Waterous CP-4 Overhaul Instructions Download Page 1

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Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000

www.waterousco.com

CP-4 and CP-4UH

Overhaul Instructions

Form Number F-2915

Issue Date: May 27, 2021

Revision Date: Jul 6, 2021

Summary of Contents for CP-4

Page 1: ...aterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651 450 5000 www waterousco com CP 4 and CP 4UH Overhaul Instructions Form Number F 2915 Issue Date May 27 2021 Revision Date Jul 6 2021 ...

Page 2: ......

Page 3: ...ing the Upper Pump Body and Bearing Cover 15 Removing the Lower Pump Body 16 Removing the Impeller Shaft Assembly 17 Removing the Impeller Shaft Components 18 Assembly 21 Preparing to Assemble the Pump 21 Tools Required 21 Best Practices 21 Optional Equipment 21 Assembling the Pump Components 21 Installing the Pump 21 Understanding the Illustrations 21 Impeller Shaft Assembly 22 Assembling the Bea...

Page 4: ...r with the tools and skills needed to safely perform the required procedures Do not modify the equipment Waterous reserves the right to make modifications to the instructions without notice Always support heavy equipment while servicing Unsupported equipment may shift or fall during dis assembly causing injury or damage Unsupported Equipment Do not touch the surface during operation allow it to co...

Page 5: ...t Electronically View this document in landscape orientation Use the table of contents to navigate directly to that section Text with this appearance is linked to a reference Printing the Document The document is viewed the best when printed in color The print on both sides and flip on long edge features can provide the best results Use a 3 ring binder to store the document Symbols Symbols are use...

Page 6: ...Assembly Identifying Exterior Components Top 6 6 4 3 2 1 5 Use the illustration to identify various components on the pump 1 Transmission 2 Oil fill plug 3 Transmission mounting hardware 4 Discharge 5 Packing cooler hose 6 Flange hardware ...

Page 7: ...ying Exterior Components Bottom 2 3 8 4 7 5 6 1 Use the illustration to identify various components on the pump 1 Transmission 2 Transmission mounting hardware 3 Intake 4 Packing cooler hose 5 Drain port 6 Flange hardware 7 Oil drain plug 8 Oil level plug ...

Page 8: ...enetrating oil to screws and nuts before disassembly Removing the Pump Removing the pump for overhaul varies by application Your application may require components such as drain lines support brackets plumbing connections and other accessories be removed or disconnected before removing the pump Furthermore some applications require you to remove the transmission and pump together before separating...

Page 9: ...y Separating the Pump and Transmission 1 2 Removing the Packing Cooler Hose Use the illustrations and instructions to remove the packing cooler hose 1 Remove the hose from the upper pump body fitting 2 Remove the hose from the pump intake fitting ...

Page 10: ...on 1 2 Removing the Bearing Housing Use the illustrations and instructions to remove the bearing housing 1 Remove the bearing housing hardware 2 Remove the bearing housing and bearing from the pump Note In some cases the bearing housing and bearing may need to be removed separately ...

Page 11: ...y Assembly Separating the Pump and Transmission 1 2 Removing the Packing Housing Screws Use the illustrations and instructions to remove the packing housing hardware 1 Remove the packing housing screws 2 Remove the packing housing screws ...

Page 12: ...mbly Separating the Pump and Transmission 1 2 Removing the Pump Body Hardware Use the illustrations and instructions to remove the pump body hardware 1 Remove the hardware from the lower pump body 2 Remove the hardware from the upper pump body ...

Page 13: ...mp and Transmission 2 1 Removing the Transmission Hardware Use the illustration and instructions to remove the upper transmission mounting hardware 1 Remove the upper transmission mounting hardware 2 Loosen but do not remove the lower transmission mounting hardware ...

Page 14: ... Separating the Pump and Transmission 1 2 Removing the Dowel Pins Use the illustrations and instructions to remove the dowel pins from the pump bodies 1 Use a hammer and punch to remove the dowel pin 2 Use a hammer and punch to remove the dowel pin ...

Page 15: ... Cover Use the illustrations and instructions to remove the upper pump body gasket and bearing cover 1 Remove the upper pump body Note If needed there are jacking screw holes to aid in separating the pump bodies 2 Remove and discard the gasket material 3 Remove the mounting hardware bearing cover and O ring then discard the O ring ...

Page 16: ...he Pump and Transmission 3 Removing the Lower Pump Body Use the illustrations and instructions to remove the remaining transmission mounting hardware and lower pump body 1 Remove the nuts and washers 2 Remove the threaded studs 3 Remove the lower pump body 1 2 ...

Page 17: ...r Shaft Assembly Use the illustrations and instructions to remove the impeller shaft assembly 1 Use locally sourced jacking screws 3 8 24 UNF with a minimum length of 1 1 2 inches to separate the impeller shaft assembly and transmission case 2 Remove the impeller shaft assembly from the transmission case 1 2 ...

Page 18: ...land halves 2 Remove the packing rings and packing housing Discard the gasket 3 Remove the retaining ring 4 Use an arbor press to remove the wear rings and impellers up to the interstage seal Remove the key after removing the second impeller Note Make sure to note the orientation of the impellers as you remove them for later in the assembly 5 Remove the interstage seal 6 Remove the retaining ring ...

Page 19: ...ller shaft 7 Use an arbor press to remove the wear rings and impellers up to the packing housing Remove the key after removing the second impeller 8 Discard the gasket then remove the packing housing packing rings gland halves and hardware 9 Remove the flinger ring 10 Remove the hardware bearing driven gear bearing spacer and key 11 Remove the bearing housing ...

Page 20: ...Notes ...

Page 21: ...hat the assembly instructions may include optional equipment not included in your application Assembling the Pump Components Refer to the service parts list SPL for part identification The SPL specific to your application is determined by the following The transmission drive method Whether the transmission drives a CAFS compressor Note Documents specific to your application are available through t...

Page 22: ...22 41 Safety Introduction Disassembly Assembly Impeller Shaft Assembly ...

Page 23: ...s and instructions to assemble the bearing housing 1 Apply grease to the bearing then press it into the bearing housing 2 Apply lubricant to the O ring groove then install the O ring around the bearing housing 3 Apply silicon sealant around the oil seal then install it into the bearing housing 1 3 2 ...

Page 24: ...ess the driven gear onto the shaft 3 Install the washer and locknut onto the end of the shaft then tighten the locknut 4 Apply grease to the shaft then install the bearing spacer onto the shaft 5 Apply grease to the bearing then press the bearing housing onto the shaft 6 Install the flinger ring onto the shaft with the rounded edge toward the bearing housing Note The flinger ring should sit 1 16 i...

Page 25: ...d gasket onto the shaft then secure them with the hardware that you removed earlier Refer to Installing and Tightening the Packing on page 27 8 Use an arbor press to install the wear rings and impellers onto the shaft in the reverse order you removed them Insert the key into the keyway before installing the first impeller 9 Install the retaining ring onto the shaft 10 Install the interstage seal o...

Page 26: ...verse order you removed them Insert the key into the keyway before installing the first impeller 12 Install the retaining ring onto the shaft 13 Install the gasket packing housing and packing rings onto the shaft Refer to Installing and Tightening the Packing on page 27 14 Install the gland halves onto the packing housing studs then secure them with the hardware that you removed earlier Refer to I...

Page 27: ...g 1 When installing the packing rings stagger the joints so that they are 90 apart 2 To properly set the gland do the following Install the nuts onto the packing housing studs so that the milled slots are facing the gland Finger tighten the nuts alternating between them to make sure that the gland stays level Use a wrench to tighten the nuts one additional turn ...

Page 28: ...28 41 Safety Introduction Disassembly Assembly Pump Body Assembly ...

Page 29: ...ssembly Assembly Installing the Impeller Shaft Assembly 1 Use the illustrations and instructions to install the impeller shaft assembly 1 Apply grease to the bearing then press the impeller shaft assembly into the transmission case ...

Page 30: ...instructions to secure the lower pump body to the transmission case 1 Align the lower pump body with the impeller shaft assembly 2 Use the threaded studs that you removed earlier to secure the lower pump body to the transmission case 3 Loosely install the washers and nuts that you removed earlier onto the studs ...

Page 31: ...ring Cover 1 2 Use the illustrations and instructions to install the bearing cover 1 Apply lubricant to the O ring groove then install the O ring around the bearing cover 2 Use the hardware that you removed earlier to secure the bearing cover to the transmission case ...

Page 32: ...ons to install the upper pump body 1 Remove any remaining gasket material then align the new gaskets with the lower pump body 2 Align the upper pump body with the lower pump body 3 Use the dowel pin that you removed earlier to connect the pump bodies 4 Use the dowel pin that you removed earlier to connect the pump bodies ...

Page 33: ... 2 1 Use the illustration and instructions to install the upper transmission mounting hardware 1 Use the screws that you removed earlier to secure the upper pump body to the transmission case 2 Loosely install the washers and nuts that you removed earlier onto the screw threads ...

Page 34: ...s to install the upper and lower pump body hardware 1 Use the hardware that you removed earlier to secure the upper pump body to the lower pump body 2 Use the hardware that you removed earlier to secure the lower pump body to the upper pump body 3 Tighten the transmission mounting hardware 200 ft lb 271 N m 200 ft lb 271 N m ...

Page 35: ...Housing Hardware 1 2 Use the illustrations and instructions to install the packing housing hardware 1 Use the hardware that you removed earlier to secure the packing housing to the pump 2 Use the hardware that you removed earlier to secure the packing housing to the pump ...

Page 36: ...lustrations and instructions to install the flinger ring and bearing 1 Install the flinger ring onto the shaft with the rounded edge toward the packing housing Note The flinger ring should sit flat against the edge of the impeller shaft groove 2 Apply grease to the bearing then press it onto the shaft ...

Page 37: ...ssembly Installing the Bearing Housing 1 2 Use the illustrations and instructions to install the bearing housing 1 Align the bearing housing with the pump 2 Use the hardware that you removed earlier to secure the bearing housing to the pump ...

Page 38: ...mbly Installing the Packing Cooler Hose 1 2 Use the illustrations and instructions to install the packing cooler hose 1 Insert one end of the hose into the pump intake fitting 2 Insert the other end of the hose into the upper pump body fitting ...

Page 39: ... Optimal leakage is 10 to 120 drops per minute Maintaining this rate facilitates the cooling of the packing 3 If the drip rate is too high turn off the pump and gradually tighten the gland nuts alternating between them to make sure that the gland stays level 4 Operate the pump at its maximum intended pressure for 2 minutes Observe the drip rate then repeat the previous step until leakage is within...

Page 40: ...Notes ...

Page 41: ...Waterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651 450 5000 www waterousco com ...

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