Waterous CP-1 Series User manual

All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
Overhaul Instructions
CP-1, CP-2, CP-2L, CPD-2, E301-A
and E302-A Series Fire Pumps Section
4205.1
Form No.
F-1031
Issue Date Rev. Date
01/18/0802/88
Table of Contents
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
Instructions subject to change without notice.
Safety Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Overhaul Information 2. . . . . . . . . . . . . . . . . . . . . .
Tools and Equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Testing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Bodies and Impellers 2. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings, Gaskets, Seals and O-rings 3. . . . . . . . . . . . . . . . .
Impeller Shafts 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Ball Bearings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Body Gaskets 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CP-1 and CP-2 Pumps 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Volute Body from Pump Head 5. . . . . . . . . . . .
Removal of Impeller 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Mechanical Seal 7. . . . . . . . . . . . . . . . . . . . . . .
Removal of Pump Packing 8. . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Impeller Shaft 8. . . . . . . . . . . . . . . . . . . . . . . . . .
CP-2L Pumps 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Volute Body from Pump Head 10. . . . . . . . . . .
Removal of Impeller 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Mechanical Seal 12. . . . . . . . . . . . . . . . . . . . . .
Removal of Impeller Shaft 12. . . . . . . . . . . . . . . . . . . . . . . . .
CPD-2 Pumps 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Volute Body from Pump Head 14. . . . . . . . . . .
Removal of Impeller 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Mechanical Seal 16. . . . . . . . . . . . . . . . . . . . . .
Removal of Impeller Shaft 17. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Impeller Shaft Assembly 18. . . . . . . . . . . .
Inspection and Repair 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Seal 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impellers 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Undersize Wear Rings 19. . . . . . . . . . . . . . . . . . .
Illustrations
1. CP-1, CP-2 Exploded View 4. . . . . . . . . . . . . . . . . . . . . . . . .
2. Volute Body Removal from Pump Head (CP-1 & 2) 5. . . . .
3. Removal of Impeller (CP-1 & 2) 6. . . . . . . . . . . . . . . . . . . . . .
4. Removal of Mechanical Seal (CP-1 & 2) 7. . . . . . . . . . . . . .
5. CP-2L Exploded View 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Volute Body Removal from Pump Head (CP-2L) 10. . . . . .
7. Removal of Impeller (CP-2L) 11. . . . . . . . . . . . . . . . . . . . . . .
8. Removal of Mechanical Seal (CP-2L) 12. . . . . . . . . . . . . . . .
9. CPD-2 Exploded View 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Volute Body Removal from Pedestal (CPD-2) 14. . . . . . . . .
11. Removal of Impeller (CPD-2) 15. . . . . . . . . . . . . . . . . . . . . . .
12. Removal of Mechanical Seal (CPD-2) 16. . . . . . . . . . . . . . .
13. Removal of Impeller Shaft Assembly (CPD-2) 17. . . . . . . . .
14. Disassembly of Impeller Shaft Assembly (CPD-2) 18. . . . .
15. Mechanical Seal Installation 21. . . . . . . . . . . . . . . . . . . . . . . .
16. Packing Removal Tool 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17. Packing and Gland Installation 23. . . . . . . . . . . . . . . . . . . . . .
CP-1, CP-2, CP-2L & CPD-2 Series Overhaul
Reassembly 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Seal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Adjustment 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Assembly 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Testing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Testing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Testing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 1 of 24Rev: 01/18/08F-1031, Section 4205.1
Safety Information
Please read through the safety information and operating instructions carefully before using your Waterous Fire Pump.
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 operat‐
ing instructions as well as other operating instructions and manuals for the ap‐
paratus, water hydraulics and component limitation.
WARNING
!
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other closures with pump in‐
take or pump discharge connections, relieve pressure by opening drains or
bleeder valves. Bleeder valves should also be used while filling a hose con‐
nected to an intake with water.
WARNING
!
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least one discharge valve slight‐
ly to prevent the pump from overheating. If the pump runs for a few minutes
completely closed, it may heat the water enough to scald someone 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 provi‐
sion designed to prevent overheating, opening a discharge valve may be un‐
necessary.
WARNING
!
Unexpected Truck Movement. May result in serious personal injury or
death.
Failure to properly shift transmission in accordance to the transmission oper‐
ating instructions may result in unexpected truck movement which may result
in serious personal injury or death.
WARNING
!
Rotating Parts Hazard 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 gland temperature.
WARNING
!
Packing Gland and Pump Body Temperature Hazard. May result in seri‐
ous burns.
Heat is dissipated through the cross-section of the packing, transferring the
heat to the packing gland and pump body.

F-1031, Section 4205.1 Page 2 of 24
Rev: 01/18/08
Introduction
This section contains overhaul instructions for Waterous CP-1, CP-2, CP-2L
and CPD-2 centrifugal fire pumps. Although several types of transmissions
are used with the CP-1 and CP-2 pumps (CP-2L is used only with the TA
transmission, CPD-2 is pedestal mounted), only the K-series transmission is
covered in this instruction. NOTE that this instruction is written to cover several
variations of the CP-1 and CP-2 pumps, not all steps will apply to any one
pump.
Also refer to the Service Parts List (SPL documents) furnished with your pump
to aid in further part identification and repair parts ordering.
E301-A and E302-A models are CP-1 and CP-2 pumps mounted on Kubota
diesel engines from the factory. Any of the following instructions for CP-1 and
CP-2 models apply to E301-A and E302-A models (respectively).
General Description
The CP series pumps are designed to provide a wide range of pressures and
capacities and can be driven by a truck transmission mounted power take-offs
or other suitable drives. All CP-1 and CP-2 pumps have an integral speed
increasing transmission with proper gear ratios to provide required impeller
speeds at available input speeds, whether pumping from tank, draft or in relay
operation. CP pumps may be operated independently, simultaneously or in
series with the main pump on the apparatus.
General Overhaul Information
Tools and Equipment
The following tools and equipment are needed to overhaul a pump:
1. Usual automotive mechanic'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 capability up 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 available
from the apparatus manufacturer or the Waterous Company. These special
items are not absolutely necessary, but they will make the mechanic'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. Excessive
speed, for instance, indicates that impellers and/or wear rings are probably
worn.
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 material
will wear bearings, 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 only clean, lint-free cloths to wipe off components.
Before reassembling a pump or its components, be sure to clean them thor‐
oughly.
Pump Bodies and Impellers
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 defective
parts.
Bearings, Gaskets, Seals and O-rings
Parts of this nature are frequently damaged during removal or disassembly. In
addition, they sometimes deteriorate or lose their effectiveness because of age
or misuse. Replacing these parts whenever overhauling a pump is a good
policy.

F-1031, Section 4205.1 Page 3 of 24
Rev: 01/18/08
Impeller Shafts
Examine shaft for severe scratches, grooves or corrosion - especially under
packing or mechanical seals. If scratches are not severe, and are not under
packing and seals, clean them with a fine-cut file. Grooves under the packing
are usually permissible if they are not sharp or too deep. Even slight longitudi‐
nal scratches will cause leaks and should be removed.
Installing Ball Bearings
Most Waterous pumps are designed so that ball bearings fit tightly on their
shafts and have relatively loose fits in the bearing housings. When mounting
these bearings on shafts, always apply force to the inner races. When bear‐
ings have a tight fit in the housings, and a heavy force is necessary to 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 body halves, or 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 applica‐
tion. Be sure all traces of previous gaskets and sealant are removed before
installing new gaskets.
Disassembly
The disassembly instructions are divided into the following sections:
•CP-1, CP-2 Pumps
•CP-2L Pumps
•CPD-2 Pumps

F-1031, Section 4205.1 Page 4 of 24
Rev: 01/18/08
CP-1 and CP-2 Pumps
A CP-1 and CP-2 pumps may be disassembled in several ways, depending
on the type of transmission or piping arrangement.
Removing the pump and transmission together and then disassembling the
pump is usually the easiest method.
IL1531
Volute Body
Front Wear Ring
Impeller Nut
Impeller
Retaining Ring
Impeller Shaft
Gasket
Bolts, Washers & Nuts attaching
Pump Head to Transmission
Impeller Washer or
Nord-Lock RWasher
Square Key
Spring Sleeve
(Prior 2/4/05)
Mechanical Seal
(Prior to 2/4/05)
Hex Hd Screws & Copper
Washers attaching Pump
Head to Volute Body
Transmission Mounting Flange - Pump Head
Rear Wear Ring
*Packing Gland,
Washers & Nuts
* Pumps with Packing Only
Figure 1. CP-1, CP-2 Exploded View
Flinger Ring
(Prior to 2/4/05)
Flinger Ring
(After 2/4/05)
Cotter Pin
(Monel Only)
Mechanical Seal
(After 2/4/05)

F-1031, Section 4205.1 Page 5 of 24
Rev: 01/18/08
Removal of Volute Body from Pump Head
1. Remove the twelve (12) hex head screws and copper washers that attach
the pump head to the volute body.
NOTE: Self-locking hex head screws (nylok) are used on pumps with
bronze bodies.
2. Separate the pump head from the volute body.
3. Remove and discard the gasket.
NOTE: The wear rings will remain in the volute body and pump head.
Removing the wear rings from the body or head is necessary only if
they are damaged or badly worn. (See page 19).
Figure 2. Volute Body Removal from Pump Head
Volute Body
Gasket
Copper Washer Hex Hd Screw,
7/16-14 x 1 in.
Pump Head

F-1031, Section 4205.1 Page 6 of 24
Rev: 01/18/08
Removal of Impeller
1. Remove the impeller nut and washers.
NOTE: Nordr-Lock washers are used on pumps manufactured after
2/04/05.
2. Remove impeller using puller holes.
3. Remove square key from impeller shaft.
Figure 3. Impeller Removal
Impeller Nut
Nordr-Lock Washers
Impeller
See Puller Hole Details
Square Key,
1/4 x 1 in.
Impeller Shaft
5/16-18 UNC-2B,
(3) Holes on 1.750 B.C.
5/16-18 UNC-2B,
(2) Holes

F-1031, Section 4205.1 Page 7 of 24
Rev: 01/18/08
Removal of Mechanical Seal
1. Remove the retaining ring from the impeller shaft.
2. Lubricate the impeller shaft.
3. Slide the mechanical seal off the impeller shaft.
Figure 4. Mechanical Seal Removal
Retaining Ring
Mechanical Seal
Impeller Shaft

F-1031, Section 4205.1 Page 8 of 24
Rev: 01/18/08
Removal of Pump Packing
(Not available on pumps manufactured after 02/04/05)
For removal of the pump packing, follow Packing - Braided Flexible Graph‐
ite (BFG) section of this manual. Note that the packing removal procedure
requires the pump and transmission to remain as one piece.
Removal of Impeller Shaft
NOTE: Removing the impeller shaft from the pump transmission is not
necessary unless it is damaged. If impeller shaft removal is necessary,
see the appropriate pump transmission overhaul instructions.

F-1031, Section 4205.1 Page 9 of 24
Rev: 01/18/08
CP-2L Pumps
Removing the CP-2L pump and TA transmission together and then disassembling the pump is usually the easiest method for overhauling.
Figure 5. CP-2L Exploded View
Flinger Ring
Oil Seal
Head
(furnished with wear ring installed)
O-ring
Hex Hd Screw
Lock Washer
Rear Wear Ring
Impeller Shaft
(Prior to 2/4/05) Square Key
Cotter Pin
Mechanical Seal
(Prior to 2/4/05)
Spring Sleeve
(Prior to 2/4/05)
Impeller
Impeller Washer
Impeller Nut
Front Wear Ring
Pipe Plug
Volute Body
(furnished with wear ring installed)
Pipe Plu
g
Pipe Plug
Retaining Ring
Impeller Shaft
(After 2/4/05)
Square Key
Cotter Pin
Mechanical Seal
(After 2/4/05)
Flinger Ring
Oil Seal

F-1031, Section 4205.1 Page 10 of 24
Rev: 01/18/08
Removal of Volute Body from Pump Head
1. Remove the twelve (12) hex head screws and copper washers that attach
the pump head to the volute body.
2. Separate the pump head from the volute body.
3. Remove and discard O-ring.
NOTE: The wear rings will remain in the volute body and pump head.
Removing the wear rings from the body or head is necessary only if
they are damaged or badly worn. (See page 19).
Figure 6. Volute Body Removal from Pump Head
Volute Body
Copper Washer
Hex Hd Screw,
7/16-14 x 1 in.
Pump Head
O-ring

F-1031, Section 4205.1 Page 11 of 24
Rev: 01/18/08
Removal of Impeller
1. Remove cotter pin, impeller nut and washer.
2. Remove impeller using puller holes.
3. Remove square key from impeller shaft.
Figure 7. Impeller Removal
Cotter Pin
Pump Head
Impeller
See Puller Hole Detail
Impeller Nut
Washer
Square Key,
1/4 x 1”
IL2927

F-1031, Section 4205.1 Page 12 of 24
Rev: 01/18/08
Removal of Mechanical Seal
1. Remove the retaining ring from the impeller shaft.
2. Lubricate the impeller shaft.
3. Slide the mechanical seal off the impeller shaft.
Figure 8. Mechanical Seal Removal
Retaining Ring
Pump Head
Mechanical Seal
Removal of Impeller Shaft
NOTE: Removing the impeller shaft from the pump transmission is not
necessary unless it is damaged. If impeller shaft removal is necessary,
see the appropriate pump transmission overhaul instructions.

F-1031, Section 4205.1 Page 13 of 24
Rev: 01/18/08
CPD-2 Pumps
Removing the CPD-2 pump and pedestal together and then disassembling the pump is usually the easiest method for overhauling.
Figure 9. CPD-2 Exploded View
Volute Body Subassembly
(furnished with wear ring installed)
Wear Ring
Impeller Nut
Nordr-Lock Washer,
(Install in pairs. Place
cam faces together.)
Impeller
Wear Ring
Square Key,
1/4 x 1 in.
Retaining Ring
Mechanical Seal
O-ring,
5-3/4 x 6 in.
Hex Hd Screw,
7/16-14 x 1 in.
Pedestal Subassembly
(furnished with wear ring installed)
Retaining Ring
Retaining Ring
Retaining Ring
Ball Bearing
Ball Bearing
Impeller Shaft

F-1031, Section 4205.1 Page 14 of 24
Rev: 01/18/08
Removal of Volute Body from Pedestal
1. Remove the four (4) hex head screws that attach the pedestal to the
volute body.
2. Separate the pedestal from the volute body.
3. Remove and discard O-ring.
NOTE: The wear rings will remain in the volute body and pedestal.
Removing the wear rings from the body or pedestal is necessary
only if they are damaged or badly worn. (See page 19).
Figure 10. Volute Body Removal from Pedestal
Volute Body
Hex Hd Screw,
7/16-14 x 1 in.
Pedestal
O-ring

F-1031, Section 4205.1 Page 15 of 24
Rev: 01/18/08
Removal of Impeller
1. Remove cotter pin, impeller nut and washer.
2. Remove impeller using puller holes.
3. Remove square key from impeller shaft.
Figure 11. Impeller Removal
Pedestal
Impeller Nut
Square Key,
1/4 x 1”
Nordr-Lock Washers
Impeller
See Puller Hole Detail
IL2927

F-1031, Section 4205.1 Page 16 of 24
Rev: 01/18/08
Removal of Mechanical Seal
1. Remove the retaining ring from the impeller shaft.
2. Lubricate the impeller shaft.
3. Slide the mechanical seal off the impeller shaft.
Figure 12. Mechanical Seal Removal
Retaining Ring
Pedestal
Mechanical Seal

F-1031, Section 4205.1 Page 17 of 24
Rev: 01/18/08
Removal of Impeller Shaft Assembly
NOTE: Removing the impeller shaft from the pedestal is not necessary
unless it is damaged. If impeller shaft removal is necessary, follow the
step outlined below.
1. Remove the retaining ring from the pedestal.
2. Press the impeller shaft assembly out of the pedestal in the direction
shown in Figure 13.
Figure 13. Impeller Shaft Assembly Removal
Pedestal
Impeller Shaft
Retaining Ring

F-1031, Section 4205.1 Page 18 of 24
Rev: 01/18/08
Disassembly of Impeller Shaft Assembly
1. Remove the retaining rings from the impeller shaft assembly. 2. Press ball bearings from shaft.
Figure 14. Impeller Shaft Assembly Disassembly
Ball Bearing
Impeller Shaft
Retaining Ring
Ball Bearing
Retaining Ring (not shown)
IL2917

F-1031, Section 4205.1 Page 19 of 24
Rev: 01/18/08
Ins
p
ection and Re
p
air
The following points cover inspection and repair of the major components of
CP pumps. Check all parts that are not covered in this instruction in accor‐
dance
with standard automotive shop practices. If the slightest doubt exists about the
actual condition of any part, replace the part as a precautionary measure.
Mechanical Seal
If a pump has a mechanical seal, always install a new mechanical seal during reassembly. Follow Mechanical Seal Installation Instructions carefully.
Impellers
Check wear rings and impeller hubs for deep grooves or scratches. Carefully
measure the outside diameter of the impeller hubs and the inside diameter of
the wear rings installed in the body and head. If the difference between these
two measurements exceeds 0.020 in., replace the wear rings as directed
below.
NOTE: Wear rings may be removed by crisscrossing two pry bars under
opposite sides of the wear ring. Pry up the wear ring by applying equal
pressure to both pry bars.
Installing Undersize Wear Rings
For all impellers for CP-1, CP-2 and CP-2L pumps which have separate wear
rings, the replacement rings are available as follows:
•0.025 in. undersize
•0.050 in. undersize
•0.075 in. undersize
If inspection shows that the wear ring clearances are excessive or the impeller
hubs are scored or grooved, turn the impeller hub on a lathe to an acceptable
dimension. Table 1 shows the original hub dimensions for each impeller and
the rework dimensions for each degree of undersize.
Table 1. Impeller and Wear Ring Repair Dimensions
Pump Model Impeller Part No. Original Impeller Hub Diameter Original Wear Ring Part No. New Wear Ring Part No. Rework Diameter of Impeller Hub
CP-1, E301-A
70224
70481 1.9930 / 1.9910 50716 50716-25 1.968 / 1.966
70603
70604 2.874 / 2.872 61436 61444
61436-25
61444-25 2.849 / 2.847
61436-50
61444-50 2.824 / 2.822
61436-75
61444-75 2.799 / 2.797
72244
72245 2.875 / 2.874 61436 61444
CP-2, E302-A
70476
70485 3.745 / 3.743
No Wear Rings - -
70476AL
70485AL 3.741 / 3.739
70823
70824
70966
70967
3.748 / 3.747 61363 61363-25
61363-50
61363-75
3.723 / 3.721
3.698 / 3.696
3.673 / 3.671
CP-2L, CPD-2 70966 3.748 / 3.747 61363