Waterous CM Series User manual

Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • [phone]
www.waterousco.com
CM Series Fire Pumps
Overhaul Instructions
Form Number: F-3005 Issue Date: Feb 6, 2023
:

Table of Contents
Safety 4
Safety Precautions 4
Introduction 5
Using this Document 5
Viewing the Document Electronically 5
Printing the Document 5
Symbols 5
Identifying Exterior Components—Rear 6
Identifying Exterior Components—Front 7
Disassembly 8
Preparing to Disassemble the Pump 8
Tools Required 8
Preparing the Apparatus 8
Best Practices 8
Removing the Pump 8
Disassembling the Pump Components 8
Optional Equipment 8
Packing Ring Removal Tool 9
Retaining Ring Removal Tool 10
Removing the Seal Cooling Hose 11
Separating the Pump and Transmission 12
Disassembling the Pump Body 16
Removing the Impeller Shaft Assembly 20
Removing the Outboard Bearing Housing 21
Disassembling the Outboard Bearing Housing 22
Disassembling the Impeller Shaft with Mechanical Seals 23
Disassembling the Impeller Shaft with Packing 29
Removing the Mechanical Seal 34
Removing the Transfer Valve Actuator—Top-Mounted 36
Removing the Transfer Valve Actuator—Bottom-Mounted 37
Removing the Transfer Valve 38
Assembly 40
Preparing to Assemble the Pump 40
Tools Required 40
Best Practices 40
Optional Equipment 40
Assembling the Pump Components 40
Installing the Pump 40
Understanding the Illustrations 40
Retaining Ring Installation Tool 41
Separable Impeller Shaft with Mechanical Seals 42
Assembling the Impeller Shaft 43
Installing the Impellers 43
Installing the Seal Housings 45
Separable Impeller Shaft with Packing 46
Assembling the Impeller Shaft 47
Installing the Impellers 47
Installing the Seal Housings 50
Installing and Tightening the Packing 51
Pump Body Assembly 52
Installing the Impeller Shaft Assembly 53
Installing the Volute Cover 54
Tightening the Volute Cover Hardware 55
Assembling the Seal Housing Covers 56
Installing the Mechanical Seals 57
Installing the Transmission 62
Installing the Seal Cooling Hose 64
Installing the Transfer Valve 65
Installing the Transfer Valve Actuator—Top-Mounted 66
Installing the Transfer Valve Actuator—Bottom-Mounted 67
Adjusting the Packing 68

4 |70
 Introduction Disassembly Assembly
Safety Precautions
• Read and understand this document before you begin the overhaul.
• Read and understand all the notices and safety precautions.
• Be aware that these instructions are only guidelines and are not meant to be
definitive. Contact Waterous when you have questions.
• Do not overhaul this equipment if you are not familiar 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.
• Unsupported equipment may
shift or fall during disassembly,
causing injury or damage.
Unsupported
Equipment
• Always support heavy
equipment while servicing.
• Do not touch the surface
during operation—allow
it to cool after operating.
• Hot surfaces can burn you.
Hot Surface
• Drain the pump after use
and before servicing.
• Liquid ejected at high
pressure can cause
serious injury.
High Pressure

5 |70
Safety Introduction Disassembly Assembly
Use this document to overhaul your Waterous equipment. Please understand
the following conditions:
• Be aware that these instructions are only guidelines and are not meant to be
definitive. Contact Waterous when you have questions.
• Understand that your configuration may require additional steps, that are not
described in the illustrations or instructions, to perform the overhaul.
• The equipment described in this document is intended to be overhauled by
a person or persons with the necessary skills and knowledge to perform the
overhaul.
This document is divided into the following sections:
Safety
This section describes general precautions and alert symbols that are in this
document.
Introduction
This section is an overview of the document.
Disassembly
This section describes disassembly procedures.
Assembly
This section describes assembly procedures.
Using this Document
Use the guidelines below when viewing this document.
Viewing the Document 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 used to illustrate additional tools or operations that are required to
complete the instruction.
Anti-seize compound—This symbol tells you to apply the
appropriate anti-seize compound to the part.
Arbor press—This symbol tells you to use an arbor press to
complete this step.
Discard—This symbol tells you to discard or recycle the part in
accordance with local regulations.
Finger tight, then full turn—This symbol tells you to secure
the hardware to finger tight, then use a wrench to tighten the
hardware an additional turn.
High-pressure grease—This symbol tells you to apply high-
pressure grease to the surfaces that you are pressing together.
Lubrication—This symbol tells you to apply the appropriate
lubricant to the part.
Sealant—This symbol tells you to apply the appropriate sealant to
the part.
Torque to specification—This symbol tells you to torque the
hardware to the specified value.

6 |70
Safety Introduction Disassembly Assembly
Identifying Exterior Components—Rear
3
Use the illustration to identify various components
on the pump.
1Pump body
2 Intake adapter
3 Tank intake adapter
4Oil cooling lines—optional
5Transmission mounting hardware
6Transmission—C22 shown
7 Oil level plug
Oil level sight plug
9 Oil drain plug
4 1
9
8
26
7
5

7 |70
Safety Introduction Disassembly Assembly
Identifying Exterior Components—Front
2
Use the illustration to identify various components
on the pump.
1 Volute cover
2Seal cooling hose
3Transmission mounting hardware
4Bearing housing
5 Transfer valve cover
6Breather
7Oil cooling lines—optional
8Oil cooler plate—optional
6
5
7
1
4
3
8

8 |70
Safety Introduction Disassembly Assembly
Preparing to Disassemble the Pump
• Read and understand the instructions before disassembling the equipment.
• Prepare a workspace suitable to accommodate and support the pump.
• Gather the necessary tools, cleaning cloths, brushes, and penetrating fluids.
• Understand that your configuration may require additional steps that are not
described in the illustrations or instructions to perform the disassembly.
• This equipment is intended to be disassembled by a person or persons with
the basic knowledge of servicing similar equipment. Contact Waterous for
more information.
Tools Required
• Typical automotive mechanics hand tools.
• Suitable arbor press.
• Suitable support and lifting equipment.
Preparing the Apparatus
• Park the apparatus on a level surface in a well-lit area.
• Engage the parking brake.
• Shut off the engine and remove the key from the ignition switch.
• Allow the apparatus to cool before servicing.
Best Practices
• Remove any dirt, sand, grease, or oil from the enclosure before you
disassemble the pump. Surface debris can transfer into the pump interior
and prematurely wear internal parts.
• Only use a clean, lint-free cloth, a debris-free work surface, and properly
maintained tools to perform the disassembly.
• Replace any gaskets and O-ring seals during the overhaul.
• Do not reuse the self-locking nuts.
• Apply penetrating 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 to be removed or disconnected before
removing the pump.
Furthermore, some applications require you to remove the transmission and
pump together before separating the pump from the transmission. Other
applications allow you to separate the pump without removing the transmission
from the apparatus. Refer to the transmission instructions before proceeding.
Record the process used to remove the equipment from the apparatus. Use
this information to install the equipment into the apparatus after the overhaul.
Disassembling the Pump Components
• Refer to the service parts list (SPL) for part identification and disassemble
order.
Note: Documents specic to your application are available through the
MyWaterous login at waterousco.com by entering the serial number for
your system. Depending on the application, the serial number for your
equipment is located on the operator panel, pump, transmission, or
some combination of the three.
• Use established industry practices to disassemble the pump.
• Record or mark components as you remove them to make sure that you
install them in the same orientation.
• Discard or recycle drained fluids collected during the overhaul in accordance
with local regulations.
Optional Equipment
Be aware that the disassembly instructions may include optional equipment not
included in your application.

9 |70
Safety Introduction Disassembly Assembly
Packing Ring Removal Tool
An optional Packing Ring Removal Tool (5782) is available from Waterous to aid in removing the packing rings—dimensions shown in inches.

10 |70
Safety Introduction Disassembly Assembly
Retaining Ring Removal Tool
An optional Retaining Ring Removal Tool (62917) is available from Waterous to aid in removing the retaining rings—dimensions shown in inches.

11 |70
Safety Introduction Disassembly Assembly
Removing the Seal Cooling Hose
1
Use the illustration and instructions to remove the
seal cooling hose.
Note: Only remove the hose if it needs to be
replaced.
1 Remove the hose from the fittings on the
underside of the pump.

12 |70
Safety Introduction Disassembly Assembly
Separating the Pump and Transmission
1
Use the illustration and instructions to separate the
pump and transmission—C22 transmission shown.
Note: Separating the pump and transmission is a
similar process regardless of transmission
model and mounting location.
1 Remove the lower transmission mounting
hardware.
2 Remove the upper transmission mounting
hardware.
2

13 |70
Safety Introduction Disassembly Assembly
Separating the Pump and Transmission
3
Use the illustration and instructions to separate the
pump and transmission.
3 Use locally sourced 1/2-13 jacking screws to
separate the pump and transmission.
4 Remove the transmission from the pump.
4

14 |70
Safety Introduction Disassembly Assembly
Removing the Tank Intake Adapter
1
3
Use the illustrations and instructions to remove the
tank intake adapter.
Note: The tank-to-pump tting or valve may dier
depending on your application.
1Remove the mounting hardware, then remove
the tank intake adapter.
2 Remove and discard the O-ring.
3 Remove the flap valve, then remove the
bearing from each end of the valve.
2

15 |70
Safety Introduction Disassembly Assembly
Removing the Intake Adapters
1
2
Use the illustrations and instructions to remove the
intake adapters.
Note: Only remove the intake adapters if they or the
pump body need to be replaced.
1 Remove the flap valve, then remove the
bearing from each end of the valve.
2Remove the mounting hardware, then remove
the intake adapter.
3 Remove and discard the gaskets.
4 Repeat the previous steps to remove the
intake adapter at the other end of the pump.
3

16 |70
Safety Introduction Disassembly Assembly
Disassembling the Pump Body
1
Use the illustration and instructions to disassemble
the pump body.
1Remove the upper bearing housing hardware.
2 Loosen, but do not remove, the lower bearing
housing hardware.
2

17 |70
Safety Introduction Disassembly Assembly
Disassembling the Pump Body
3
4
Use the illustrations and instructions to disassemble
the pump body.
3 Insert locally sourced 1/2-13 jacking screws
into the volute cover jacking screw holes.
4 Remove screws on both sides of the volute
cover to accommodate the threaded rods.

18 |70
Safety Introduction Disassembly Assembly
Disassembling the Pump Body
5
Use the illustration and instructions to disassemble
the pump body.
5 To prepare the threaded rods to lower the
volute cover, do the following:
• Thread a spacer (6 inches), 2
washers, and a nut onto each rod
(1/2-13 x 18 inches).
• Install the rods into the volute cover.
• Tighten the nuts so that the spacers
sit 1/2 to 3/4 inch below the cover.
6 Remove the remaining volute cover hardware.
6

19 |70
Safety Introduction Disassembly Assembly
Disassembling the Pump Body
7
8
Use the illustrations and instructions to disassemble
the pump body.
7 Tighten the jacking screws to separate the
volute cover from the pump body, alternating
between them to avoid damaging the dowel
pins.
8 Loosen the nuts on the rods, alternating
between them to gradually lower the volute
cover.

20 |70
Safety Introduction Disassembly Assembly
Removing the Impeller Shaft Assembly
1
3
Use the illustrations and instructions to remove the
impeller shaft assembly from the volute cover.
1 Remove and discard the molded gaskets and
O-rings.
2Remove the lower bearing housing hardware.
3 Remove the impeller shaft assembly.
2