DARLEY ZSP Nstallation, Operation, Maintenance, Repair And Troubleshooting Instructions Download Page 63 | Manualshive

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DARLEY ZSP Nstallation, Operation, Maintenance, Repair And Troubleshooting Instructions Download Page 63

Prepared by: RJG

Revision: A

Approved by: WAH

Original release date: 03/16/12

Revised by: WAH VIA ECO 11337

Revision release date: 02/19/2016

1201050.doc

Lubricate universal joint cross using a good quality E.P. (extreme pressure) grease meeting N.L.G.I. E.P. Grade 2
specifications. (Consult your local lubricant source for greases that meet this specification.

PRIMER CONNECTION: For 12/24-volt electrically-clutched belt-driven priming pump installation,
see drawings DVC0306 through DVC0309

found in “Section 4 - Pump Detail” of the “ZSP Installation,

Operation, Maintenance, Repair and Troubleshooting Manual”.

ENGINE COOLING/PUMP HEATER: Two tapped openings in the pump suction head are provided
for circulating engine coolant through the heater jacket/heat exchanger to prevent pump freezing in
cold weather, and to aid in engine cooling in warm weather. Use no smaller than a 1/2” heater hose
for this connection. See drawing DGS0400. An external heat exchanger should be added to aid in
cooling the engine on units that do not have an internal heater jacket/heat exchanger in the suction
head.

PUMP SHIFT INSTALLATION: For power shift installation, refer to DGS1100

for automatic

transmission wiring details.

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Summary of Contents for ZSP

Page 1: ...CTIONS FOR THE ZSP Fire Pump Corporate Office Pump Manufacturing Apparatus Division 325 Spring Lake Drive 1051 Palmer St 920 Kurth Rd Itasca Illinois 60143 2072 Chippewa Falls WI 54729 Chippewa Falls WI 54729 800 323 0244 fax 708 345 8993 800 634 7812 Fax 715 726 2656 800 527 0068 Fax 726 2648 WWW DARLEY COM This manual is for DARLEY FIRE PUMP Model ZSP Pump Serial Number ________ ...

Page 2: ...ions plus an appendix Each section details the operation safety use and maintenance of the ZSP pump system The appendix includes supplementary information Section 1 Definition of Symbols and Immediate Safety Information Section 2 General Information and Operations Recommendations PTO Information General Operations Info Definitions NFPA Discharge Reach and Friction Loss Tables Section 3 ZSP Fire Pu...

Page 3: ...tallation 1201050 Driveline Guideline Drawing DGM1301 ZSP Suction Pipe Mounting Bracket Detail DGM2902 Suction Mounting Bracket Pivot Detail DGM1302 ZSP Standard Transmission Mounting Bracket Detail DGM2908 Vibration isolating mounting bracket assembly for the pump s suction head DGM2905 Vibration isolating mounting bracket assembly for the pump s gearbox DGM2906 Mounting Bracket 4042200 Mounting ...

Page 4: ...ple Drain Valve DGC0904 Ball Valve 1200000 Valve Cross Section DGC0100 Relief Valve Discharge Valve 1200503 RV and Remote Head Schematic and Cross Section DGC0141 RV and Remote Head Dimensional DGD0800 RV Alarm Installation 1201002 Butterfly Valve DGD0104 DGD0101 1200572 Pump Overheat Protection DGM0117 Overheat Valve 12VDC 5209401 Overheat Valve 24VDC 5209402 Appendix Detailed Specifications 1200...

Page 5: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Section 1 Definition of Symbols and Immediate Safety Information ...

Page 6: ...ardous situation that could result in death or serious injury or Signifies a potentially hazardous situation that could result in death or serious injury Signifies a potentially hazardous situation that might result in minor or moderate injury Signifies a potentially hazardous situation that might result in property damage Ignoring any of these identified hazards is not recommended W S Darley does...

Page 7: ...ent safety relief type devices such as Suction Relief Valves and or Discharge Relief Valves Failure to follow this recommendation could result in phenomena such as water hammer and system pressure spikes Such occurrences can cause severe personnel injury and severe equipment damage Great care must be taken in the layout of pump systems drivelines Interference and driveline vibration must be consid...

Page 8: ... rings would be sufficiently attached to the chassis frame and sufficiently strong enough to prevent a broken u joint assembly from allowing a driveline to slide out from underneath the truck at high speeds while still rotating causing severe personnel injury Said safety rings would be larger than the drive tube OD and provide enough clearance for dynamic non rotational movement of the drivelines ...

Page 9: ...ley utilizes can distribute and can train qualified individuals to use the Allison Multiple Joint Driveline Analysis program W S Darley requires that Power Take Off PTO driven pumps have at most 500 radians per second2 torsional vibration and at most 1000 radians per second2 inertial drive torsional vibration as calculated by the Allison Multiple Joint Driveline Analysis program for a completed dr...

Page 10: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Section 2 General Information and Operations ...

Page 11: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc THINGS TO REMEMBER ...

Page 12: ...uction strainer when pumping from draft and a hydrant strainer when pumping from a hydrant 13 Foreign matter in impellers is a result of failure to use adequate strainers and is a common source of trouble 14 Drain pump immediately after each run This is especially critical in freezing conditions 15 Do not run the pump long with discharge completely shut off 16 Do not close a Shutoff nozzle when pu...

Page 13: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc PTO SAFETY AND SHIFTING INFORMATION ...

Page 14: ... the auxiliary driveshaft and or to the auxiliary equipment being powered Damaged components or equipment could malfunction causing serious personal injury to the vehicle operator or to others nearby To avoid personal injury and or equipment damage Always refer to Chelsea catalogs literature and owner s manuals Follow Chelsea recommendations when selecting installing repairing or operating a Power...

Page 15: ...ve the hub of the yoke does not permit the same amount of torquing as does a square head set screw Also a square head set screw if used with a lock wire will prevent loosening of the screw caused by vibration Regardless of the choice made with respect to a set screw an exposed rotating auxiliary driveshaft must be guarded Important Safety Information and Owner s Manual Chelsea Power Take Offs are ...

Page 16: ...the driving compartment and on the pump operator s panel to indicate that the pump shift has been successfully completed 16 10 4 2 An OK to Pump indicator shall be provided in the driving compartment to indicate that the pump is engaged the chassis transmission is in neutral and the parking brake is engaged 16 10 5 Stationary Pump Driven Through Transmission Mounted PTO Front of Engine Crankshaft ...

Page 17: ...ump Engaged indicator shall be provided both in the driving compartment and on the pump operator s panel to indicate that the pump shift has been successfully completed 16 10 7 2 An OK to Pump indicator shall be provided in the driving compartment to indicate that the pump is engaged and the parking brake is engaged 16 10 7 3 An OK to Pump and Roll indicator shall be provided in the driving compar...

Page 18: ...indicating device for this Throttle Ready condition is the same indicating device as in 16 10 11 2 Other apparatus may not have equipment for which there is a need to control engine speed from the pump operator s panel Engine speed control at the pump operator s panel for these apparatus may not be desirable since on many chassis engines activating remote throttle operation will automatically disa...

Page 19: ...in 3 minutes of PTO engagement disengage PTO and troubleshoot priming difficulty Do not run the pump dry for extended periods of time 6 Confirm that the Throttle Ready indicator at the pump operator s panel is now illuminated 7 Observe discharge pressure gage on panel while advancing vernier throttle to ensure that it is indicating pressure If Pump is not engaged no pressure will show 8 Remember t...

Page 20: ... 7 Release parking brake 8 Shift chassis transmission into road gear The Pump Engaged indicator both in the driving compartment and on the pump operator s panel will indicate if the pump shift has been successfully completed The OK to Pump indicator will not be illuminated The OK to Pump and Roll indicator in the driving compartment will indicate that the pump is engaged the chassis transmission i...

Page 21: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc GENERAL OPERATIONS INFO ...

Page 22: ...onged without an adequate supply of cooling water flowing Coolant temperatures should never be allowed to exceed 200o F while pumping and 180o F is usually taken as a safe operating temperature Always shut off cooling line when through pumping SUCTION STRAINERS A large suction strainer which will prevent the passage of a body larger than the pump impeller ports must always be used on the free end ...

Page 23: ...ended a foot or more above the bottom or if this is not possible it should be laid on a board or piece of sheet metal A rope tied to the suction strainer is a convenient means of holding it off the bottom OBSTRUCTION OF SUCTION STRAINER BY FOREIGN MATTER The high velocity of water entering the suction line will carry loose foreign bodies in against the strainer from a considerable distance Therefo...

Page 24: ...ION LINE If the suction line is laid so that part of it is higher than any other part that is nearer to the pump as when hose is laid over a high bridge rail an air trap is formed at the highest part of the hose from which the air cannot be sucked out by the primer This trapped air is expanded and carried into the pump with the first rush of water causing the pump to immediately lose its prime If ...

Page 25: ...fuse In many fire protection areas cisterns or reservoirs are built and allowed to fill up with rain water to be used in emergencies PUMPING IN COLD WEATHER The first insurance against cold weather trouble is to keep fire apparatus stored in heated quarters All water must be eliminated from pump casing and primer line between periods of operations When setting up for pumping unnecessary delays sho...

Page 26: ...under the stress of emergency and neglect some little detail that may cause trouble or delay in getting the equipment into operation Therefore we urge that practice tests be conducted repeatedly until operators are thoroughly trained More than one person in the department should be a competent operator Practice should include pumping from low lifts high lifts with short and long suction lines with...

Page 27: ...rectly into the hose nozzle from the center of the issuing stream the other end of the tube being connected to an accurate pressure gage The nozzle jet drives straight into the Pitot tube and converts the velocity of the jet to pressure which is an accurate measure of velocity of the water as it leaves the nozzle The tip of the Pitot tube should be one half the diameter of the nozzle away from noz...

Page 28: ...formance of a selected factory adjusted engine operating without fan generator muffler or other accessories and corrected for ideal conditions i e sea level barometer 29 92 of mercury 60o F and high humidity Therefore the actual power delivered by an average truck mounted engine is considerably lower than the manufacturers rating and allowances must be made in predicting pump performance EFFECTS O...

Page 29: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc DEFINITIONS OPERATING CHARACTERISTICS OF PUMPS AND CONVERSION FACTORS ...

Page 30: ...OTAL SUCTION LIFT the static lift plus the friction in suction line plus entrance losses NET PUMP PRESSURE the total dynamic head of the pump EFFECTIVE NOZZLE PRESSURE the pump discharge pressure minus hose friction plus or minus the difference in elevation above or below pump WATER HORSEPOWER the theoretical power required to deliver a given quantity of water per minute against a given head BRAKE...

Page 31: ...echanism mechanically but rather complex hydraulically in that many factors enter into the design of the impeller and water ways which will affect the pump s efficiency DISPLACEMENT PUMPS Rotary and piston pumps are termed Positive Displacement pumps because each revolution displaces or discharge theoretically an exact amount of liquid regardless of the resistance The capacity is therefore proport...

Page 32: ...One foot of water 0 43 pounds per square inch One inch of mercury 1 13 feet of water 0 49 pounds per square inch One cubic foot of water 62 4 pounds 7 5 gallons One gallon of water 231 cubic inches 0 13 cubic feet 8 34 pounds 3 8 liters One Imperial Gallon 1 2 U S gallons Atmospheric Pressure Sea Level 14 8 pounds per square inch 29 9 inches of mercury 34 feet of water ...

Page 33: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc NFPA 1901 TABLES ...

Page 34: ...62 193 200 or 3 375 1 1 1 4 66 244 250 2 100 1 1 3 4 or 68 2 1 1 4 66 1 2 or 71 2 1 1 2 57 1 1 3 4 or 60 2 1 1 4 58 3 500 1 1 1 2 57 244 250 3 100 1 2 or 71 2 1 1 2 57 Class A 20 of 5 750 GPM Fire Pump 1000 GPM Fire Pump 4 1000 157 165 Siamesed Min discharge pressures listed above are for pumps operating with full 10 static suction lift These pressures must be increased by 1 PSI for each 2 3 ft le...

Page 35: ...3 100 and or 2 1 1 4 66 1 50 2 20 of 2 1 3 4 or 68 3 1 1 2 57 Class A Siamesed 6 Max Min discharge pressures listed above are for pumps operating with full 10 static suction lift These pressures must be increased by 1 PSI for each 2 3 ft less than 10 of lift 3 750 245 250 4 1500 157 165 2 1050 194 200 20 of 6 or 6 Min 1250 GPM Fire Pump 143 150 3 50 1500 GPM Fire Pump 1 1500 142 150 3 50 20 of 4 1...

Page 36: ...00 2 1575 2 1 3 4 76 196 200 Siamesed 3 1125 2 1 1 2 72 246 250 4 2250 2 2 1 4 56 153 165 4 Class A 2 1400 199 200 or 2 20 of 6 4 50 1 2000 147 150 4 2000 163 165 3 1000 Min discharge pressures listed above are for pumps operating with full 10 static suction lift These pressures must be increased by 1 PSI for each 2 3 ft less than 10 of lift 249 250 4 100 2250 GPM Fire Pump 20 of 8 1750 158 165 20...

Page 37: ... Siamesed 3 1500 2 1 3 4 68 197 200 1 3500 2 2 1 2 and 45 95 100 2 Groups 3 100 1 2 1 4 44 Siamesed 2 2450 2 2 1 4 67 146 150 3 1750 2 2 55 197 200 2 50 Siamesed Class A Min discharge pressures listed above are for pumps operating with full 10 static suction lift These pressures must be increased by 1 PSI for each 2 3 ft less than 10 of lift 2 20 of 8 2500 GPM Fire Pump 20 of 8 3000 GPM Fire Pump ...

Page 38: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc DISCHARGE TABLES ...

Page 39: ... 854 1050 34 11 23 43 67 98 131 172 218 269 327 389 457 530 693 880 1082 36 11 24 44 69 100 135 177 224 277 336 400 470 546 713 905 1114 38 11 25 45 71 103 138 182 231 285 345 411 483 561 733 930 1144 40 11 26 46 73 106 142 187 237 292 354 422 496 575 752 954 1174 42 11 26 47 74 109 146 192 243 299 363 432 508 589 770 978 1203 44 12 27 49 76 111 149 196 248 306 372 442 520 603 788 1000 1231 46 12 ...

Page 40: ...5 1780 94 17 39 71 111 162 218 286 363 447 543 647 759 881 1152 1460 1800 96 17 40 72 113 164 220 289 367 452 549 654 767 890 1164 1476 1819 98 17 40 73 114 166 223 292 370 456 554 660 775 900 1176 1491 1838 100 18 41 73 115 168 225 295 374 461 560 667 783 909 1189 1506 1856 105 18 42 75 118 172 230 303 383 473 574 683 803 932 1218 1542 1902 110 19 43 77 121 176 236 310 392 484 588 699 822 954 124...

Page 41: ... 126 168 216 265 311 357 402 70 136 182 234 287 337 385 435 80 145 194 250 308 361 414 465 90 154 206 265 325 383 437 492 100 162 217 280 343 405 462 520 110 171 228 295 360 425 485 549 120 179 239 307 377 444 510 572 130 186 249 318 392 462 530 596 140 193 258 330 407 480 549 618 150 200 267 341 421 497 567 175 215 288 374 455 538 200 230 309 395 486 225 243 328 420 250 257 345 This table is offe...

Page 42: ...3 151 227 205 60 100 67 64 72 89 63 73 65 69 75 95 132 76 92 200 74 68 84 117 65 86 70 78 89 126 196 88 115 400 87 76 107 173 69 112 79 94 116 188 111 161 600 101 85 131 231 74 138 88 111 143 250 135 208 800 114 93 153 79 164 98 127 170 158 1000 127 101 178 83 190 107 143 197 182 1500 161 122 237 95 155 130 184 264 2000 195 142 106 153 225 80 100 88 85 96 117 83 99 87 92 99 126 175 101 103 200 97 ...

Page 43: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc REACH AND FRICTION LOSS TABLES ...

Page 44: ... NOZZLE PRESSURE MAXIMUM VERTICAL REACH Feet 40 60 65 70 75 78 79 80 80 80 60 70 75 85 95 105 106 108 110 110 80 78 83 95 105 117 125 132 140 140 100 80 88 100 110 122 135 145 155 155 NOZZLE PRESSURE EFFECTIVE HORIZONTAL REACH Feet 40 20 25 30 40 44 50 55 62 66 60 25 32 37 50 54 61 67 75 80 80 28 35 40 57 62 70 76 84 88 100 30 37 42 60 66 76 84 93 95 NOZZLE PRESSURE MAXIMUM HORIZONTAL REACH Feet 4...

Page 45: ...0 100 72 0 17 5 5 9 268 0 33 0 8 4 120 25 0 8 3 386 0 47 0 11 7 140 34 0 11 0 62 0 16 0 5 2 2 0 0 9 1 4 160 43 0 14 0 78 0 20 0 6 6 2 6 1 2 1 9 180 53 0 17 7 97 0 25 0 8 3 3 2 1 5 2 3 200 63 0 21 5 121 0 30 6 10 1 3 9 1 8 2 8 220 146 0 12 0 4 6 2 1 3 3 240 173 0 14 1 5 4 2 5 3 9 260 204 0 16 4 6 3 2 9 4 5 280 237 0 18 7 7 2 3 3 5 2 300 272 0 21 2 8 2 3 7 5 9 320 23 8 9 3 4 2 6 6 340 26 9 10 5 4 7 ...

Page 46: ... 8 25 89 0 27 0 7 1 3 4 1 2 30 125 0 39 0 10 0 4 7 1 7 0 6 35 51 0 13 0 6 3 2 2 0 7 40 66 0 17 0 8 0 2 9 0 9 45 82 0 21 0 10 0 3 6 1 2 50 99 0 26 0 12 0 4 3 1 4 0 6 60 140 0 38 0 17 0 6 1 2 0 0 8 70 49 0 23 0 8 0 2 7 1 1 80 63 0 29 0 10 0 3 4 1 5 90 78 0 36 0 13 0 4 3 1 8 100 96 0 44 0 15 0 5 1 2 2 0 5 125 144 0 66 0 24 0 7 8 3 3 0 8 150 93 0 33 0 11 0 4 6 1 1 175 125 0 44 0 15 0 6 1 1 5 200 56 0 ...

Page 47: ... 3 9 4 9 6 5 8 2 10 0 13 0 TABLE NO 9 To Convert Pounds per Square Inch to Feet Elevation of Water 2 308ft head 1 0 psi 1ft head 433psi Feet 5 10 15 20 25 30 35 40 45 50 60 70 80 90 Pounds 2 2 4 3 6 5 8 7 11 13 15 17 20 22 26 30 35 39 Feet 100 120 130 140 150 160 170 180 190 200 220 240 260 280 Pounds 43 52 56 61 65 69 74 78 82 87 95 104 113 121 Feet 300 320 340 360 380 400 425 450 475 500 525 550...

Page 48: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Section 3 Installation ...

Page 49: ...Prepared by RJG Revision A Approved by WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc INSTALLATION OF TYPE ZSP PTO DRIVEN Fire Pump ...

Page 50: ... per second2 inertial drive torsional vibration as calculated by the Allison Multiple Joint Driveline Analysis program for a completed driveline installation A completed driveline installation includes the entire multi driveshaft assembly from the power source of the PTO output flange to the input flange of the PTO driven pump Failure to design and analyze a proper driveline layout could result in...

Page 51: ...cated that the centerline of each shaft intersects the midpoint of the shaft connecting each universal joint intersecting angles o This arrangement may be required if the coupling shaft between pump and PTO is relatively short or the engine is mounted with its driveshaft horizontal Refer to attached drawing DGM1301 for examples of parallel shaft and intersecting angle installations o DGM1301 shows...

Page 52: ...Prepared by RJG Revision A Approved by WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc ...

Page 53: ...is can be done by drilling frame rail mounting holes in a manner to rotate the entire pump transmission assembly at an angle As well up and down positioning is important Measure the vertical angle between the truck PTO shaft centerline and chassis frame often 4o Suspend the pump so that the pump driveshaft centerline is as close as possible to being inline and parallel to the truck PTO shaft cente...

Page 54: ... of frames Attach brackets to the suction extensions with pipe U bolts One of the two suction manifold brackets must be free to pivot as seen in drawing DGM1302 Choose one side of the frame or the other for the location of the pivot the opposite must be rigidly secured with 2 5 8 fasteners Drill holes through the side frames and attach the mounting brackets Note both mounting brackets are designed...

Page 55: ...ision A Approved by WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc Reference drawing DGM2908 for the KM02102 and KM02103 bracket assembly locations on the ZSP ...

Page 56: ... WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc Assembly KM02102 depicted by drawing DGM2905 is the vibration isolating mounting bracket that attaches to the pump s suction head ...

Page 57: ... by WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc Assembly KM02103 depicted by drawing DGM2906 is the vibration isolating mounting bracket that attaches to the pump s gearbox ...

Page 58: ...s 4042200 is the item that the customer will have to attach their own fabricated bracketing and cross members to for securing the ZSP back to the apparatus frame rails If need be customers can fabricate their own bracket to replace the 4042200 bracket from within the KM02103 or KM02103 assemblies The 4042200 bracket is intended to be secured with 1 2 fasteners or welded back to the customers brack...

Page 59: ... the transmission and pump assembly is not directly above the centerline of the rubber isolators it is offset therefore the snubbing washer see 3603931 on the next page should be on the core bushing side of the rubber isolator see below images Therefore the snubbing washer should be on top of the smaller rubber section of the isolator not the ring portion So for this application the stack up from ...

Page 60: ...ion A Approved by WAH Original release date 03 16 12 Revised by WAH VIA ECO 11337 Revision release date 02 19 2016 1201050 doc Ring Portion of Rubber Isolator Core Bushing of Rubber Isolator Core Bushing of Rubber Isolator ...

Page 61: ...cation of the pivot the opposite must be rigidly secured with 2 5 8 fasteners Provide adequate support for all piping Keep the following points in mind when positioning the pump and constructing the driveline 1 Do not exceed recommended universal joint operating angles Complimentary shaft angles should be equal and as low as possible 2 Do not exceed universal joint torque limitations 3 Do not exce...

Page 62: ...50 744 844 LB FT SERIES RECOMMENDED BOLT TORQUE 2210 260 298 LB FT SPL90 45 60 LB FT 1210 13 18 LB FT BEARING PLATE 1280 13 18 LB FT SERIES RECOMMENDED BOLT TORQUE 1310 13 18 LB FT 1610 26 35 LB FT 1330 13 18 LB FT 1710 38 48 LB FT 1350 30 35 LB FT 1760 38 48 LB FT 1410 30 35 LB FT 1810 38 48 LB FT 1480 55 60 LB FT 1880 60 70 LB FT 1550 55 60 LB FT 1610 55 60 LB FT New part kits with lockstraps 17...

Page 63: ...ction 4 Pump Detail of the ZSP Installation Operation Maintenance Repair and Troubleshooting Manual ENGINE COOLING PUMP HEATER Two tapped openings in the pump suction head are provided for circulating engine coolant through the heater jacket heat exchanger to prevent pump freezing in cold weather and to aid in engine cooling in warm weather Use no smaller than a 1 2 heater hose for this connection...

Page 64: ......

Page 65: ...8 TUBE R592 HEAT EXCHANGER ENGINE CAB HEATER HEAT sEtEcToR rNbFF PostTroN CAB HEATER SUPPTY IINE ENGINE PANETVATVE f ruae TO PUMPSUCTION DRAIN VATVE F618 HEAT EXCHANGER w s DARLEy co 2000 ANsoN DRtvE MELROSE PARK lt 601603121345 8050 CABHEATER RETURN tINE FROMPUMPDISCHARGE COOTING tINE STRAINER ...

Page 66: ......

Page 67: ...DRIVELINE INSTALLATION J3311 1 DSSP AUGUST 2008 Supersedes J3311 1 HVTSS Dated February 2005 ...

Page 68: ...near an exposed shaft when engine is running Shut off engine before working on power take off or driven equipment Exposed rotating driveshafts must be guarded WARNING GUARDING AUXILIARY DRIVESHAFTS We strongly recommend that a power take off and a directly mounted pump be used to eliminate the auxiliary driveshaft whenever possible If an auxiliary driveshaft is used and re mains exposed after inst...

Page 69: ...shaft Torque 2 Common Causes of Vibrations 3 Universal Joint Operating Angles 5 Eliminating Compound Angle Induced Vibrations 11 Multiple Shaft Installations 13 Mounting a Midship Mounted PTO Pump or Auxiliary Transmission 16 Maximum Safe Operating Speed 18 ...

Page 70: ...al joint deterioration are 1 Vibrations Driver should report to maintenance 2 Universal joint looseness End play across bearings 3 Universal joint discoloration due to excessive heat build up 4 Inability to purge all four trunnion seals when re lubing universal joint Items 2 thru 4 should be checked at re lube cycle and if detected reported to the maintenance supervisor for investigation Experienc...

Page 71: ...ation switch to a size with a rating compatible to your calculation However the series selected cannot be more than one series below the series called for by the LGT calculation For Off Road or On Off Road Applications Use Low Gear Torque value only to verify or switch to a size with a rating compatible to your calculation LGT Maximum Driveshaft Low Gear Torque SR Torque Converter Stall Ratio if a...

Page 72: ...cation Make sure it will not operate at a speed higher than Spicer s recommended safe operating speed Use Spicer Calculator P N J 3253 to determine safe operating speed Checking for a Possible Critical Speed Problem Here is what you must do to make sure you won t have a critical speed problem Determine the safe operating speed of the driveshaft you want to use in your application Insert the tube d...

Page 73: ...fe operating speed of the driveshaft is greater than 2658 RPM Changing the Safe Operating Speed of a Driveshaft A driveshaft s safe operating speed can be raised by increasing its tube diameter or by shortening the installed center to center length of the driveshaft Changing the installed length of a driveshaft will require the use of multiple driveshafts with center bear ings Important The critic...

Page 74: ...re that you follow the basic rules that apply to universal joint operating angles RULE 1 UNIVERSAL JOINT OPERATING ANGLES AT EACH END OF A DRIVESHAFT SHOULD ALWAYS BE AT LEAST 1 DEGREE RULE 2 UNIVERSAL JOINT OPERATING ANGLES ON EACH END OF A DRIVESHAFT SHOULD ALWAYS BE EQUAL WITHIN 1 DE GREE OF EACH OTHER ONE HALF DEGREE FOR MOTOR HOMES AND SHAFTS IN FRONT OF TRANSFER CASE OR AUXILIARY DEVICE RULE...

Page 75: ...nt of vibration the angles on each end of a driveshaft should always be SMALL To cancel an angle vibration the universal joint operating angles need to be EQUAL within 1 degree at each end of a driveshaft On motor home applications and auxiliary transmission installations the tolerance is 1 2 degree See Fig 2 Figure 2 Trans Axle Make angles small Make angles equal ...

Page 76: ... angles of drivetrain components Set Anglemaster or protractor on machined surfaces of engine transmission axle or on machined lugs of transmission and axle yoke s Note Universal joint angles can change significantly in a loaded situation Therefore check vehicle loaded and unloaded to achieve the accepted angle cancellation Figure 3 Example Engine Transmission Output 4 30 Down 1 Main Driveshaft 7 ...

Page 77: ...uce the possibility of vibration keep any offset between connected points to a minimum There are two things you can do to always make sure Single Plane angles are SMALL and EQUAL Make sure the transmission and axle are mounted so their centerlines are parallel when viewed from both the side and the top Make sure the offset between them is small in both views ANGLE CHART Figure 4 Axle Angles in Top...

Page 78: ...enterlines however are parallel in both views See Fig 5 When you have a compound angle you have to calculate the True Universal Joint Operating Angle of each universal joint It is the True Universal Joint Operating Angle that must meet the three rules shown on page 5 Figure 5 Axle Engine Trans Engine Trans Axle Driveshaft Top View Parallel Centerlines Side View Parallel Centerlines ...

Page 79: ... one end of a shaft compound angle C in the formula shown in Fig 6 insert the universal joint operating angle measurement obtained in the side view and the universal joint operating angle obtained from the chart into the formula Do the same for the other end of the shaft Compare the resultant calculated universal joint operating angle for each end They should be EQUAL within 1 degree If they re no...

Page 80: ...ngle Please contact Spicer Driveshaft Engineering if you have an application where the compo nents cannot be installed with their centerlines parallel If adjustments must be made to the system Install shims between the axle housing and springs to rotate the axle input yoke to change operating angles Change operating angle on torque arm type suspensions by lengthening or shortening torque arms Rais...

Page 81: ...pare it to this chart The angles shown on this chart are the maximum universal joint operating angles recommended by Spicer Engineers and are di rectly related to the speed of the driveshaft Any universal joint operating angle greater than 3 degrees will lower universal joint life and may cause a vibration Remember to check maximum safe driveshaft RPM by using the Spicer Safe Operating Speed Cal c...

Page 82: ... avoid building a compound universal joint operating angle into the first coupling shaft by installing it in line with the transmission If it ends up being compound make sure the true universal joint operating angle determined by using the information mentioned earlier is 1 to 1 1 2 degrees Install or tilt the axle so it is mounted on the same angle as the first coupling shaft the centerlines of t...

Page 83: ... is less than 1º and the transmission universal joint operating angle is greater than 1 5º rotate the end yoke at the center bearing position so that the ears of the yoke are 90º to the ears of the tube yoke on the transmission end of the coupling shaft See Fig 10 As an alternative rotate the slip yoke on the driveshaft 90º if the slip spline has 16 teeth Figure 9 Figure 10 True angle 1 to 1 1 2 C...

Page 84: ...o the previous coupling shaft Install or tilt the axle to the same angle as the last fixed coupling shaft so the centerline of the axle and the last fixed coupling shaft are parallel Note THIS ASSURES THE UNIVERSAL JOINT OPEARTING ANGLE AT EACH END OF THE LAST SHAFT WILL AUTOMATICALLY BE EQUAL See Fig 11 Figure 11 1 to 1 1 2 Angle o o Shaft 1 Shaft 2 Mount on same angle as shaft 2 Check size of th...

Page 85: ...nsmission with little or no universal joint operating angle on the joints raise or lower it so there is enough offset to create the required 1 to 1 1 2 degree universal joint operating angle on each end of the driveshaft See Fig 12 If there is only one driveshaft between the device and the rear axle rotate the rear axle using shims in the appropriate place so it is the same angle as the device Thi...

Page 86: ... PTO will produce a vibration that may cause failure of the PTO pump blower or other driven device Any remote driven device must be mounted parallel and in line if possible with the PTO To select the appropriate auxiliary driveshaft for these types of applications you should consider proper torque safe operating speed which is different than the critical speed for tubular driveshafts and angularit...

Page 87: ...nstalled to minimize vibrations caused by incorrect universal joint operating angles Capable of absorbing shock loads Capable of changing length as needed Guarded so as to prevent inadvertent entanglement MAXIMUM OPERATING SPEED BY TUBE SIZE SOLID SHAFT SIZE AND LENGTH For speeds over 6000 RPM contact Spicer Universal Joint Division Engineering TUBING MAXIMUM INSTALLED LENGTH IN INCHES FOR GIVEN R...

Page 88: ...ge driven equipment by hand from under the vehicle when the engine is running Fasteners should be properly selected and torqued to the manufacturer s specifications If a setscrew protrudes above the hub of an end yoke you may want to replace it with a recessed Allen type setscrew If you decide that a recessed setscrew does not have enough holding power for your application and you must use a protr...

Page 89: ......

Page 90: ...Corporation Spicer Service Parts Canada 5095 South Service Road Beamsville Ontario LOR 1BO Dana Holding Corporation Spicer Service Parts PO Box 321 Toledo Ohio 43697 0321 1 800 SAY DANA 729 3262 www spicerparts com Dana Holding Corporation Spicer Service Parts International 419 861 6325 ...

Page 91: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Section 4 Pump Detail ...

Page 92: ...eased this turn valve will automatically close and contain the prime of the pump system Before the pump can be primed booster line valves drain valves cooling line valve and all other openings into the pump must be closed and absolutely air tight In cases where the discharge side of the pump is sealed by a check valve the main discharge valves need not be closed When operating from draft suction h...

Page 93: ...he primer will evacuate the pump and 20 of 8 hose within 24 seconds As soon as prime is reached the pump will develop pressure When pumping from hydrants the primer is not needed and must be kept closed It may be necessary to use the primer momentarily when pumping from a booster tank when the suction head is insufficient to force all the air out of the pump Lubricating System Electric Priming Pum...

Page 94: ...if these problems occur Vibration in belt clutch assembly o Could be indicated by Damaged Belt Contaminated Bearing Loose clutch body mounting bolt through clutch bore into primer rotor shaft assembly Loose bolts holding belt tension Revisit the primer assembly drawing and contact W S Darley Customer Service if necessary Proper belt tension is a must Belt tension can be inspected and validated by ...

Page 95: ...venting the belt drive system from transferring rotational energy to the rotary vane primer pump Excessive belt wear o Could be indicated by Misalignment between Driver and Driven pulleys Axial or Angular Revisit the primer assembly drawing and contact W S Darley Customer Service if necessary Belt drives must have nearly zero misalignment for long life and proper function Minimal vacuum creation b...

Page 96: ... 26 27 28 44 1 2 SCALE A A SECTION APPLY THIN COAT DOW CORNING 111 SILICONE LUBRICANT TO THE END CAP HOUSING BORE AND HOUSING END CAP SURFACES TO ENHANCE THE VANE SEAL FILL BUSHING LUBRICANT RESERVOIR WITH ISO VG 63 COMPRESSOR OIL TED 32 BUSHING PIPE 1 x 0 75 BR 1080648 1 33 ELBOW 75 M X 75 F 3500543 1 34 FITTING 75NPTMx 75JICM 3501553 2 35 FTG BARB 1 00 ID X 1 00 NPT MALE 3502031 1 36 NIPPLE PIPE...

Page 97: ...26 27 28 TED 32 BUSHING PIPE 1 x 0 75 BR 1080648 1 33 ELBOW 75 M X 75 F 3500543 1 34 FITTING 75NPTMx 75JICM 3501553 2 35 FTG BARB 1 00 ID X 1 00 NPT MALE 3502031 1 36 NIPPLE PIPE 75 X CLOSE BR 1081048 1 37 PLATE PRIMER PUSH BUTTON 1978500 1 38 PLATE PRIMER LUBRICANT TANK 1963400 1 39 PULLEY PRIMER DRIVE 4822600 1 40 SWITCH C7H PUSH BTN 2600008 1 41 TANK PRIMER 4 QUART W CAP 4403703 1 42 TUBE PRIME...

Page 98: ...038110 1 23 VANE ROTOR 25 CU IN 1905 THICK 4434200 4 24 WASHER 1 00 x 1 50 x 273 SS 3603342 1 25 WASHER FLAT 375 ID 3603820 1 26 RING RETAINER SH 118 SS 3600450 2 27 WASHER LOCK 0 250 ID SST 3603532 2 28 PULLEY PRIMER DRIVE 4822600 1 29 TUBE FITTING STR 25 X 19 3500021 1 30 RETAINER BEARING PRIMER CLUTCH 2314400 1 31 O RING 4 75 x 4 94 x 0 09 3601114 1 32 PLATE PRIMER PUSH BUTTON 1978500 1 33 SWIT...

Page 99: ...H ANTI ROTATION 4038110 1 23 VANE ROTOR 25 CU IN 1905 THICK 4434200 4 24 WASHER 1 00 x 1 50 x 273 SS 3603342 1 25 WASHER FLAT 375 ID 3603820 1 26 RING RETAINER SH 118 SS 3600450 2 27 WASHER LOCK 0 250 ID SST 3603532 2 28 PULLEY PRIMER DRIVE 4822600 1 29 TUBE FITTING STR 25 X 19 3500021 1 30 RETAINER BEARING PRIMER CLUTCH 2314400 1 31 O RING 4 75 x 4 94 x 0 09 3601114 1 32 PLATE PRIMER PUSH BUTTON ...

Page 100: ...38110 1 23 VANE ROTOR 25 CU IN 1905 THICK 4434200 4 24 WASHER 1 00 x 1 50 x 273 SS 3603342 1 25 WASHER FLAT 375 ID 3603820 1 26 RING RETAINER SH 118 SS 3600450 2 27 WASHER LOCK 0 250 ID SST 3603532 2 28 PULLEY PRIMER DRIVE 4822600 1 29 TUBE FITTING STR 25 X 19 3500021 1 30 RETAINER BEARING PRIMER CLUTCH 2314400 1 31 O RING 4 75 x 4 94 x 0 09 3601114 1 32 PLATE PRIMER PUSH BUTTON 1978500 1 33 SWITC...

Page 101: ...ATION 4038110 1 23 VANE ROTOR 25 CU IN 1905 THICK 4434200 4 24 WASHER 1 00 x 1 50 x 273 SS 3603342 1 25 WASHER FLAT 375 ID 3603820 1 26 RING RETAINER SH 118 SS 3600450 2 27 WASHER LOCK 0 250 ID SST 3603532 2 28 PULLEY PRIMER DRIVE 4822600 1 29 TUBE FITTING STR 25 X 19 3500021 1 30 RETAINER BEARING PRIMER CLUTCH 2314400 1 31 O RING 4 75 x 4 94 x 0 09 3601114 1 32 PLATE PRIMER PUSH BUTTON 1978501 1 ...

Page 102: ...x 0 37 SST 5401400 1 29 SPACER 406 X 88 X 38 3309000 1 30 STRAP CLUTCH ANTI ROTATION 4038110 1 31 SWITCH C7H PUSH BTN 2600008 1 32 TANK PRIMER 4 QUART W CAP 4403703 1 33 TUBE PRIMER CONNECT 4434800_ZSP 1 34 TUBE ROUND 0 19 X 6 NEO 1101937 1 35 TUBE FITTING STR 25 X 19 3500021 1 36 VALVE ACTUATED 12 24VDC 75NPT FE 5209404 1 37 VANE ROTOR 25 CU IN 1905 THICK 4434200 4 38 WASHER 1 00 x 1 50 x 273 SS ...

Page 103: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc PUMP DRAWINGS ...

Page 104: ...3 O RING 13 00 x 12 75 x 0 12 3601272 3 14 O RING 3 75 x 3 94 X 0 09 3601133 2 15 O RING 5 25 x 5 50 x 0 12 3601232 1 16 OIL SEAL 2 125 ID X 3 000 OD 3600571 1 17 PIN COTTER 125 x 2 00 SST 3605207 1 18 PLUG 1 5 16 12 SAE ORB HEX SOC 3501575 1 19 PLUG PIPE 0 125 SST SOC HD 1080533 1 20 PLUG PIPE 0 250 SST SOC HD 1080535 5 21 PLUG PIPE 0 750 SST SQ HD 1080543 1 22 PLUG PIPE 0 750 SST SOC HD 1080551 ...

Page 105: ...38 JICM X 9 16 18 SAE ORB 3501567 1 40 FTG 38 JICM X 9 16 18 SAE ORB 3501576 1 41 FTG BRANCH TEE ADJUSTABLE 38 3501609 1 42 FTG 88JICM RIGX 75MORB SVL 90 3501639 1 43 FTG 88MORB RIGIDX1 8NPT FEMAL 3501634 1 44 GEAR DRIVE 51T 6DP RH PTO 2719305 1 45 GEAR PINION 6 DP LH 29 T 2720410 1 46 GEARCASE 2 GEAR ZSE 1806300 1 47 HHCS 625 11 x 8 00 GR5 5400108 3 48 HHCS FLANGED 313 18 X 1 25 5402844 4 49 HHCS...

Page 106: ...7 1 40 FTG 38 JICM X 9 16 18 SAE ORB 3501576 1 41 FTG BRANCH TEE ADJUSTABLE 38 3501609 1 42 FTG 88JICM RIGX 75MORB SVL 90 3501639 1 43 FTG 88MORB RIGIDX1 8NPT FEMAL 3501634 1 44 GEAR DRIVE 51T 6DP RH PTO 2719305 1 45 GEAR PINION 6 DP LH 29 T 2720410 1 46 GEARCASE 2 GEAR ZSE 1806300 1 47 HHCS 625 11 x 8 00 GR5 5400108 3 48 HHCS FLANGED 313 18 X 1 25 5402844 4 49 HHCS FLANGED 375 16 X 1 25 5402856 8...

Page 107: ... 38 JICM X 9 16 18 SAE ORB 3501567 1 40 FTG 38 JICM X 9 16 18 SAE ORB 3501576 1 41 FTG BRANCH TEE ADJUSTABLE 38 3501609 1 42 FTG 62 JICM X 3 4 16 SAE ORB 3501569 1 43 FTG 88MORB RIGIDX1 8NPT FEMAL 3501634 1 44 GEAR DRIVE 51T 6DP RH PTO 2719305 1 45 GEAR PINION 6 DP LH 29 T 2720410 1 46 GEARCASE 2 GEAR ZSE 1806300 1 47 HHCS 625 11 x 8 00 GR5 5400108 3 48 HHCS FLANGED 313 18 X 1 25 5402844 4 49 HHCS...

Page 108: ... FTG 38 JICM X 9 16 18 SAE ORB 3501576 1 41 FTG BRANCH TEE ADJUSTABLE 38 3501609 1 42 FTG 62 JICM X 3 4 16 SAE ORB 3501569 1 43 FTG 88MORB RIGIDX1 8NPT FEMAL 3501634 1 44 GEAR DRIVE 51T 6DP RH PTO 2719305 1 45 GEAR PINION 6 DP LH 29 T 2720410 1 46 GEARCASE 2 GEAR ZSE 1806300 1 47 HHCS 625 11 x 8 00 GR5 5400108 3 48 HHCS FLANGED 313 18 X 1 25 5402844 4 49 HHCS FLANGED 375 16 X 1 25 5402856 8 50 HHC...

Page 109: ...ION 29 36 745 8 24 43 620 4 4 53 13 5 DWG ZSP INPUT ABOVE CROSS SECTION 14 Jul 14 DZD0034 1 4 SMS DZC0019 10JUL2014 1 1 D AS LISTED OPTIONAL PUMP CASING POSITIONS DISCHARGE CENTERED TO SUCTION APPROXIMATE WEIGHT 690 LBS 312 12 1 2 13 UNC 2B 1 00 THR D ON 10 375 BC 2 3 8 18 NPT HEATER CORE PORTS 3 1 4 18 NPT DISCHARGE PRESSURE PORTS GEAR CASE OIL FILL VENT 1 4 18 NPT SCREENED DISCHARGE PORT DARLEY ...

Page 110: ...4 8 11 206 16 32 414 4 10 63 270 7 59 192 8 11 75 298 5 4 53 13 5 DWG ZSP INPUT LEFT CROSS SECTION 15 Jul 14 DZD0035 1 4 SMS WAH DZD0035 10JUL2014 1 1 D AS LISTED OPTIONAL PUMP CASING POSITIONS DISCHARGE CENTERED TO SUCTION APPROXIMATE WEIGHT 690 LBS 312 KG 1 4 18 NPT SCREENED DISCHARGE PORT 3 1 4 18 NPT DISCHARGE PRESSURE PORTS 2 3 8 18 NPT HEATER CORE PORTS 12 1 2 13 UNC 2B 1 00 THR D ON 10 375 ...

Page 111: ...4 11 16 283 4 36 47 926 2 25 28 642 1 8 00 203 2 SUCTION 4 53 13 5 DWG ZSP INPUT RIGHT CROSS SECTION 15 Jul 14 DZD0036 1 4 SMS DZD0036 10JUL2014 1 1 D AS LISTED APPROXIMATE WEIGHT 690 LBS 312 KG OPTIONAL PUMP CASING POSITIONS DISCHARGE CENTERED TO SUCTION 3 1 4 18 NPT DISCHARGE PRESSURE PORTS 2 3 8 18 NPT HEATER CORE PORTS 1 4 18 NPT SCREENED DISCHARGE PORT 12 1 2 13 UNC 2B 1 00 THR D ON 10 375 BC...

Page 112: ... 129 8 58 217 9 8 97 227 7 7 59 192 8 10 63 270 11 75 298 5 11 29 286 8 24 43 620 4 DWG ZSP INPUT STANDARD CROSS SECTION 15 Jul 14 DZD0037 1 4 SMS WAH DZC0020 10JUL2014 1 1 D AS LISTED OPTIONAL PUMP CASING POSITIONS DISCHARGE CENTERED TO SUCTION APPROXIMATE WEIGHT 690 LBS 312 KG 1 4 18 NPT SCREENED DISCHARGE PORT 3 1 4 18 NPT DISCHARGE PRESSURE PORTS 12 1 2 13 UNC 2B 1 00 THR D ON 10 375 BC 3 4 14...

Page 113: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc MECHANICAL SEAL ...

Page 114: ...polished seal faces of the primary and mating rings are pressed together by a spring mechanism to provide adequate force to affect a seal The force acting between the seal faces increases in direct proportion to product pressure The elastomer bellows seal utilized in this pump has the following design features Mechanical drive of the primary seal ring The drive band s notch design eliminates overs...

Page 115: ...esign rating or dry running Mechanical shaft seal design relies on the sealed media in this case water to cool and lubricate the sealing surfaces Therefore extended dry operation may cause overheating and scoring or damage to the sealing surfaces resulting in excessive leakage or a much shortened seal life To maximize seal life minimize operation at pump pressures higher than pump rating While ope...

Page 116: ... Inspect the pump shaft surface under the bellows ensuring it is clean and nick free to provide a proper sealing surface Isopropyl alcohol may be used to clean surface if required 3 Lightly lubricate the entire o ring on the mating ring with a single drop of P 80 water soluble rubber lubricant evenly distributed do not over lubricate and push it into the cavity using the recommended installation t...

Page 117: ...maged during installation Place the primary ring and lubricated bellows assembly without the spring on the shaft using a proper pusher push the assembly into position so that the seal surfaces are in contact Remove the seal save from the shaft 8 Put the spring in place seated tight against the spring retainer on the primary ring Note Some springs may be slightly tapered so one end fits the seal be...

Page 118: ...fter assembly it may be necessary to run the pump for approximately 30 minutes at 50 60 psi to rinse out excess lubricant and other contaminants Once a mechanical seal has been installed it is recommended that it not be reused If further information is needed call DARLEY in Chippewa Falls WI at 800 634 7812 or 715 726 2650 ...

Page 119: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc ELECTRICALLY CLUTCHED BELT DRIVEN ROTARY VANE PRIMER ...

Page 120: ...eased this turn valve will automatically close and contain the prime of the pump system Before the pump can be primed booster line valves drain valves cooling line valve and all other openings into the pump must be closed and absolutely air tight In cases where the discharge side of the pump is sealed by a check valve the main discharge valves need not be closed When operating from draft suction h...

Page 121: ...he primer will evacuate the pump and 20 of 8 hose within 24 seconds As soon as prime is reached the pump will develop pressure When pumping from hydrants the primer is not needed and must be kept closed It may be necessary to use the primer momentarily when pumping from a booster tank when the suction head is insufficient to force all the air out of the pump Lubricating System Electric Priming Pum...

Page 122: ...if these problems occur Vibration in belt clutch assembly o Could be indicated by Damaged Belt Contaminated Bearing Loose clutch body mounting bolt through clutch bore into primer rotor shaft assembly Loose bolts holding belt tension Revisit the primer assembly drawing and contact W S Darley Customer Service if necessary Proper belt tension is a must Belt tension can be inspected and validated by ...

Page 123: ...venting the belt drive system from transferring rotational energy to the rotary vane primer pump Excessive belt wear o Could be indicated by Misalignment between Driver and Driven pulleys Axial or Angular Revisit the primer assembly drawing and contact W S Darley Customer Service if necessary Belt drives must have nearly zero misalignment for long life and proper function Minimal vacuum creation b...

Page 124: ... 1978500 1 29 PLATE PRIMER LUBRICANT TANK 1963400 1 30 PULLEY PRIMER DRIVE 4822600 1 31 RETAINER BEARING PRIMER CLUTCH 2314400 1 32 SEAL FURON MECHANICAL 1 250 1843403 1 33 SHCS 250 20 x 0 37 SST 5401400 1 34 SPACER 406 X 88 X 800 3309001 1 35 SPACER 0 49 x 0 68 x 2 12 3306724 2 36 STRAP CLUTCH ANTI ROTATION 4038110 1 37 STRAP PRIMER SUPPORT ZSE 4038013 1 38 SWITCH C7H PUSH BTN 2600008 1 39 TANK P...

Page 125: ...401501 2 27 PIN COTTER 125 SST HAIRPIN 3605213 2 28 PLATE PRIMER PUSH BUTTON 1978500 1 29 PLATE PRIMER LUBRICANT TANK 1963400 1 30 PULLEY PRIMER DRIVE 4822600 1 31 RETAINER BEARING PRIMER CLUTCH 2314400 1 32 SEAL FURON MECHANICAL 1 250 1843403 1 33 SHCS 250 20 x 0 37 SST 5401400 1 34 SPACER 406 X 88 X 800 3309001 1 35 SPACER 0 49 x 0 68 x 2 12 3306724 2 36 STRAP CLUTCH ANTI ROTATION 4038110 1 37 S...

Page 126: ...ON 1978500 1 29 PLATE PRIMER LUBRICANT TANK 1963400 1 30 PULLEY PRIMER DRIVE 4822600 1 31 RETAINER BEARING PRIMER CLUTCH 2314400 1 32 SEAL FURON MECHANICAL 1 250 1843403 1 33 SHCS 250 20 x 0 37 SST 5401400 1 34 SPACER 406 X 88 X 800 3309001 1 35 SPACER 0 49 x 0 68 x 2 12 3306724 2 36 STRAP CLUTCH ANTI ROTATION 4038110 1 37 STRAP PRIMER SUPPORT ZSE 4038013 1 38 SWITCH C7H PUSH BTN 2600008 1 39 TANK...

Page 127: ... 4401501 2 27 PIN COTTER 125 SST HAIRPIN 3605213 2 28 PLATE PRIMER PUSH BUTTON 1978500 1 29 PLATE PRIMER LUBRICANT TANK 1963400 1 30 PULLEY PRIMER DRIVE 4822600 1 31 RETAINER BEARING PRIMER CLUTCH 2314400 1 32 SEAL FURON MECHANICAL 1 250 1843403 1 33 SHCS 250 20 x 0 37 SST 5401400 1 34 SPACER 406 X 88 X 800 3309001 1 35 SPACER 0 49 x 0 68 x 2 12 3306724 2 36 STRAP CLUTCH ANTI ROTATION 4038110 1 37...

Page 128: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Section 5 Optional Equipment ...

Page 129: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc MULTIPLE DRAIN VALVE ...

Page 130: ......

Page 131: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc BALL VALVE ...

Page 132: ...lace if necessary 6 Remove valve ball 3 Check for scratches corrosion and wear Replace if necessary 7 Remove seat assembly 4 Check condition of rubber seat Replace seat assembly if necessary REASSEMBLY OF BALL VALVE ILLUSTRATION DGC0100 1 Position ball 3 in body so ball guide screw 6 engages bottom of ball as it is screwed into position 2 Put valve stem 7 into position Make certain stem engages sl...

Page 133: ......

Page 134: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc PRESSURE RELIEF VALVE ...

Page 135: ...7 31 1200503 ...

Page 136: ...7 32 1200503 ...

Page 137: ...D RING 2 88 x 3 25 x 0 19 3601600 1 47 WASHER 0 39 x 0 61 x 06 BR 3603705 1 48 STEM RELIEF VALVE SWITCH 5241101 1 49 SHIM SWITCH SPACER 0 0125 4400800 1 50 PLUG PIPE 0 125 SST SOC HD 1080533 1 51 PIN PILOT VALVE 5321600 1 52 BALL CAM 0 44 4402400 1 53 HEAD PILOT CONTROL 2802001 1 54 COVER ON OFF VALVE 2502100 1 55 O RING 1 12 x 1 25 x 0 06 3601008 1 56 PLUG VALVE 5321201 1 57 O RING 0 50 x 0 69 x ...

Page 138: ...ALVE 3 5323500 1 41 BODY RELIEF VALVE 3 5321502 1 42 O RING 3 50 x 3 69 x 0 09 3601101 2 43 CENTER PLUG PISTON SPRING 4412900 1 44 SPRING PISTON 3600012 1 45 PIN SPRING 0 16 X 0 88 3605003 4 46 QUAD RING 2 88 x 3 25 x 0 19 3601600 1 47 WASHER 0 39 x 0 61 x 06 BR 3603705 1 48 STEM RELIEF VALVE SWITCH 5241101 1 49 SHIM SWITCH SPACER 0 0125 4400800 1 50 PLUG PIPE 0 125 SST SOC HD 1080533 1 51 PIN PIL...

Page 139: ...7 35 1200503 ...

Page 140: ...7 36 1201002 ...

Page 141: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc BUTTERFLY VALVE ...

Page 142: ...7 66 ...

Page 143: ...7 65 ...

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Page 145: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc PUMP OVERHEAT PROTECTION ...

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Page 152: ...Prepared by RJG Rev A Approved by WAH Date 03 16 12 Revised by WAH Via ECO 11337 Rev Date 02 19 2016 1200643 doc Appendix ...

Page 153: ...s for greater resistance to wear torsional vibration and torque imposed by engine as well as ease of maintenance and repair Impeller The impeller shall be a high strength bronze alloy of mixed flow design splined to the pump shaft for precision fit durability and ease of maintenance Impeller shall be vacuum cast designed for maximum lift and highest capacity The seal rings shall be renewable doubl...

Page 154: ...t exchanger providing low operating temperatures thus extending lubricant life and change intervals The lubrication circuit shall include a 100 mesh stainless steel oil pickup screen The transmission shall include a secondary splash lubrication system which will provide continued bearing and gear lubrication in the event of primary lubrication system malfunction High Capacity Vacuum Primer When sp...

Page 155: ...g Lake Drive Itasca Illinois 60143 2072 Toll Free Phone 800 323 0244 Phone 630 735 3500 Fax 708 345 8993 Apparatus Division 920 Kurth Rd Chippewa Falls WI 54729 Toll Free Phone 800 527 0068 Phone 715 726 2645 Fax 715 726 2648 Pump Manufacturing 1051 Palmer St Chippewa Falls WI 54729 Toll Free Phone 800 634 7812 Phone 715 726 2650 Fax 715 726 2656 ...

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