Waterous CPK-5 Series User manual

CPK-5 Fire Pumps
InstallationInstructions
Table of Contents
Safety Information ......................................................2
Introduction.................................................................3
General Description....................................................3
Pump Mounting - General Information.....................3
Pump Mounting........................................................4-9
Pump and Transmission.........................................4-7
Oil Pump and Cooler..............................................8-9
Final Checks..............................................................10
Lubrication...............................................................10
Testing ....................................................................10
Read through the installation in-
structions carefullybefore installing
yourWaterous CPK-5 Series Fire
Pump.
NOTE: Instructions subject to change without notice
F-1031, Section 3046 (Revised: 12/7/18)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com

F-1031, Section 3046
Page 2 of 10
Read through and communicate safety information to the end user of this Waterous Fire Pump.
SafetyInformation
WARNING
Death or serious personal injury might occur if proper
operating procedures are not followed. The pump op-
erator, as well as individuals connecting supply or dis-
charge hoses to the apparatus must be familiar with
pump operating instructions as well as other operating
instructions and manuals for the apparatus, water hy-
draulics and component limitation.
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 connec-
tions, relieve pressure by opening drains or bleeder
valves.Bleedervalves shouldalso beused while filling
a hose connected to an intake with water.
WARNING
Scalding Water Hazard. May result in serious
burns.
When operatingthe pump, be sure to open at least one
discharge valve slightly to prevent the pump from over-
heating. 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 dam-
age the packing, seals and other pump parts. If the ap-
paratus builder has installed a by-pass system or other
provision designed to prevent overheating, opening a
discharge valve may be unnecessary.

F-1031, Section 3046
Page 3 of 10
Introduction
This instruction covers the installation of a Waterous CPK-
5 Series firepump.TheCPK-5 is rated at 320 GPM @ 1350
PSI (1200 l/min @ 93 bar)
The CPK-5 is available with the following transmission:
• Extra Heavy Duty K Series - The K transmission is a
gear driven transmission designed primarily to be
driven bya power take-off or power divider. (see Figure
1).
The following installation instructions are available:
• Priming System, F-1031, Section 3006
• Manifold Drain Valves, F-1031, Section 3008
• Pressure Control System, F-1031, Section 3010
• Overheat Protection Manager, F-1031, Section 3015
Before proceeding with the installation of the CL, read the in-
structions carefully. Check the appropriate dimensional draw-
ings in the Engineering Manual as needed.
Pump Mounting - General Information
Select a mounting location which will make the pump and its
accessories readilyaccessibleformaintenance.
Table 2 gives maximum universal joint angles for installations
where propeller shaft flanges are parallel and yokes are
aligned. Refer to this table when positioning a pump to deter-
mine proper shaft angles. Be sure to keep at least a minimum
of 1U-joint operating angle, but do not exceed those speci-
fied in the table. This is the preferred method of propeller shaft
installation. For additional information on this method, or for
alternative methods, see driveshaft installation guidelines
such as Spicer/Driveshaft InstallationTechniques, J-3311.
CAUTION
Be sure the propeller shafts used are of the slip-joint de-
sign. Frame deflection, temperature changes and similar
factors may cause a propeller shaft without slip-joints to
produce severe axial loads on the bearings and damage
the pump.
Table 2. Maximum U-joint Operating Angles
Driveshaft RPM
Maximum Operating Angle
5000
3.2
4500
3.7
4000
4.2
3500
5.0
3000
5.8
2500
7.0
2000
8.7
1500
11.5
NOTE: The angles shown in Table 2 are the maximum
recommended U-joint operating angles and are directly
related to the speed of the driveshaft. Any U-joint oper-
ating angle greater than 3will lower the U-joint life and
may cause vibration1.
1 From Spicer Driveshaft Installation Techniques, FormJ-3311 dated5/94.

F-1031, Section 3046
Page 4 of 10
Pump Mounting - CPK-5 Series
Figure 1 shows the mounting areas on a CPK-5 pump. To
mountthepump/transmissiontothe vehiclechassis, construct
a bracket that willspantheframerails of the vehicleandattach
to the transmission mounting holes (several locations are pro-
vided).
NOTE: Before installation, make sure your pump has
the right rotation as compared to the driveshaft rota-
tion (see dimensional drawings for correct rotation
configurations).
Position the pump/transmission within the vehicle frame
rails and secure the brackets (not supplied) to the vehicle
frame.
Support the pump by using the mounting plate on the pump
as shown in Figure 1.
NOTE:Tightenthemounting screws to standard torque
specifications.
Finally, provide adequate support for any intake and dis-
charge piping assemblies.
Figure 1. CPK-5 Mounting Diagram
(6) Mounting Holes
(7/16-14 UNC-2B x .625 in. deep)
(2) Mounting Holes
(7/16-14 UNC-2B x .625 in. deep)
Pump Mounting Plate

F-1031, Section 3046
Page 5 of 10
Figure 2. Pump Dimensions,
Inverted Transmission
Pump Mounting –CPK 5 Series
(con’t)

F-1031, Section 3046
Page 6 of 10
Pump Mounting –CPK 5 Series (con’t)
Figure 3. Pump Dimensions, Horizontal Transmission

F-1031, Section 3046
Page 7 of 10
Pump Mounting –CPK 5 Series (con’t)
Figure 3. Pump Dimensions, Vertical Transmission

F-1031, Section 3046
Page 8 of 10
Oil Pump and Cooler Mounting
Figure 4 shows mounting locations and connection points
for the oil pump and cooler that is used on the CPK-5. NOTE: Before installation, make sure your pump has
the right rotation as compared to the driveshaft rota-
tion (see dimensional drawings for correct rotation
configurations).
Figure 4. Oil Pump and Cooler Mounting Diagram

Figure 5.Oil Pump and Cooler Mounting Diagram Continued
F-1031,Section 3046
Page 9 of 10

Final Checks
After thepump,accessories,pipingand miscellaneous con-
nections are completely installed, check the points listed
below:
Lubrication
K Transmission
Gear lube spec: 75W-90 full synthetic.
Capacity:
Inverted mounting: 1.2 quarts
Horizontal mounting: 1.5 quarts
Vertical mounting: 1.6 quarts
(Capacity measurements are approximate and
include the transmission, oil cooler, and oil
pump. Hoses and fittings are not included.
Adjust accordingly to application).
Oil fill procedure:
1. With oil level plug installed, fill transmission
with 1.5 quarts of gear lube.
2. Run electric oil pump for 1 minute.
3. Stop oil pump.
4. Remove oil level plug.
5. Drain excess oil or add oil until a small
stream of oil runs out oil level hole.
6. Install oil level plug.
7. Repeat steps 2-6 until no additional oil is
required.
Testing
Perform the tests listed in F-1031, Section 1000, “Centrifu-
galFire Pump Principles of Operation, Inspection Tests and
Troubleshooting Guide.”During the running tests, monitor
the smoothness of operation, listen for unusual noises and
check for leaks.
CAUTION
Failure to properly lubricate the pump, transmission or
primers may result in serious damage to the equip-
ment.
F-1031, Section 3046 Page 10 of 10