CX Series Centrifugal Fire Pumps
Installation Instructions
Table of Contents
Read through the safety information
and overhaul instructions carefully
before installing your Waterous CX
Series Fire Pump.
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4
Pump Mounting:
CXV With C20 Series Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 7
CXV With K Series Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
CXV With PA Series Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CXV With T Series Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CXV With D Series, Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CXS With D Series, Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CXS With K Series Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Installation of Shift Unit:
C20 Series Transmissions Only:
See Instruction F-1031, Section 3030
Electronic Tachometer:
Optional on C20 Series, Standard on PA Series Transmissions . . . . . . . . . . . . . . . . . . . . . 16
Mechanical Tachometer:
Optional on K and T Series Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Final Checks:
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C20 Transmission Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
NOTE: Instructions subject to change without notice
F-1031, Section 3014 (REV: 05/31/12)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000
www.waterousco.com
Safety Information
Read through and communicate safety information to the end user of this Waterous Fire Pump.
!
WARNING
Death or serious personal injury might occur if proper operating procedures are not
followed. The pump operator, as well as individuals connecting supply or discharge
hoses to the apparatus must be familiar with these pump operating instructions as
well as other operating instructions and manuals for the apparatus, water hydraulics
and component limitation.
!
WARNING
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
OEM Installation Warnings
!
WARNING
Unexpected Truck Movement. May result in serious personal injury or death.
Failure to properly install the pump shift control and pump shift indicator system in the
apparatus or failure to incorporate in the Pump Operator’s Panel Engine Speed Interlock
System may result in unexpected truck movement which may result in serious personal
injury or death.
!
WARNING
Inability to Pump Water. May result in serious personal injury or death.
Failure to properly install the pump shift control and pump shift indicator system in the
apparatus or failure to incorporate in the Pump Operator’s Panel Engine Speed Interlock
System may result in the inability to pump water which may result in serious personal injury or death.
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.
!
WARNING
Rotating Parts Hazard or Unexpected Truck Movement. May result in serious personal injury or death.
!
WARNING
Exceeding Power Train Torque Ratings. May result in inability to pump water causing serious personal injury or death.
This fire pump may have the capability under certain pumping conditions to exceed the
torque rating of the power train.
A means to control the engine output to a torque level no greater than the power train’s
continuous−duty torque rating must be considered when specifying power train components and engine control system parameters.
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 3014
Page 2 of 18
Introduction
This instruction covers the installation of a Waterous CX Series single stage fire pumps. Four different CX models are available as follows:
Model
Intake
CXS
6 in. Victaulic® Tee with a Front Facing 5 in.
Victaulic®Connection
Discharge
4 in. ANSI Flange
or
Manifold with 4 in. End Flanges and Eight (8) 2-1/2
in., 4-Bolt Side Pads
or
CXV
Manifold with 3-1/2 in. End Flanged and two (2) 2-1/2
in. 4-Bolt and two (2) 2-1/2 NPT Side Pads
6 in. Victaulic®
(See the next page for diagrams of pumps)
The CX pump is available with the following transmissions:
·
C20 Series: The C20 transmission is an aluminum, split-shaft, chain driv­
en transmission that transmits power from the truck's transmission to ei­
ther the fire pump or the drive axle of the truck.
·
PA Series: The PA transmission an aluminum chain drive transmission
designed to be driven off the ten-bolt power take-off (PTO) provision avail­
able on the left side of the Allison MD or HD automatic transmission.
·
K Series: The K transmission is an iron, two-gear speed increaser de­
signed primarily to be driven by a power take-off (PTO) or power divider.
·
T Series: The T transmission is an iron, two-gear speed increaser de­
signed to be mounted directly to an engine bell housing.
·
D Series: Direct drive from a power take-off (PTO).
The following installation instructions are available:
Instruction Name
Monarch™ Intake Valve (BFV)
Drain Valves
Pressure Control System
Overheat Protection Manager (OPM)
FoamPro® System
Advantus® System
Foam Manager™ Systems
Aquis™ System
Eclipse™ ES CAFSystem
Priming Systems
Shift Unit
F−1031, Section 3014
Instruction Number
F-1031, Section 2318
F-1031, Section 3008
F-1031, Section 3010
F-1031, Section 3015
F-1031, Section 3012
F-1031, Section 3026
F-1031, Section 3031
F-1031, Section 3018
F-1031, Section 3023
F-1031, Section 3030
Page 3 of 18
Introduction (Continued)
CXS Models
CXV Models
CXD Models
CXSD Models
F−1031, Section 3014
Page 4 of 18
Pump Mounting with C20 Series Transmission
NOTE: Remove shipping brackets and discard. Do not use for mounting pump.
Figure 1. Drop Size Dimensions
Select a mounting location which will make the pump and its accessories readily acces­
sible for maintenance and which will make the pump driveshaft parallel with the output
shaft of the chassis transmission or bearing housing. Also, select the location so that
when the apparatus is loaded, the universal joints on the propeller shaft will have a
proper working angle. Note that the C20 Series transmission is available with a range of
drop sizes (see Table 1 and Figure 1, Dimension “A").
Table 1. C20 Series Transmission Drop Ranges
Table 1. C20 Series Transmission Drop Ranges
Model
C20C
C20D
C20E
C20F
Dim A. (IN/mm)
13.811 / 350.80
14.856 / 377.34
16.920 / 429.77
18.972 / 481.99
*NOTE:
2.27 ratio drop values shown. Drop values vary for other output ratios, see dimensional
drawings for specific drops by ratio.
Table 2 gives maximum universal joint angles for installations where propeller shaft
flanges are parallel and yokes are aligned. Refer to this table when positioning a pump
to determine proper shaft angles. Be sure to keep at least a minimum of 1_ U-joint oper­
ating angle, but do not exceed those specified in the table. This is the preferred method
of propeller shaft installation. For additional information on this method, or for alterna­
tive methods, see driveshaft installation guidelines such as Spicerr/Driveshaft Installa­
tion Techniques.
CAUTION
Be sure the propeller shafts used are of the slip-joint design. Frame deflection, tem­
perature changes and similar factors may cause a propeller shaft without slip-joints
to produce severe axial loads on the bearings and damage the pump / transmis­
sion.
Table 2. Maximum U−joint Operating Angles
Driveshaft RPM
Maximum Operating Angle
5000
4500
4000
3500
3000
2500
2000
1500
3.2_
3.7_
4.2_
5.0_
5.8_
7.0_
8.7_
11.5_
F−1031, Section 3014
Figures 2 and 3 show the mounting areas on an CXC20 pump. To mount the pump/
transmission to the vehicle chassis, attach brackets (not supplied by Waterous) on ei­
ther side of the transmission. Position the pump/transmission within the vehicle frame
rails, blocking temporarily to provide correct shaft angularity. With the pump/transmis­
sion in the correct position, secure the brackets (not supplied) to the vehicle frame us­
ing a three point mounting technique. The bracket on one side of the transmission shall
use only one bolt when attaching to the rail. The bracket on the other side of the trans­
mission should be attached to the chassis rail using two bolts. This three point tech­
nique will allow for slight vehicle frame twist without undo stress on the pump/transmis­
sion assembly.
The transmission cap also contains five (5) mounting holes for further support of the
CXC20.
Support the pump by fashioning a bracket (not supplied by Waterous) and mount it to
the the intake side of the pump using the existing intake mounting screw holes.
NOTE: You will need to remove one or more intake mounting screws from the
intake side of the pump and replace them with longer screws to compensate for
the thickness of the bracket.
NOTE: Tighten the mounting screws to standard torque specifications.
Connect shift unit per installation instruction F-1031, Section 3030.
Page 5 of 18
Pump Mounting with C20 Series Transmission (Continued)
Figure 2. CXVC20 Dimensions
F−1031, Section 3014
Page 6 of 18
Pump Mounting with C20 Series Transmission (Continued)
Figure 3. CXVC20 Mounting
Mounting Holes on Transmission
Five (5) Mounting Holes
(3/8-16 UNC-2B x .563 Deep)
Mounting Holes on Pump Intake
Remove the screw(s) and install bracket (not supplied
by Waterous). Tighten bracket to the intake of the
pump using 1/2 in. screw(s).
NOTE: Use longer 1/2 in. screws to secure the
bracket to the pump than were originally supplied
with the pump to compensate for the thickness of
the bracket.
Eight (8) 1/2-13 UNC-2B x .688
Deep Intake Mounting Screws
Four (4) Mounting Holes
(5/8-11 UNC-2B x .938 Deep)
(2 Holes on each side of tranmission)
F−1031, Section 3014
Anti-seize should be applied to the shaft
threads before installing end yoke or compan­
ion flange. Do not reuse self-locking nuts,
Torque to 475-525 lb-ft.
Page 7 of 18
Pump Mounting with K Series Transmission
Support the pump by fashioning a bracket (not supplied by Waterous) and
mount it to the the intake side of the pump using the existing intake mounting
screw holes.
Figure 4 shows the mounting areas on a CXK pump. To mount the pump/
transmission to the vehicle chassis, fashion a bracket that will span the frame
rails of the vehicle and attach to the transmission mounting holes (several
locations are provided).
NOTE: Before installation, make sure your pump has the right rotation as
compared to the driveshaft rotation (see dimensional drawings for cor­
rect rotation configurations).
Position the pump/transmission within the vehicle frame rails, blocking tempo­
rarily to provide correct shaft angularity. With the pump/transmission in the cor­
rect position, secure the brackets (not supplied) to the vehicle frame.
NOTE: You will need to remove one or more intake mounting screws
from the intake side of the pump and replace them with longer screws to
compensate for the thickness of the bracket.
NOTE: Tighten the mounting screws to standard torque specifications.
Finally, provide adequate support for any intake and discharge piping assem­
blies.
Figure 4. CXVK Mounting Diagram
Mounting Holes on Pump Intake
Remove the screw(s) and install bracket (not supplied by Waterous).
Tighten bracket to the intake of the pump using 1/2 in. screw(s).
Mounting Holes on Transmission
See the next page for optional
Suspension Pin mounting.
Six (6) Mounting Holes
(7/16-14 UNC-2B x .625 in. deep)
NOTE: Use longer 1/2 in. screws to secure the bracket to the
pump than were originally supplied with the pump to compensate
for the thickness of the bracket.
Anti-seize should be applied to the shaft
threads before installing end yoke or
companion flange. Do not reuse selflocking nuts, Torque to 275-325 lb-ft.
Intake Side
of CX Pump
Eight (8) Intake Mounting Screws
(1/2−13 UNC−2B x .688 Deep)
F−1031, Section 3014
Page 8 of 18
Pump Mounting with K Series Transmission - Optional Suspension Pin Mounting (K520)
An optional mounting technique on the CXK pump is the Suspension Pin
Mounting Kit. The kit consists of a bracket, two 7/16" screws, two lockwashers,
two cotter pins and the suspension pin. To mount the transmission using this
kit, follow the instructions below:
3. Line up the hole in the bracket with the hole in the suspension pin and in­
sert a cotter pin.
1. Mount the bracket to the transmission using the top two mounting holes.
Secure the bracket with the two 7/16" screws and lockwashers.
5. Install the bracket on the suspension pin and hold in place by inserting a
cotter pin through the hole on the suspension pin.
4. Fashion a bracket that will span the vehicle's chassis. Cut out a hole in the
bracket that will allow the suspension pin to pass through.
2. Insert the suspension pin into the bracket.
Figure 5. Optional Suspension Pin (K520)
Suspension Pin Bracket
Cotter Pin
Cotter Pin
Two (2) Mounting Holes
7/16-14 UNC-2B x .625 in. Deep
Suspension Pin
Two (2) 7/16-14 x 1-1/4 in.
Hex Hd Screws and Lock­
washers
F−1031, Section 3014
Page 9 of 18
Pump Mounting with PA Series Transmission
Figure 6 shows the mounting areas on a CXPA pump. To mount the pump/
transmission to the vehicle chassis, fashion a bracket that will span the frame
rails of the vehicle and attach to the transmission mounting holes.
Support the pump by fashioning a bracket (not supplied by Waterous) and
mount it to the the intake side of the pump using the existing intake mounting
screw holes.
Position the pump/transmission within the vehicle frame rails, blocking tempo­
rarily to provide correct shaft angularity. With the pump/transmission in the cor­
rect position, secure the brackets (not supplied) to the vehicle.
NOTE: You will need to remove one or more intake mounting screws
from the intake side of the pump and replace them with longer screws to
compensate for the thickness of the bracket.
NOTE: Tighten the mounting screws to standard torque specifications.
Finally, provide adequate support for any intake and discharge piping assem­
blies.
Figure 6. CXVPA Mounting Diagram
Mounting Holes on Pump Intake
Mounting Holes on Transmission
Remove the screw(s) and install bracket (not supplied by Waterous).
Tighten bracket to the intake of the pump using 1/2 in. screw(s).
NOTE: Use longer 1/2 in. screws to secure the bracket to the
pump than were originally supplied with the pump to compensate
for the thickness of the bracket.
Four (4) Mounting Holes
(1/2-13 UNC-2B x 1.0 in. deep)
Intake Side
of CX Pump
Eight (8) Intake Mounting Screws
(1/2-13 UNC-2B x .688 Deep)
IL2346
Anti-seize should be applied to the shaft
threads before installing end yoke or
companion flange. Do not reuse selflocking nuts, Torque to 275-325 lb-ft.
F−1031, Section 3014
Page 10 of 18
Pump Mounting with T Series Transmission
Figure 7 shows the CXT pump. The CXT is a direct-engine mounted pump.
The bellhousing attaches to the vehicles flywheel housing.
NOTE: Before installation, make sure your pump has the right rotation as
compared to the driveshaft rotation (see dimensional drawings for cor­
rect rotation configurations).
3. With a suitable hoist, guide the pump drive shaft into the drive plate and
pilot bearing. Align screws holes in the pump mounting flange with those in
the flywheel housing. Install the twelve (12) screws and tighten securely.
4. Finally, provide adequate support for any intake and discharge piping as­
semblies.
NOTE: Tighten the mounting screws to standard torque specifications.
To install the CXT pump, perform the following:
1. Supply input shaft support bearing.
2. Install the drive plate assembly according to the manufacturer's instruc­
tions.
Figure 7. CXVT Mounting Diagram
Eight (8) 3/8-16 UNC-2B Tapped Holes
in Flywheel. Use Class 8 Screws.
Flywheel for Driving-Ring Type
over center clutch per SAE J620.
Bearing
1-3/4-10 SAE Spline
Drive Plate
Bell Housing Adapter
F−1031, Section 3014
Page 11 of 18
Pump Mounting
CX with D Series Direct Drive, Model CXD
Mounting Bracket Attachment Points
Figure 8 shows the mounting areas on an CXD pump. There are mounting
holes on the bearing housing.
Figure 8. CX Mounting
Attach brackets (not supplied by Waterous) to the bearing housing. Secure the
pump and bearing housing to the vehicle.
NOTE: Tighten the mounting screws to standard torque specifications.
(4) Mounting Holes
Anti-seize should be applied to the
shaft threads before installing end yoke
or companion flange. Do not reuse
self-locking nuts, Torque to 275-325
lb-ft.
F−1031, Section 3014
Page 12 of 18
Pump Mounting
CXS with D Series Direct Drive, Model CXSD
Mounting Bracket Attachment Points
Figure 9 shows the mounting areas on an CXSD pump. There are mounting
holes on the bearing housing.
Figure 9. CXS Mounting
Attach brackets (not supplied by Waterous) to the bearing housing. Secure the
pump and bearing housing to the vehicle.
NOTE: Tighten the mounting screws to standard torque specifications.
(4) Mounting Holes
Anti-seize should be applied to the
shaft threads before installing end yoke
or companion flange. Do not reuse
self-locking nuts, Torque to 275-325
lb-ft.
F−1031, Section 3014
Page 13 of 18
CXS with K Series Transmission Mounting
Figure 10 shows the mounting areas on a CXSK pump. To mount the pump/
transmission to the vehicle chassis, fashion a bracket that will span the frame
rails of the vehicle and attach to the transmission mounting holes (several
locations are provided).
NOTE: Before installation, make sure your pump has the right rotation as
compared to the driveshaft rotation (see dimensional drawings for cor­
rect rotation configurations).
Position the pump/transmission within the vehicle frame rails, blocking tempo­
rarily to provide correct shaft angularity. With the pump/transmission in the cor­
rect position, secure the brackets (not supplied) to the vehicle frame.
NOTE: Tighten the mounting screws to standard torque specifications.
Finally, provide adequate support for any intake and discharge piping assem­
blies.
Figure 10. CXSK Mounting Diagram
F−1031, Section 3014
Page 14 of 18
Pump Mounting with K Series Transmission - Optional Suspension Pin Mounting (K520)
An optional mounting technique on the CXSK pump is the Suspension Pin
Mounting Kit. The kit consists of a bracket, two 7/16" screws, two lockwashers,
two cotter pins and the suspension pin. To mount the transmission using this
kit, follow the instructions below:
3. Line up the hole in the bracket with the hole in the suspension pin and in­
sert a cotter pin.
1. Mount the bracket to the transmission using the top two mounting holes.
Secure the bracket with the two 7/16" screws and lockwashers.
5. Install the bracket on the suspension pin and hold in place by inserting a
cotter pin through the hole on the suspension pin.
4. Fashion a bracket that will span the vehicle's chassis. Cut out a hole in the
bracket that will allow the suspension pin to pass through.
2. Insert the suspension pin into the bracket.
Figure 11. Optional Suspension Pin (K520)
Suspension Pin Bracket
Cotter Pin
Cotter Pin
Two (2) Mounting Holes
7/16-14 UNC-2B x .625 in. Deep
Suspension Pin
Two (2) 7/16-14 x 1-1/4 in.
Hex Hd Screws and Lock­
washers
Anti-seize should be applied to
the shaft threads before installing
end yoke or companion flange.
Do not reuse self- locking nuts,
Torque to 275-325 lb-ft.
F−1031, Section 3014
Page 15 of 18
Tachometer
Electronic Tachometer Drive
(Optional on C20 Series, Standard on PA Series Transmissions)
The magnetic pick-up in the transmission mates with an Amphenol connector
(P/N MS3106A-10SL-4S). This connector should be wired to a wall mount re­
ceptacle on the operator's panel. Cable assembly 63033 available from Water­
ous.
Mechanical Tachometer Drive
(Optional on K and T Transmissions Only)
Install a cable from the tachometer take-off on the driveshaft (front housing of
the transmission).
C20 Series Transmission:
To verify the rotational speed of the drive shaft, the frequency (Hz) reading
from the tachometer sensor should be multiplied by 10.
Hz x 10 = RPM
PA Series Transmission:
To verify the rotational speed of the drive shaft, the frequency (Hz) reading
from the tachometer sensor should be multiplied by 6.
Hz x 6 = RPM
NOTE: Frequency reading can be measured with hand held multimeter.
Cable connector assembly V 3398 available for connecting wall mount
receptacle to multimeter.
from DPL82074
F−1031, Section 3014
Page 16 of 18
Optional Corrosion Protection
Zinc Intake Screens
Waterous offers zinc intake screens that fit 4, 4-1/2, 5 and 6 inch intake fittings sizes.
The screen is designed to fit in the counter bore in the inside diameter of the fittings.
There must be a strong electrical contact between the screen and the intake fitting. Re­
move 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: Zinc intake 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.
Zinc Anodes
Zinc anodes may be mounted in the intake piping or, if no intake pads are available, in
the discharge piping.
NOTE: The zinc must make contact with water to be effective. Do not paint or use
any other coating on the zinc elements.
Zinc anodes are available for the following:
·
Pads machined with 2-1/2 in., 4-bolt mounting patterns
·
Pads machined with 2-1/2 in. or 3 in. NPT taps.
Zinc Anodes - Bolt On
Pads Machined with 2-1/2 in.,
4-bolt Mounting Pattern
Zinc Anodes - Threaded
Pads Machined with 2-1/2 in.,
or 3 in. NPT Taps
F−1031, Section 3014
Page 17 of 18
Final Checks
After the pump, accessories, piping and miscellaneous connections are completely installed, check the items listed below:
Lubrication
CAUTION
Failure to properly lubricate the pump and transmission may result in seri­
ous damage to the equipment.
Testing
Perform the tests listed in F-1031, Section 1000, “Centrifugal Fire Pump Prin­
ciples of Operation, Inspection Tests and Troubleshooting Guide." During the
running tests, monitor the smoothness of operation, listen for unusual noises
and check for leaks.
C20 Series Transmission
Add any type of automatic transmission fluid (ATF) through the fluid level hole or
by removing the breather. Approximately 6 quarts is required to fill the transmis­
sion when completely drained. The fluid should be level with bottom of the fluid
level hole.
C20 Transmission Temperature Specifications
The maximum temperature permitted at transmission external surfaces is 250° F
(121° C)
K Series Transmission
Add any type of SAE 80W-90 gear oil through the fluid level hole or by removing
the breather. Approximately 1 quart is required to fill the transmission when
completely drained. The fluid should be level with bottom of the fluid level hole.
PA Series Transmission
Add any type of automatic transmission fluid (ATF) through the fluid level hole or
by removing the breather. Approximately 3 quarts is required to fill the transmis­
sion when completely drained. The fluid should be level with bottom of the fluid
level hole.
T Series Transmission
Add any type of SAE 80W-90 gear oil through the fluid level hole or by removing
the breather. Approximately 1 quart is required to fill the transmission when
completely drained. The fluid should be level with bottom of the fluid level hole.
D Series Direct Drive
Drive housing contains sealed ball bearings. Lubrication is not required.
F−1031, Section 3014
Page 18 of 18