82897
PAGE 26 OF 29
REV: 10/31/06
204
205
205
Page 205
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 27 OF 29
REV: 10/31/06
205
206
Driven Shaft Components
DESCRIPTION
REF.
NO.
DESCRIPTION
T9
Lock Washer, M10
T65
Case Cap
T19
Oil Seal
T95
Bearing Spacer
T23
Oil Seal Housing
T135
Hex Hd Screw, M10 x 25 mm
T24
Gasket
T183
Ball Bearing
T25
Ball Bearing
T241
Wave Spring
T26
Driven Sprocket
T242
Oil Seal
T29
Bearing Spacer
T243
Retaining Ring
T31
Oil Seal Housing
T244
Socket Hd Screw, M10 x 25 mm
T32
Bearing Nut Washer
T248
O−ring, 3−1/4 x 3−7/16 in.
T33
Bearing Lock Nut
206
Page 206
REF.
NO.
SPL82897
PAGE 28 OF 29
REV: 10/31/06
206
207
207
Page 207
C10 TRANSMISSION ASSEMBLY
SPL82897
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
PAGE 29 OF 29
REV: 10/31/06
207
208
208
Page 208
125 Hardman Avenue South, South St. Paul, Minnesota 55075−2456 USA (651) 450−5000
208
209
Issued:
WATEROUS COMPANY
2/7/92
Revised: 08/25/06
SOUTH ST. PAUL, MINNESOTA
Pneumatic Shift
REF NO.
DESCRIPTION
REF NO.
DESCRIPTION
Index:
Description
After 4/21/06
Shift Unit on Transmission
2
4
In−Cab and Operator’s Panels
3
5
Body
End cap
Piston
Quad ring, 1−1/4 x 1−1/2 in.
O−ring, 1−3/4 x 1−7/8 in.
Hex hd screw, 5/16−18 x 3/4 in. with thread sealant
Lock washer, 5/16 in.
Push button switch
Wire assembly, white, 4−1/2 in.
Indicating light, green
Gasket
Shift switch bracket
H29
H30
H31
H33
H34
H38
H39
H40
H41
H42
H44
H45
Panel plate, operators panel
Panel plate, in cab
Air control valve
Light Bulb, 12 volt (#1819), 24 volt (#313)
Pneumatic shift subassembly
Wire assembly, black, 25 ft 9 in.
Wire assembly, black, 18 ft
Wire assembly, black, 72 in.
Repair kit, air control valve
Repair kit (includes H4, H5 and H22)
In−cab panel mounting hardware
Operator’s panel mounting hardware
209
Page 209
H1
H2
H3
H4
H5
H6
H7
H8
H17
H20
H22
H23
Prior to 4/21/06
SPL 81871
WHEN ORDERING PARTS PLEASE SUPPLY PUMP SERIAL NUMBER
PAGE 1 OF 5
209
PLEASE NOTE
210
210
Page 210
SPL 81871
PAGE 2 OF 5
REV: 08/25/06
210
211
211
Page 211
SPL 81871
PAGE 3 OF 5
REV: 08/25/06
211
212
212
Page 212
SPL 81871
PAGE 4 OF 5
REV: 08/25/06
212
213
213
Page 213
SPL 81871
PAGE 5 OF 5
REV: 08/25/06
213
214
Issued:
WATEROUS
04/17/06
Revised: 11/03/06
SOUTH ST. PAUL, MINNESOTA
Vacuum Activated (VAP) Priming Valve and Piping
Index:
Material
See Page
CM, CS
Iron
Bronze
2*
3
Iron or Bronze
4
Iron or Bronze
5
Page 214
CLS
CGVG
CP−2, CP−3, CP−4
CLR, CLV
CGV, CGVN, CGVR
CXN, CXR, CXV
CH−4
CR
CZ, CZU
S100
E200, E300, E500
214
Pump Model
* For Iron CM pumps with inverted pump body see page 4.
REF NO.
Q1
Q2
Q3
Q4
Q5
DESCRIPTION
Compression tube fitting, 3/4 in.
Street elbow, 45_, 3/4 in.
Hex hd screw, 5/16−18 x 1−3/4 in.
Priming valve subassembly
Priming tube repair kit
REF NO.
Q6
Q7
Q8
Q9
Q10
DESCRIPTION
Pipe nipple, 3/8 NPT x 1−1/2 in.
Mountable or push−mount cable tie
Priming valve repair kit
Round hd screw, 10−24 x 3/8 in.
Street elbow, 90_, 3/4 in.
PLEASE NOTE
WHEN ORDERING PARTS PLEASE SUPPLY PUMP SERIAL NUMBER
SPL82507
PAGE 1 OF 5
214
215
215
Page 215
SPL 82507
PAGE 2 OF 5
REV: 11/03/06
215
216
216
Page 216
SPL 82507
PAGE 3 OF 5
REV: 11/03/06
216
217
217
Page 217
SPL 82507
PAGE 4 OF 5
REv: 11/03/06
217
218
218
Page 218
SPL 82507
PAGE 5 OF 5
REV: 11/03/06
218
219
Issued:
WATEROUS
02/13/06
Revised: 07/14/06
SOUTH ST. PAUL, MINNESOTA
Models VPO & VPOS Priming Pumps
REF NO.
DESCRIPTION
REF NO.
Index:
Model VPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model VPOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration if Prime−Safet Lubricant is not Used . . . . . . . .
Configuration if Prime−Safet Lubricant is Used . . . . . . . . . . . .
Wiring Connection to Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vane
Oilite bearing
Rotor assembly
Adapter (Includes K2 & K6)
Motor, 12V or 24V (Includes K4)
O−Ring, .612 x .818
O−Ring, 3.859 x 4.137
Dowel pin, 3/16 x 3/4
Headless plug, 1/8
Housing (Includes K2 & K8)
Primer subassembly, 12V or 24V
Bracket, top
Bracket, bottom Y & C10 Series Transmissions
Bracket, bottom W Series Transmissions
2
3
4
4
4
K15
K16
K16
K17
K18
K19
K20
K21
K22
K23
K24
K25
K26
K27
K28
K29
Hex hd screw, 3/8−10 x 1−1/4
(Y & W Series Transmissions)
Hex hd screw, M10 x 30mm (used prior to 06/25/02) or
M10 x 20mm, grade 8.8 (used after 06/25/02)
(C10 Transmissions)
Lock washer, 3/8 (Y & W Series Transmissions)
Lock washer, M10 (C10 Transmissions)
Socket hd screw, 5/16−18 x 1”
Lock washer, 5/16
Repair kit
Control panel assembly, electric prime
Socket hd screw, 1/4−20 x 1”
Lock washer, 1/4
Kit − solenoid replacement, 12V or 24V
Wire clamp
Check valve, 1/8 in.
Compression fitting, 1/8 in.
Prime−Safet Decal
Extension cable, electric prime
Fastener packet, control panel
PLEASE NOTE
SPL82890
WHEN ORDERING PARTS PLEASE SUPPLY PUMP SERIAL NUMBER
PAGE 1 OF 4
219
Page 219
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K12
K13
K14
K14
K15
DESCRIPTION
219
220
220
Page 220
220
221
221
Page 221
SPL 82890
PAGE 2 OF 4
REV: 07/14/06
221
222
222
Page 222
222
223
223
Page 223
SPL 82890
PAGE 3 OF 4
REV: 07/14/06
223
224
224
Page 224
224
225
225
Page 225
SPL 82890
PAGE 4 OF 4
REV: 07/14/06
225
226
226
Page 226
226
227
Document Number
Issue Date
Rev. Date
DPL 81867
11/13/91
12/06/06
Intake Fitting Dimensional Drawing
Description
Mounting Flange Size on
Pump
1
Standard Flange Intake Fittings
2
Large Flange Intake Fittings
Used on Pump Models
See Page
Iron Pumps
Bronze Pumps
9.375 in. x 6.750 in.
Rectangular (12) Bolts
CGVG
CM, CMH, CS, CSH,
CGVG
2−7
11.500 in. x 8.125 in.
Rectangular (16) Bolts
CM, CMU, CMH, CMUH,
CS, CSU, CSH, CSUH
CMU, CMUH, CSU,
CSUH
8−15
Used with Section 1
Fittings
CGVG
CM, CMH, CS, CSH,
CGVG
Used with Section 2
Fittings
CM, CMU, CMH, CMUH,
CS, CSU, CSH, CSUH
CMU, CMUH, CSU,
CSUH
227
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Section
3
Intake Extensions
4
Round Flange Intake Fittings
(6) Bolts on 5.750 in B.C.
CLS
17
5
6 in. ANSI Flange Intake Fittings
6 in. ANSI Flange
CXN
18−19
6
Intake Screens
N/A
All Models
20
Waterous Company Since 1886
Subsidiary of American Cast Iron Pipe Company
16
Printed in U.S.A.
227
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INTAKE FITTINGS
DPL81867
WATEROUS COMANY
SOUTH ST. PAUL, MN 55075
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SECTION 1 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 1 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 2 − INTAKE FITTINGS
DPL81867
WATEROUS COMANY
SOUTH ST. PAUL, MN 55075
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SECTION 2 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 2 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 2 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 2 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 3 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 4 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 5 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 5 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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SECTION 6 − INTAKE FITTINGS
DPL81867
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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Document Number
Issue Date
Rev. Date
DPL 82085
06/13/95
05/26/06
Discharge Fittings Dimensional Drawings
248
Page 248
Extensions
Tees
Elbows
WYES
Blind Flanges
Waterous Company Since 1886
Subsidiary of American Cast Iron Pipe Company
Tapped Flanges
Printed in U.S.A.
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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DISCHARGE FITTINGS
DPL82085
WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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WATEROUS COMPANY
SOUTH ST. PAUL, MN 55075
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258
Maintenance Chart
Fire Pumps
258
Form No.
F−1077
Issue Date
07/94
Rev. Date
05/04/06
DATE
EACH OPERATION
CP−3 TRANSFER VALVE − Add grease and switch
back and forth between positions
CAFS SYSTEM − Check lubricant level
(add if required), check for leaks
WEEKLY
PRIMING PUMP − Operate to exercise
(also cycles fresh lubricant in lubricated systems)
BUTTERFLY VALVE − Operate through open−close
cycle
CAFS SYSTEM − Check and clean water strainer
MONTHLY
TRANSMISSION / BEARING HOUSING
Check lubricant level − add if required
Check fluid pump operation (if provided)
KC HYDRAULIC SHIFT RESERVOIR
Check fluid level − add if required
PRIMING PUMP − Perform vacuum test
PILOT VALVES − Exercise and clean strainer
PACKING − Check packing leakage
INTAKE SCREENS − Check condition
RUNNING TESTS (Consult operator manual)
CAFS SYSTEM − Check air intake filter
6 MONTHS OR 100 HOURS (Total running time)
ANODES − Check Condition
TRANSMISSION / BEARING HOUSING
Change lubricant
Clean lubricant pump (sump) strainer (if provided)
Clean drain plug and breather
IMPELLER SHAFT BEARING(S) − Add grease
CH−4 MECHANICAL SEAL − Flush seal chamber
KC HYDRAULIC SHIFT ACCUMULATOR
Check pressure
CAFS SYSTEM − Check PolyChainr and clutch
ANNUALLY
CAFS SYSTEM − Change compressor oil and filter
24 MONTHS
CAFS SYSTEM − Change air/oil serparator cartridge
MECHANICS INITIALS
* Consult appropriate Waterous instructions for maintenance information.
See page 2 for lubricants.
Page 258
Page 1 of 2
259
259
259
RECOMMENDED LUBRICANTS
The types of lubricants recommended for Waterous equipment are listed below:
LUBRICATION REQUIREMENTS
MODEL SERIES
CAPACITY *Quarts or *Liters
Y, TY, C10, TC10
12
W
6
KC
1/2 (Hydraulic Shift Reservoir)
2−1/4 (Transmission)
TMR
5
PA, TPA
3
QA
1−1/2
CR, CZ , CZU Bearing Housings
1/4
S100D Bearing Housing
1/2
HL200, HL300 Pedestal
1
K
T
LUBRICANT
ATF (All Climates ) or
SAE 15W−40 in
Warm Climates
ATF or SAE 30 Oil
SAE 30 Oil
1
TML
4
TMS
6
TG100
3
Air Compressor
10
SAE 80W−90 Gear Oil
ISO 68 Hydraulic Oil
*Capacities shown are approximate, always fill to the bottom of the plug labeled “oil level”, window in sight
plug or marking on dipstick. Quantities vary based on ratio and/or mounting orientation.
OTHER LUBRICANTS:
ITEM
LUBRICANT
Impeller Shaft Bearing(s)
Ball Bearing Grease
Priming Tank
Waterous “Prime−Safe”t Lubricant (Part No. 72800)
CP−3 Transfer Valve
No. 4 Calcium Base Water Pump Grease
Waterous Company Since 1886
Subsidiary
ofAmericanCastIronPipeCompany
Page 2 of 2
Page 259
260
260
260
Document Number
F−2538
Issue Date
Rev. Date
05/27/04
Pump Operation’s Checklist
Note that these instructions apply only to Waterous fire pumps and accessories. If your fire apparatus is equipped
with non−Waterous systems, please test them according to the manufacturer’s recommendations.
Please read through the safety information in your operation and maintenance instructions prior to using your Waterous
pump.
Setup
1. Move the apparatus to a safe operating area.
2. Set the apparatus parking brake.
3. Place wheel chocks.
4. Open the tank−to−pump valve.
5. Open the tank fill valve half−way.
Weekly Performance Checks
The following procedures should be performed at least weekly.
. Priming System
1. Check priming lubricant level (if applicable).
2. Fill priming lubricant tank with Prime−Safet lubricant (if applicable).
3. Operate the pump priming system(s) for twenty seconds.
Monthly Performance Checks
The following procedures should be performed at least monthly.
. Pump Shift Unit
1. Engage the pump per the transmission operating instructions.
2. Check all shift indicating lights for proper operation.
. Transfer Valve Actuator
1. (Model CP−3 pumps only) Add 1 oz. of calcium−based water pump grease through lube fitting.
2. With the pump at idle, operate the transfer valve between pressure (series) and volume (parallel) for at least two cycles.
3. Check all indicating lights for proper operation.
. Discharge Relief Valve System
1. Increase the pump discharge pressure to 150 psi.
2. With the pilot valve OFF, remove the strainer assembly. Clean the strainer and the orifice in the end of the rod.
3. Cover the strainer opening with your hand and slowly turn the pilot valve ON and OFF several times. Water should flow
from the strainer opening in the ON position and the relief valve should open (amber light). Water flow should stop and
the relief valve should close (green light) in the OFF position.
4. Check the strainer O−rings and replace if required; replace the strainer assembly (hand−tight only).
5. With the pilot valve OFF, turn the pressure adjustment handle counterclockwise until it stops.
6. Slowly turn the pilot valve ON. The relief valve should open (amber light) and the pump discharge pressure should drop.
7. Slowly turn the pilot valve OFF. The relief valve should close (green light) and the pump discharge pressure should rise
back to 150 psi.
8. Repeat steps 6 and 7 until the system responds quickly when turned ON and OFF.
9. Reset the pilot valve to the desired setting and decrease the engine speed to idle.
. Disengage the pump per the transmission operating instructions.
Printed in U.S.A.
Waterous − Since 1886
Subsidiary of American Cast Iron Pipe Company
Page 1 of 2
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261
261
261
Monthly Performance Checks Continued
. Discharge Valves
1. Open all discharge valve drains and disconnect any pre−connected fire hose.
2. With the pump flooded, open and close each discharge valve repeatedly until it operates smoothly.
3. After water flow has stopped, close all drains and reconnect the hoses.
. Pump Master Drain
CAUTION
Never open or close the pump drain valve while the pump is under pressure. Doing so may result in valve seal failure.
1. Open and close the drain valve several times to allow debris to flush after each pumping operation.
2. Refill the apparatus water tank.
. Dry Vacuum Test
1. Close the tank−to−pump valve and tank fill valve
2. Remove all caps, except on openings without valves.
3. Close all intake, discharge and drain valves.
4. Operate priming system to produce a vacuum of at least 22” Hg.
CAUTION
Operating the priming pump for more than one minute continuously may damage the electric motor.
5. Watch the intake (compound) gauge. Vacuum should not drop more than 10” of Hg in five minutes.
. Intake Relief Valve System
1. Clean the pilot valve strainer once per month or as needed. Remove the screen using a 24mm wrench. Clean and
re−install.
2. Remove and clean the throttle screw from the pilot valve. If the bore is plugged, it can be flushed out with water.
3. Test the intake relief valve system with a pressurized water source capable of supplying continuous flow at 60 to 100 psi.
a. Set the pilot valve slightly above the source pressure and apply this pressure to the pump intake. The relief valve
should remain closed.
b. Reduce the pilot valve setting to slightly below the source pressure. The relief valve should open, “dumping” a large
volume of water.
c.
Reset the pilot valve above the source pressure. Relief valve should close.
. Miscellaneous Items
1. Check the pump transmission lubricant level and refill if necessary.
2. Model KC Transmission only: Check the fluid level in the hydraulic shift reservoir and refill if necessary.
3. Check the condition of all intake strainers and anodes; replace if necessary.
The fire pump system should be performance tested on an annual basis per NFPA 1911, Standard for Service Tests of Fire
Pump Systems on Fire Apparatus.
Form No. F−2538
Page 2 of 2
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