Waterous CM Series User manual

OverhaulInstructions
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 Disassemblyof 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
remotelymounted transmission or P.T.O.,
the pump is turned byan end yoke on the
impeller shaft.)
3
5
Replacement of Packing or Mechanical
SealsWithout Disassembling the Pump
Direct Drive or Transmission Mounted
Directlyto the Pump
4
6
Removal and Installation of Transfer
Valve
Direct Drive or Transmission Mounted
Directlyto the Pump
5
7
Visit us at www.waterousco.com
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
Instructions subject to change without notice.

F-1031, Section 4212
Page 2 of 61
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
Safety Information
Please read through the safety information and operating instructions carefully before using your Waterous Fire Pump.
WARNING
Packing Gland and Pump Body Temperature Hazard. May result in
serious burns.
Heat is dissipated through the cross-section of the packing, transferring
the heat to the packing gland and pump body.
WARNING
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least one discharge valve
slightly to prevent the pump from overheating. If the pump runs for a few
minutes completely closed, it may heat the water enough to scald some•
one 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 PartsHazardorUnexpectedTruckMovement.Mayresultin 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 gland temperature.
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 byopening drains
or bleeder valves. Bleeder valves should also be used while filling a hose
connected to an intake with water.
WARNING
Unexpected Truck Movement. May result in serious personal injury
or death.
Failure to properly shift transmission in accordance to the transmission
operating instructions may result in unexpected truck movement which
may result in serious personal injury or death.
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.

F-1031, Section 4212
Page 3 of 61
Table 1: Complete Disassembly of Transmission Mounted Pumps
(For Transmissions Mounted Direcly to the Rear of the Pump)
OverhaulOperation
See Page
Pumps with
MechanicalSeals
Pumps with Packing
SafetyInformation
2
2
GeneralInformation
8
8
RemovalOf:
Transmission
9
9
IntakeAdapters
11
11
Impeller Shaft Assembly
12
12
Disassemblyof
Impeller Shaft
Components
OutboardBearingRemoval
Prior to 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
ImpellerRemoval
28
28
Reassemblyof
Impeller Shaft
Components
Cooling Line Check
29
30
InstallingUndersizeWear Rings
31, 32
31, 32
Impeller /Wear Ring Installation
33, 34
33, 34
SealHousing Installation
26
27
MechanicalSealInstallation
41, 42
-
Packing
Installation
-
44
Adjustment
-
44
OutboardBearingInstallation
Prior to April 21, 2006
14, 22
16, 22
After April 21, 2006
15, 23
17, 23
InstallingImpeller Shaft Assembly
35
35
InstallingBodyHardware
37
37
Installation of Transmission
9
9
Vacuum Test
45
45

F-1031, Section 4212
Page 4 of 61
Table 2: Complete Disassembly of Transmission Mounted Pumps
(For Transmissions Mounted Direcly to the Front of the Pump)
OverhaulOperation
See Page
Pumps with
MechanicalSeals
Pumps with Packing
SafetyInformation
2
2
GeneralInformation
8
8
RemovalOf:
Transmission
10
10
IntakeAdapters
11
11
Impeller Shaft Assembly
13
13
Disassemblyof
Impeller Shaft
Components
OutboardBearingRemoval
15, 21
17, 21
Interstage Seal and Seal Housing
Removal
26
27
Check
29
30
ImpellerRemoval
28
28
Reassemblyof
Impeller Shaft
Components
Cooling Line Check
29
30
InstallingUndersizeWear Rings
31, 32
31, 32
Impeller /Wear Ring Installation
33, 34
33, 34
SealHousing Installation
26
27
MechanicalSealInstallation
41, 42
-
Packing
Installation
-
44
Adjustment
-
44
OutboardBearingInstallation
15, 23
17, 23
InstallingImpeller Shaft Assembly
36
36
InstallingBodyHardware
37
37
Installation of Transmission
10
10
Vacuum Test
45
45

F-1031, Section 4212
Page 5 of 61
Table 3: Complete Disassembly of Direct Drive Pumps
OverhaulOperation
See Page
Pumps with
MechanicalSeals
Pumps with Packing
SafetyInformation
2
2
GeneralInformation
8
8
RemovalOf:
IntakeAdapters
11
11
Impeller Shaft Assembly
Rear Drive
12
12
Front Drive
13
13
Disassemblyof
Impeller Shaft
Components
OutboardBearingRemoval
Front or Rear Drive w/o Tachometer
14
16
Front Drive with Tachometer
18
18
End Yoke Removal on Drive End
Front Drive with Tachometer
24
24
Front or Rear Drive w/o Tachometer
25
25
SealHousing Removal
26
27
ImpellerRemoval
28
28
Interstage Seal and Seal Housing Check
29
30
Reassemblyof
Impeller Shaft
Components
InstallingUndersizeWear Rings
31, 32
31, 32
Impeller /Wear Ring Installation
33, 34
33, 34
SealHousing Installation
26
27
MechanicalSealInstallation
41, 42
-
Packing
Installation
-
44
Adjustment
-
45
OutboardBearingInstallation
Front or Rear Drive w/o Tachometer
14
16
Front Drive with Tachometer
18
18
End Yoke Installation on Drive End
Front Drive with Tachometer
24
24
Front or Rear Drive w/o Tachometer
25
25
InstallingImpeller Shaft Assembly
Rear Drive
35
35
Front Drive
36
36
InstallingBodyHardware
37
37
Vacuum Test
45
45

F-1031, Section 4212
Page 6 of 61
Table 4: Replacement of Packing / Mechanical Seal Without Disassembly the Pump
Pump Driven By
Type of Seal
Operation
See Page
Transmission
(Mounted Directly to the Pump)
Mechanical Seals
Safety Information
2
General Information
8
Removal Of:
Transmission
Mounted to Rear of Pump
9
Mounted to Front of Pump
10
Removal Of:
Outboard Bearing
Prior to 4/21/2006
14, 19, 20
After 4/21/2006
15, 21
Seals
38, 39, 40
Cooling Line Check
29
Installation Of:
Seals
41, 42
Outboard Bearing
Prior to 4/21/2006
14, 22
After 4/21/2006
15, 23
Transmission
9
Vacuum Test
45
Packing
Safety Information
2
General 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 turned by an end yoke on the impeller shaft)
Mechanical Seals
Safety Information
2
General Information
8
Removal Of:
Outboard Bearing
With Tachometer
18
Without Tachometer
16
Drive End Yoke
With Tachometer
24
Without Tachometer
25
Seals
38, 39, 40
Cooling Line Check
29
Installation Of:
Seal Installation
39, 40
Outboard Bearing Installation
14, 22
Drive End Yoke
Front Drive with Tachometer
24
Front or Rear Drive without
Tachometer
25
Cooling Line Check
29
Packing
Safety Information
2
General Information
8
Packing Removal
43
Cooling Line Check
30
Packing
Installation
44
Packing
Adjustment
44
Vacuum Test
45

F-1031, Section 4212
Page 7 of 61
Table 5: Removal / Replacement of Transfer Valve
Date of Pump
Actuator
Overhaul Operation
See Page
Style
Mounting
Operation
After January 1, 2000
Rotary
Bottom
Manual
Actuator
Removal From Pump
46
Installation in Pump
Overhaul
F-1031, Section 2315
Transfer Valve
Removal From Pump
50, 51, 52, 53
Installation in Pump
Electric Motor
Actuator
Removal From Pump
47
Installation in Pump
Overhaul
F-1031, Section 2315
Transfer Valve
Removal From Pump
50, 51, 52, 53
Installation in Pump
Top
Manual
Actuator
Removal From Pump
48
Installation in Pump
Overhaul
F-1031, Section 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 Pump
50, 51, 52, 53
Installation in Pump
After January 1, 2000
Reciprocating
Bottom
Manual
Actuator
Removal From Pump
54
Installation in Pump
Transfer Valve
Removal From Pump
59, 60, 61
Installation in Pump
Electric Motor
Actuator
Removal From Pump
55
Installation in Pump
Transfer Valve
Removal From Pump
59, 60, 61
Installation in Pump
Top
Manual
Actuator
Removal From Pump
56
Installation in Pump
Transfer Valve
Removal From Pump
59, 60, 61
Installation in Pump
Electric Motor
Actuator
Removal From Pump
57, 58
Installation in Pump
Transfer Valve
Removal From Pump
59, 60, 61
Installation in Pump

GeneralOverhaul Information
Tools and Equipment
The following tools and equipment maybe needed to overhaul a pump:
1. Usual automotivemechanic's hand tools.
2. An arbor press for assembling or disassembling components.
3. An engine lathe for turning impeller hubs.
4. A suitable hoist and slings.
5. Torque capabilityup to 325 lb-ft.
While no special tools and equipment are required, a few special items are
illustrated or described so the mechanic can make them or they are avail•
able from the apparatus manufacturer or theWaterous Company. These
special items are not absolutelynecessary, but they will make the me•
chanic's work much easier.
Preliminary Testing
Before disassembling a pump, test it thoroughly, if possible, and record
the results. A comparison of this test with periodic tests recommended in
form F-1031, Section 1000 can often reveal specific pump troubles. Ex•
cessive speed, for instance, indicates that impellers and/or wear rings are
probably worn. For a two stage pump in series, excessive speed may indi•
cate a worn transfer valve or interstage seal, leaking flap valve or a mal•
functioningrelief valve.
Cleaning
The continued satisfactory operation of a pump depends to a great extent
upon the cleanliness of its internal parts. Sand, dirt or other abrasive mate•
rial will wear gears and related parts. Before disassembling a pump for
repairs, be sure to clean its exterior. Make sure the working space,
benches and tools are clean. Use onlyclean, lint-free cloths to wipe off
components. Before reassembling a pump or its components, be sure to
clean them thoroughly.
Pump Bodies, Impellers and Transfer Valves
Flush out these components and related parts with clean water. Use a stiff
brush to remove loose scale, caked sediment, etc. Be sure to remove all
traces of old gaskets. Examine pump bodies, covers, adapters and fittings
for cracks, severe corrosion or other damage. Almost all damage to these
parts results from improper use or maintenance, or from freezing. Replace
defectiveparts.
Bearings, Gaskets, Seals and O-rings
Parts of this nature are frequently damaged during removal or disassemb•
ly. In addition, theysometimes deteriorate or lose their effectiveness be•
cause of age or misuse. Replacing these parts whenever overhauling a
pump is a good policy.
Impeller Shafts
Examine shaft for severe scratches, grooves or corrosion - especiallyun•
der packing or mechanical seals. If scratches are not severe, and are not
under packing and seals, clean them with a fine-cut file. Grooves are usu•
allypermissible if theyare not sharp or too deep. Even slight longitudinal
scratches will cause leaks and should be removed.
Installing Ball Bearings
MostWaterous pumps are designed so that ball bearings fit tightly on their
shafts and have relatively loose fits in the bearing housings. When mount•
ing these bearings on shafts, always apply force to the inner races.When
bearings have a tight fit in the housings, and a heavyforce is necessaryto
install them, be sure to apply force only to the outer bearing races. For
either type of fit, applying force to the wrong bearing race may damage the
balls and race.
Installing Body Gaskets
To provide added sealing for gaskets between bodies and intake adapters,
coat both sides of these gaskets with a suitable sealant. A compound such
as Permatex Super 300 is recommended for this application. Be sure all
traces of previous gaskets and sealant are removed before installing new
gaskets.
End Yoke and Companion Flange Nuts
Do not reuse self-locking nuts. Apply lubrication oil to the threads before
removing. Applyanti-seize to the threads before installing a new self- lock•
ing nut.
F- 1, Section 4212 Page 8 of 61

F-1031, Section 4212
Page 9 of 61
Transmission Removal / Installation
(Transmission Mounted Directly to the Rear of the Pump)
Pump
Transmission
IL1206
1. Remove thefour cap screws and lock washersthat attach
the transmission to the pump.
2. ApplyLoctite#242 (blue) to threads when transmissionis
reattachedto the pump.
3. Use the jackingscrewholes to separate the transmission
from the pump body.
4. Support transmission and pull straight back from pump.
Jacking Screw Holes
IL2729

F-1031, Section 4212
Page 10 of 61
Transmission Removal / Installation
(Transmission Mounted Directly to the Front of the Pump)
Pump
Transmission
JackingScrew
Hole
(One Per Side)
1. Remove the four cap screws and lock washers that attach
the transmission to the pump.
2. ApplyLoctite #242 (blue) to threads when transmission is
reattached to the pump.
3. Use the jacking screw holes to separate the transmission
from the pump body.
4. Support transmission and pull straight back from pump.
Jacking Screw Hole
(One Per Side)

F-1031, Section 4212
Page 11 of 61
1. Remove the hex hd screws that attach
the intake adapters to the pump body.
2. Remove the adapters and gaskets.
NOTE: Removal of intake adapters is
only necessary if pump body or adapt-
Intake Adapter Removal / Installation
ers need to be replaced.

F-1031, Section 4212
Page 12 of 61
Removal of Impeller Shaft Assembly
Transmissions Mounted Directly to the Rear of the Pump and Rear Driven Direct Drive Pumps
Volute Body
IL2732
Loosen but do not remove these screws.
1. Use either threaded rods or a transmission jack
to lower the cover from the body.
2. Remove the two screws that attach the bearing
housing to the volute body(upper half).
3. Loosen but do not remove the two screws that
attach the bearing housing to the volute cover
(lower half). The impeller shaft assembly will re•
main in the volute cover.
4. Remove the screws that attach the volute cover
to the volute bodyand separate the body and
cover using the tapped holes.
5. Remove gasketmaterial and O-ring from the two
pump halves.
Jacking
Screw Hole
O-ring
BearingHousing Volute Cover
Jacking Screw Hole
IL1208

F-1031, Section 4212
Page 13 of 61
Removal of Impeller Shaft Assembly
Transmissions Mounted Directly to the Front of the Pump and Rear Driven Direct Drive Pumps
Volute Body
BearingHousing
IL2732
Loosen but do not remove these screws.
1. Use either threaded rods or a transmission jack to
lower the cover from the body.
2. Remove the two screws that attach the bearing
housing to the volute body(upper half).
3. Loosen but do not remove the two screws that at•
tach the bearing housing to the volute cover (lower
half). The impeller shaft assembly will remain in the
volute cover.
4. Remove the screws that attach the volute cover to
the volute bodyand separate the body and cover
using the tapped holes.
5. Remove gasketmaterial and O-ring from the two
pump halves.
Jacking
Screw Hole
Volute Cover
Jacking
Screw
Hole
IL3515
O-ring BearingHousing

F-1031, Section 4212
Page 14 of 61
Outboard Bearing Removal / Installation - Prior to 4/21/2006
(Transmission Mounted Pumps with Mechanical Seals or Direct 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
comes out of the lube relief
fitting. Check that the seal has
not leaked.
CAUTION
To prevent seal from pushing out
of housing, do not use power
grease gun.

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)

F-1031, Section 4212
Page 16 of 61
Outboard Bearing Removal / Installation (Prior to 4/21/06)
(Transmission Mounted Pumps with Packing or Direct Drive Pumps without Tachometer with Packing)
(Reference 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 leaked.
CAUTION
To prevent seal from pushing out
of housing, do not use power
grease gun.
V-RingFlinger Installation
Make sure flat side is facing away from bearing
housing when reassembled on shaft.

F-1031, Section 4212
Page 17 of 61
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
housing when reassembled on shaft.

F-1031, Section 4212
Page 18 of 61
CAUTION
CAUTION
To prevent seal from pushing out
of housing, do not use power
grease gun.
Outboard Bearing Removal / Installation
(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
fitting. Check that the seal has
not leaked.
V-RingFlingerInstallation
IL1291
Make sure flat side is facing away from bearing
housing when reassembledon shaft.

F-1031, Section 4212
Page 19 of 61
CAUTION
Make sure center of hub puller screw does not damage the threaded center of
shaft. Apply grease to shaft center or bearing removal tool before installing hub
puller.
Outboard Bearing Removal (Prior to 4/21/2006)
1. Remove the oil pump (if so equipped) and the bearing housing cap.
2. Remove the bearing outer retaining ringfrom the impeller shaft
3. Remove the (4) hex hd screws attaching the bearing housing to the pump
body.
4. Install hubpullerbar.(Usebearingremovaltool if removingoutboardbearing
on units equipped with lube pump - See Page 17).
5. Tighten hub puller screw, causing the bearing housing to pullthe bearing off
of the end of the impeller shaft.
6. Remove inner bearing retaining ring from impeller shaft. (Note: Inner retain•
ing ring not used on pumps with packing).
7. Removeanddiscardlubricationseal.Removebearingfrombearinghousing.
Completelyclean bearing housing of grease and replace bearing.
8. Remove inner bearing retaining ring from impeller shaft. (Note: Inner retain•
ing ring not used on pumps with packing).
CAUTION
Remove outer retaining ring before installing puller.
CAUTION
Do not damage internal thread of
impellershaft.
Outboard Bearing Removal (without Lube pump, Prior to 4/21/2006)
Hex Hd Screw, 3/8-16 x 3 (Coarse Thread)
Hub Puller Screw,
tighten screw to pull
bearing off shaft
BearingHousing
Hub Puller Bar
Lubrication Seal
Inner Retaining Ring
(Mechanicalseal equipped pumps only)
Hub puller bar, attach to
bearing housing in place of
bearing housing cap
Hex Hd Screw,
3/8-16 x 3
(CoarseThread)
Applygrease to
center of shaft
IL2026

F-1031, Section 4212
Page 20 of 61
Outboard Bearing Removal with Lube Pump (Prior to 4/21/2006)
Hex Hd Screw, 3/8-16 x 3
(CoarseThread)
BearingHousing
CAUTION
Do not damage external thread
of impeller 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 place of bearing housing cap Bearing Removal Tool
Hex Hd Screw,
3/8-16 x 3 (Coarse Thread) Applygrease to pilot in
bearing removal tool IL2003
CAUTION
Remove outer retaining ringbefore installing puller.