Waterous CR Series Troubleshooting guide

CR/CRU-1/CRU-2 Series
Operation and Maintenance Instructions
Table of Contents
Safety Information ----------------------------------------------2, 3
Introduction......................................................................4
General Description.........................................................4
Components.....................................................................4
Options.............................................................................4
Available Models..............................................................5
Operating Instructions
Pumping from Water Tank............................................7
Pumping from Hydrant or in Relay ...............................8
Pumping from Draft......................................................9
Fire Hose Testing.......................................................10
Lubrication
CR Models..................................................................11
CRU-1/CRU-2 Models.......................................... 12-14
Mechanical Seal.........................................................15
Overheat Protection Manager.......................................15
Read through the installation
instructions carefully before using
your Waterous CR/CRU-1/CRU-2 Series Pump
NOTE: Instructions subject to change without notice
F-1031, Section 2112 (6/21/18)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com

F-1031, Section 2112
Page 2 of 15
Safety Information
Read through the safety information and operating instructions carefully before
using your Waterous Fire Pump.
! WARNING ! 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.
! 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 by opening drains or
bleeder valves. Bleeder valves should also be used
while filling a hose connected to an intake with water.
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 close, 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 bypass system or other provision designed
to prevent overheating, opening a discharge valve
may be unnecessary.

F-1031, Section 2112
Page 3 of 15
Safety Information
Read through the safety information and operating instructions carefully before
using your Waterous Fire Pump.
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken
to prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should
not be used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event
a hose bursts during testing.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must
be used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.

F-1031, Section 2112
Page 4 of 15
Introduction
This instruction contains information needed for the operation and maintenance of CR/CRU/CRU-2 Series centrifugal
pumps.
General Description
The CR/CRU-1/CRU-2 Series fire pumps are single stage, vertically-split and designed to operate from a water tank,
hydrant or from draft. They are designed for direct-drive (Model CR/CRU-1/CRU-2) or can be driven via a chain driven QA
transmission (CRQA), a chain-driven QB Transmission (CRQB), a chain-driven QC Transmission (CRU-
QC2/CRQC/CRUQC-2 with Bell Housing Adapter) or a chain-driven C21 Transmission (CRUC21-2).
Components
Body Assembly
The body assembly includes the volute body, intake and
discharge adapters and related parts. These parts are
available in either cast iron or bronze (except CRU-2).
Impeller Shaft Assembly
The impeller shaft assembly consists of a bronze impeller
mounted on a stainless steel shaft, bronze wear rings,
mechanical seal and related parts. The impeller is
mechanically and hydraulically balanced and the impeller
shaft is supported by ball bearings.
Mechanical Seals
Mechanical seals are standard on CR series pumps.
A mechanical seal consists of a flat, highly polished
(lapped), spring-fed carbon ring that is sealed to and
rotates with the impeller shaft. It presses against a highly
polished (lapped), silicone carbide, stationary ring that is
sealed in the pump body. This seals the shaft and pre-
vents air from entering and water from leaving.
A mechanical seal does not leak or drip water, even when
pumping.
Anodes
Options
Overheat Protection Manager (OPM)
As additional corrosion protection for iron body pumps,
Waterous has available zinc anodes to fit any unused
opening in the intake fitting. Anodes provide an additional
sacrificial zinc surface to the water to supplement the zinc
intake screens.
The Overheat Protection Manager (OPM) acts as a safety
device by releasing hot water to the ground or back to the
water tank from the discharge area of the pump.

F-1031, Section 2112
Page 5 of 15
Available Models
Model CR Direct Drive
Model CRU-1 Direct Drive
Model CRQA
Model CRUQC-2
Model CRQB
Model CRQC
IL3838
IL1806

F-1031, Section 2112
Page 6 of 15
Available Models (con’t)
Model CRUQC-2
with Bell Housing Adapter
Model CRUC21-2
Model Rear Facing CRUC21-2
Pump mounted on front (input shaft side) of transmission.
Pump mounted on rear (output shaft side) of transmission.

F-1031, Section 2112
Page 7 of 15
Operating Instructions
! WARNING
Pumping from Water Tank
After Pumping
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
! 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 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 provision
designed to prevent overheating, opening a discharge
valve may be unnecessary.
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh water
for several minutes to remove all traces of impurities.
3. If pump is kept full of water when not in use, make
sure water is clean and non-corrosive. Make sure the
pump is completely full or completely drained -
never partially full.
NOTICE
! WARNING
Unexpected Truck Movement. May result in
personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
1. Open valves in piping between water tank and pump
intake and at least one discharge valve.
2. Allow about 30 seconds for water to flow into pump.
NOTE: Priming the pump may be necessary under
some conditions because of air trapped in the
pump and piping.
3. Engage pump drive and accelerate engine to obtain
desired discharge pressure and capacity.
NOTICE
Do not attempt to pump more water than is avail-
able from the water tank. Always make sure the
intake compound gage reading stays above zero.
Freezing water hazard. May cause damage to
the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
4. Close all drains and install intake and discharge
caps.
5. If truck is equipped with a priming pump, operate it
until fluid is discharged from priming pump discharge
pipe. Also check fluid level in priming tank, and refill
if necessary.
For pump and roll operation, engage the PTO as directed
by the apparatus builder.

F-1031, Section 2112
Page 8 of 15
Pumping from Hydrant or in Relay
! WARNING
After Pumping
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains or bleeder valves.
! WARNING
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains or bleeder valves.
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 even 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 provision
designed to prevent over- heating, opening a
discharge valve may be unnecessary.
! WARNING
Unexpected Truck Movement. May result in
personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
NOTE: Limit inlet pressure to 150 psi (10.3 bar) if
possible. The pump will operate properly with higher
in- take pressure but will accelerate mechanical seal
wear.
1. Engage pump drive.
2. Open intake, hydrant and other valves as necessary
to allow water to enter the pump.
NOTE: Bleeder valves should be used while filling
a hose connected to an intake with water.
3. Open discharge valves and accelerate engine to
obtain desired discharge pressure and capacity.
4. Set relief valves or other pressure governing device
to desired pressure.
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh water
for several minutes to remove all traces of impurities.
3. If pump is kept full of water when not in use, make
sure water is clean and non-corrosive. Make sure the
pump is completely full or completely drained -
never partially full.
NOTICE
Freezing water hazard. May cause damage to
the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
4. Close all drains and install intake and discharge
caps.
5. If truck is equipped with a priming pump, operate it
until fluid is discharged from priming pump discharge
pipe. Also check fluid level in priming tank, and refill
if necessary.
NOTICE
Do not attempt to pump more water than is avail-
able from the hydrant or relaying pumper. Always
make sure the intake pressure compound gage
reading stays above zero.
NOTE: Some fire departments operate at a
minimum intake pressure of 10 psi (.7 bar)
when pumping from hydrant or in relay to
prevent a “soft” intake hose from collapsing.

F-1031, Section 2112
Page 9 of 15
! WARNING
Pumping from Draft
After Pumping
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains.
! WARNING
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
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 even 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 provision
designed to prevent over- heating, opening a
discharge valve may be unnecessary.
! WARNING
Unexpected Truck Movement. May result in
personal injury or death.
Failure to properly shift transmission in accordance
with the transmission operating instructions may result
in unexpected truck movement which may result in
serious personal injury or death.
NOTE: To get full capacity, quick prime and maintain
pump efficiency:
a) Position vehicle as near as possible to water supply.
b) Avoid humps and sharp bends in intake hose. Make
sure no part of hose is higher than pump inlet. (Air
pockets in intake hose may cause loss of prime or
erratic pump action, and may reduce pump capacity.)
c) Make sure all intake connections are tight and discharge
valves are closed.
d) Immerse intake strainer at least two feet below water
surface to prevent pump from drawing air. (Whirlpools
forming above intake strainer indicate that strainer is too
close to surface of water.)
e) Make sure intake strainer is far enough from bottom to
prevent sand, gravel and other foreign matter from
being drawn into the pump.
1. Prime the pump (see separate instructions supplied
with primer).
2. Engage pump drive.
3. Open discharge valves, and accelerate engine to
obtain desired discharge pressure and capacity.
4. Set relief valves or other pressure governing device
to desired pressure.
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh water
for several minutes to remove all traces of impurities.
3. If pump is kept full of water when not in use, make
sure water is clean and non-corrosive. Make sure the
pump is completely full or completely drained -
never partially full.
NOTICE
Freezing water hazard. May cause damage to
the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
4. Close all drains and install intake and discharge
caps.
5. If truck is equipped with a priming pump, operate it
until fluid is discharged from priming pump discharge
pipe. Also check fluid level in priming tank, and refill
if necessary.

F-1031, Section 2112
Page 10 of 15
Fire Hose Testing
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to
prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be
used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
NFPA 1962 Standard for the Inspection, Care, and use of Fire Hose, Couplings, and Nozzles and the Service Testing of Fire
Hose provides requirements and testing procedures for service-testing fire hose at least annually. NFPA 1962 includes
procedures for service testing with either a hose testing machine or with a pump on a fire department fire apparatus.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a
hose bursts during testing.
During fire hose testing with a fire pump on a fire department fire apparatus, the fire pump is required to be operated at high
discharge pressure with little or no flow out of the apparatus.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be
used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.
CAUTION
If a fire pump on a fire department apparatus is used for service testing of fire hoses, operating the pump at high discharge
pressure with little or no flow may result in severe damage to the pump.

F-1031, Section 2112
Page 11 of 15
Lubrication
1. Check the lubrication level once a month and change
after every 100 hours of operation or at least every
spring and fall. Under severe conditions where pump
has been used continuously at high output, change
more frequently.
2. Always fill to the bottom of the plug hole labeled “Oil
Level”. Do not Overfill.
NOTICE
If fluid level is low, locate the source of the leak
and repair. If the fluid level is high, loosen the drain
3. Note that the breather may be removed and the hole
used as the lubricant fill.
4. Capacities shown are approximate, quantities listed
vary based on ratio and/or mounting orientation.
5. Be sure to clean the drain plug and breather.
6. Synthetic oil substitutes are acceptable.
NOTICE
Fluid temperature hazard.
May cause premature seal wear and do amage.o
plug until the fluid drops to the proper level. If
excessive water drains out, change the fluid
and determine the source of the water
leakage and repair.
Fluid temperature should not exceed 250 F (121C)
Model CRU-2 Direct Drive
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with
service classification SA, SB, SC should
be used.
Fluid temperature hazard.
May cause premature seal wear and damage.
Fluid temperature should not exceed 250F
(121C) for an extended period of time in order to
prevent seal wear and damage.
Lubricant
Capacity
ATF
1.50 Quarts
1.42 Liters

F-1031, Section 2112
Page 12 of 15
Lubricant
Capacity
ATF
4.50 Quarts
4.27 Liters
Lubricant
Capacity
ATF
4.0 Quarts
3.8 Liters
Lubrication (con’t)
Model CR (Direct Drive)
Lubricant
Capacity
ATF or
SAE 30 Motor Oil
.25 Quarts
.24 Liters
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with service
classification SA, SB, SC should be used.
Model CRQA
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with
service classification SA, SB, SC should
be used.
Model CRQB
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with
service classification SA, SB, SC should
be used.
IL3839
Lubricant
Capacity
ATF
1.50 Quarts
1.42 Liters
Lubricant
Capacity
ATF
4.50 Quarts
4.27 Liters

F-1031, Section 2112
Page 13 of 15
Lubricant
Capacity
ATF
4.50 Quarts
4.27 Liters
Lubricant
Capacity
ATF
4.0 Quarts
3.8 Liters
Model CRQC
Lubricant
Capacity
ATF
4.0 Quarts
3.80 Liters
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with service
classification SA, SB, SC should be used.
Model CRU-1 (Direct Drive)
For Ambient Temperature Over 90° F:
SAE 20 Oil 300 SSU @ 100° F with service
classification SA, SB or SC should be used.
Model CRUQB-1
For Ambient Temperature Over 90° F:
SAE 20 Oil 300 SSU @ 100° F with service
classification SA, SB or SC should be used.
IL3839
Lubricant
Capacity
ATF or
SAE 30 Motor Oil
(Non-Detergent)
.25 Quarts
.24 Liters
Lubricant
Capacity
ATF
4.50 Quarts
4.27 Liters

F-1031, Section 2112
Page 14 of 15
Lubricant
Capacity
ATF
4.50 Quarts
4.27 Liters
Lubricant
Capacity
ATF
4.0 Quarts
3.8 Liters
Model CRUQC-2
Lubricant
Capacity
ATF
4.0 Quarts
3.8 Liters
For Ambient Temperature Over 90F:
SAE 20 Oil 300 SSU @ 100F with service
classification SA, SB or SC should be used.
Model CRUQC-2 with Bell Housing Adapter
Model CRUC21-2
For Ambient Temperature Over 90° F,
SAE 20 Oil 300 SSU @ 100° F with service
classification SA, SB or SC should be used.
IL3839
Capacity
Lubricant
Vertical Inverted
4.0 Quarts 3.0 Quarts
3.8 Liters 2.8 Liters
ATF
For Ambient Temperature Over 90° F:
SAE 20 Oil 300 SSU @ 100° F with service
classification SA, SB or SC should be used.

F-1031, Section 2112
Page 15 of 15
Mechanical Seal
A mechanical shaft seal is used and no adjustment is
required. When the pump operates, the water being
NOTICE
pumped cools and lubricates the shaft seal to prevent it
from overheating. Prolonged dry pump operation or operating a dry
pump at high speeds will reduce the life of the
mechanical seal.
If the mechanical seal leaks, replace the entire seal.
The same drain (weep hole) is used to vent the mechani-
cal seal on the pump shaft and the oil seal for the bearing
housing. Inspect for water (mechanical seal) or oil (oil
seal) leaks.
Overheat Protection Manager
Check the electrical circuit by pressing the test button
located on the panel plate every 100 hours of pump
operation or every six months, whichever comes first.
If the light does not flash, the light bulb or flasher may
need replacement (provided all wire connections are
solid).