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Waterous CM Series, Overhaul Instructions, Page: 1 / 61

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Overhaul Instructions

 

CM/CMU Series Fire Pumps

 

 

 

 

 

 

 
 

 

Form No.

 

F-1031

 

Section

 

4212

 

Issue Date

 

06/30/95

 

Rev. Date

 

5/11/18

 

 
 

 

Table of Contents

 

 

Type of Overhaul

 

Pump Drive

 

See

 

Table

 

Page

 

 
 
 

 

Complete Disassembly of Pump

 

Transmission Mounted Directly to the Rear 

of the Pump

 

1

 

3

 

Transmission Mounted Directly to the Front 

of the Pump

 

2

 

4

 

Direct Drive (The pump is driven by a 

remotely mounted transmission or P.T.O., 

the pump is turned by an end yoke on the 

impeller shaft.)

 

 

3

 

 

5

 

Replacement of Packing or Mechanical 

Seals Without Disassembling the Pump

 

Direct Drive or Transmission Mounted 

Directly to the Pump

 

4

 

6

 

Removal and Installation of Transfer 

Valve

 

Direct Drive or Transmission Mounted 

Directly to the Pump

 

5

 

7

 

 
 
 
 
 
 
 
 
 
 
 

 

Visit us at www.waterousco.com

 

 

 

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

Instructions subject to change without notice.

 

Summary of Contents for CM Series

Page 1: ...The pump is driven by a remotely mounted transmission or P T O the pump is turned by an end yoke on the impeller shaft 3 5 Replacement of Packing or Mechanical Seals Without Disassembling the Pump Di...

Page 2: ...or Unexpected Truck Movement May result in seri ous personal injury or death Stop the engine set parking brake and chock the wheels before going under the truck to adjust packing or to check packing...

Page 3: ...April 21 2006 14 19 20 16 19 20 After April 21 2006 15 21 17 21 Interstage Seal and Seal Housing Removal 26 27 Check 29 30 Impeller Removal 28 28 Reassembly of Impeller Shaft Components Cooling Line...

Page 4: ...Impeller Shaft Components Outboard Bearing Removal 15 21 17 21 Interstage Seal and Seal Housing Removal 26 27 Check 29 30 Impeller Removal 28 28 Reassembly of Impeller Shaft Components Cooling Line Ch...

Page 5: ...Front or Rear Drive w o Tachometer 25 25 Seal Housing Removal 26 27 Impeller Removal 28 28 Interstage Seal and Seal Housing Check 29 30 Reassembly of Impeller Shaft Components Installing Undersize Wea...

Page 6: ...eneral Information 8 Packing Removal 43 Cooling Line Check 30 Packing Installation 44 Adjustment 44 Vacuum Test 45 Direct Drive Pump is driven by a remotely mounted transmission or P T O The pump is t...

Page 7: ...ion 2315 Transfer Valve Removal From Pump 50 51 52 53 Installation in Pump Electric Motor Actuator Removal From Pump 49 Installation in Pump Overhaul F 1031 Section 2315 Transfer Valve Removal From Pu...

Page 8: ...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 impr...

Page 9: ...n IL1206 1 Remove the four cap screws and lock washers that attach the transmission to the pump 2 Apply Loctite 242 blue to threads when transmission is reattached to the pump 3 Use the jacking screw...

Page 10: ...w Hole One Per Side 1 Remove the four cap screws and lock washers that attach the transmission to the pump 2 Apply Loctite 242 blue to threads when transmission is reattached to the pump 3 Use the jac...

Page 11: ...move the hex hd screws that attach the intake adapters to the pump body 2 Remove the adapters and gaskets NOTE Removal of intake adapters is only necessary if pump body or adapt Intake Adapter Removal...

Page 12: ...the two screws that attach the bearing housing to the volute body upper half 3 Loosen but do not remove the two screws that attach the bearing housing to the volute cover lower half The impeller shaft...

Page 13: ...2 Remove the two screws that attach the bearing housing to the volute body upper half 3 Loosen but do not remove the two screws that at tach the bearing housing to the volute cover lower half The impe...

Page 14: ...t Drive Pumps without Tachometer with Mechanical Seals Reference Pages 16 17 and 19 NOTE Fill the bearing housing chamber with a medium consistancy ball and roller bearing grease until the grease come...

Page 15: ...F 1031 Section 4212 Page 15 of 61 Outboard Bearing Removal Installation After 4 21 2006 Transmission Mounted Pumps with Mechanical Seals Reference Pages 18 and 20...

Page 16: ...Pages 16 17 and 19 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 leak...

Page 17: ...Outboard Bearing Removal Installation After 4 21 06 Transmission Mounted Pumps with Packing Reference Pages 17 and 18 V Ring Flinger Installation IL1291 Make sure flat side is facing away from bearing...

Page 18: ...ation Direct Drive Pumps Front Drive with Tachometer NOTE Fill the bearing housing chamber with a medium consistency ball and roller bearing grease until the grease comes out of the lube relief fittin...

Page 19: ...Remove inner bearing retaining ring from impeller shaft Note Inner retain ing ring not used on pumps with packing 7 Remove and discard lubrication seal Remove bearing from bearing housing Completely c...

Page 20: ...shaft Hub Puller Screw tighten screw to pull bearing off shaft Hub Puller Bar Lubrication Seal Inner Retaining Ring Mechanical seal equipped pumps only Hub puller bar attach to bearing housing in plac...

Page 21: ...ff of the end of the impeller shaft 6 Remove inner bearing retaining rings from impeller shaft and bearing housing NOTE Inner retaining ring on shaft is not used on pumps with pack ing 7 Remove bearin...

Page 22: ...the hex nut against the bearing installation tool housing It may be necessary to hold the hex hd screw to prevent it from turn ing with the hex nut 7 Remove the tool and install the bearing outer reta...

Page 23: ...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 h...

Page 24: ...ber with a medium consistency 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 housin...

Page 25: ...chamber with a medium consistency 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 h...

Page 26: ...4 in Throttle Bushing Iron Pumps Only Mechanical Seal Mechanical Seal Stationary Ring Seal Housing Seal Chamber Cover O ring Seal Housing Gasket Seal Housing Gasket 6 Hex Hd or Socket Hd Screws 1 4 20...

Page 27: ...aft NOTE Install lantern ring packing gland studs washers and nuts in seal housing before installing on shaft See Page 40 Lantern Ring Seal Housing Gasket Unbalanced Nut 5 16 18 Seal Housing Seal Hous...

Page 28: ...IL1198 Impeller Shaft Interstage Seal Retaining Ring Impeller 1 Remove wear rings and retaining rings 2 Press impellers toward shaft center and remove lock rings Square Key 5 16 x 1 3 8 in Lock Ring W...

Page 29: ...s greater than 0 015 in the interstage seal should be replaced Seal Housing If the total clearance between the seal housing and the im peller shaft is greater than 0 020 in the seal housing should be...

Page 30: ...er than 0 015 in the interstage seal should be replaced Packing Housing Seal Housing If the total clearance between the seal housing and the im peller shaft is greater than 0 020 in the seal housing s...

Page 31: ...b 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 dimensio...

Page 32: ...B Dia IL1292 Original Min Hub Dia Original Wear Ring No Reworked Hub Dia A Reworked Hub Dia B New Wear Ring No A 6 368 B 6 426 72407 6 350 6 348 6 325 6 323 6 300 6 298 6 407 6 405 6 382 6 380 6 357 6...

Page 33: ...ller over square key on shaft far enough to allow the installation of lock ring 2 Install lock ring and press impeller back over the lock ring NOTE Be sure of impeller is correct See page 31 for impel...

Page 34: ...r Ring Installation Continued Apply a dab of grease to tool to hold retaining ring in place ROTATION Pump Body Volute Eye of Impeller Intake Impeller Vanes Retaining Ring Installation Tool Part Number...

Page 35: ...s thoroughly Coat seal housings and areas of the body and cover where seal housings are located with Never Seezr or equivalent NOTE After reassembling pump performance test per NFPA 1911 before the tr...

Page 36: ...es thoroughly Coat seal housings and areas of the body and cover where seal housings are located with Never Seezr or equivalent NOTE After reassembling pump performance test per NFPA 1911 before the t...

Page 37: ...27 to 34 Sixth 35 36 37 Ref Letter Size Type Qty Torque Prior to Aug 27 2001 After Aug 27 2001 A 1 2 13 x 1 1 2 in Hex Head Socket Head 20 105 LB FT B 1 2 13 x 1 1 2 in Socket Head Socket Head 1 C 5 8...

Page 38: ...ical seal removal installation tools Parts of Kit K 628 Mechanical Seal Removal Installation Tools REMOVAL TOOL P N 72385 TOOL PROTECTION SLEEVE INSTALLATION TOOL Use as a cover to protect removal too...

Page 39: ...nd Discard Remove Throttle Bushing and Discard Iron Pumps Only Not Used on Bronze Pumps IL1276 3 Clean the impeller shaft using the impeller shaft brush P N V2633 4 Remove the screws and washers if ap...

Page 40: ...body but tighten screws hand tight only 10 Turn the hex head on the removal tool clockwise until it touches seal then 1 inch to 1 1 4 inch further the primary ring in the mechanical seal may break fr...

Page 41: ...Liberally coat shaft and sleeve with lubricant supplied with kit before installing the mechani cal seal b Place spring retainer and spring on the shaft Coat inside of mechanical seal bellows with lubr...

Page 42: ...Throttle Bushing Bellows Seal primary ring Nose End Stationary Ring Gasket or O ring IL1276 IL3148 Installation Tool Blunt End Figure 2 Outboard Bearing End Seal Installation Shaft Shoulder Installat...

Page 43: ...housing Packing Removal 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...

Page 44: ...staggered at least 90 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 b...

Page 45: ...p 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 th...

Page 46: ...ior to 1 7 08 Mounting Bracket Stamped Arrow Under Mounting Bracket Gear Case Shaft Encoder Ground Wire Location After 1 7 08 Lock Washer 5 16 Socket Head Screw 5 16 18 x 5 8 Spirol Pin 1 8 x 3 4 U jo...

Page 47: ...Valve Overhaul Encoder Ground Wire Location Prior to 1 7 08 Stamped Arrow Under Mounting Bracket Gear Motor Shaft Encoder Ground Wire Location After 1 7 08 Lock Washer 5 16 Socket Head Screw 5 16 18...

Page 48: ...hen reinstalling extension shaft This will ensure proper alignment Extension Shaft IL1973 Key 3 16 x 1 1 4 5 For repair of the transfer valve actuator sub assembly refer to form F 1031 Section 2315 Tr...

Page 49: ...oose from trans fer valve actuator Make sure key 3 16 x 1 1 4 is in place when reinstalling extension shaft This will ensure proper alignment 5 For repair of the transfer valve actuator sub assembly r...

Page 50: ...the seals in the transfer valve 1 Remove the 3 hex head screws 1 2 13 x 1 that attach the transfer valve cover to the pump body Do not remove the 4 socket head screws 5 16 18 x 3 4 until the transfer...

Page 51: ...Can Be Removed With Punch From Top Of Body O ring 1 1 8 x 1 3 8 Groove Pin 5 16 x 1 1 4 Wave Spring Transfer Valve Housing Transfer Valve Seal Transfer Valve Housing Dowel Pin 1 4 x 3 4 Transfer Valve...

Page 52: ...lve Cover for Rotary Style Actuator After 2000 Transfer Valve Cover Mounting Side IL1977 When reassembling transfer valve make sure cast stops on transfer valve ball are located on transfer valve cove...

Page 53: ...le transfer valve ball in the Volume Position as shown Stamped arrows with the letter V on the transfer ball and transfer valve cover must be aligned to be in Volume Position This is to ensure that th...

Page 54: ...x 1 in Roll Pin 1 8 x 11 16 in 1 Remove control arm assembly by re moving ball joint 1 8 x 1 in cotter pin and flat washer Be careful not to lose spring when removing arm 2 Check to make sure sector g...

Page 55: ...ces sary to remove the override from the end of the actuator if so equipped by removing 1 4 x 1 1 8 in roll pin and universal joint 3 Remove operating arm from the transfer valve cover by removing 1 8...

Page 56: ...ol arm assembly by removing ball joint and 1 8 x 1 in cotter pin and flat washer Be careful not to lose spring when removing arm assembly 2 Check to make sure sector gear and exten sion shaft are mark...

Page 57: ...nect actuator assembly from operating arm by removing 5 16 18 hex jam nut 2 flat washers and 5 16 18 x 2 in hex hd screw 2 Swing aside the actuator It may be necessary to remove the override from the...

Page 58: ...as far as needed to provide 1 32 in clearance between brass washer and actuator 3 Thread hex hd screw into valve operating arm up to jam nut Tight en jam nut against valve operating arm 4 Check for a...

Page 59: ...screws that attach the transfer valve cover to the pump body Do not remove the four 5 16 18 x 3 4 in socket head screws 2 Use the two jacking screw holes to remove the transfer valve from the pump bo...

Page 60: ...ansfer Valve Removal Installation for Reciprocating Actuators Prior to 2000 NOTE Locate transfer valve ball stops in position shown Top View of Assembled Transfer Valve IL1240 Manual Transfer Valve IL...

Page 61: ...oved With Punch From Top Of Body O ring 1 1 8 x 1 3 8 Transfer Valve Housing Dowel Pin 1 4 x 3 4 Wave Spring Transfer Valve Ball Reciprocating Actuator Groove Pin 1 4 x 1 3 4 Transfer Valve Housing Tr...

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