Waterous CR User manual

Model CR, CRU-1 and CRU-2 Fire Pump
Overhaul Instructions
Table of Contents
F-1031-4214 (Revised: 5/8/20)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651)
450-5000 www.waterousco.com
General Overhaul Information……………………………………………. 2
Disassembly:
Remove Intake End of Pump…………………………………. 3
Remove Pump from Bearing Housing
or Transmission………………………………………………… 4
Inspection and Repair…………………………………………... 5, 6
Reassembly:
Install Mechanical Seal…………………………………...……7, 8
Install Impeller and Intake Adapter……………………………... 9
Lubrication…………………………………………………………… 10
Testing……………………………………………………………….. 10
CR Pump
CRU-1 Pump
CRU-2 Pump

F-1031, Section 4214
Page 2 of 10
Tools and Equipment
General Overhaul Information
Pump Bodies and Impellers
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 avail-
able from the apparatus manufacturer or the Waterous Company. These
special items are not absolutely necessary, 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.
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 thoroughly.
Flush out these components and related parts with clean water. Use a stiff
brush to remove loose scale, caked sediment, etc. 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 mainte-
nance, or from freezing. Replace defective parts.
Bearings, Gaskets, Seals and O-rings
Parts of this nature are frequently damaged during removal or disas-
sembly. 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.
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 are
usually permissible if they are not sharp or too deep. Even slight longitu-
dinal 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 bearings have a tight fit in the housings, and a heavy force is nec-
essary 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.

F-1031, Section 4214
Page 3 of 10
Disassembly - Remove Intake End of Pump
Intake Adapter, Impeller & Mechanical Seal Removal
NOTE: The wear ring in the intake adapter cannot be removed without being destroyed. Inspect the wear rings and impeller per instructions on Page 5 to determine if
replacement is required.
•Make a witness mark on the intake adapter and volute body to indicate their
relationship to each other which will be referenced during reassembly.
•Remove the sixteen (16) hex head screws attaching the intake adapter to the
volute body. The screws may be threaded into the four (4) jacking screw
holes in the adapter flange and tightened in a circular sequence to separate
the intake adapter from the pump volute body.
•Pull the intake adapter off of the pump body volute. Remove and discard the
O-ring.
•Remove the cotter pin, impeller locknut and washer from the end of the im-
peller shaft.
1. Remove the impeller. Tapping the impeller lightly with a soft hammer will help to
break it loose from the shaft. If necessary, the seven (7) 3/8-16 UNC tapped holes
through the impeller vanes may be used to attach a puller. If the seal spring retainer
remains attached to the back of the impeller, remove and discard.
2. Remove the impeller key from the shaft.
3. Remove the mechanical seal spring.
4. Remove the mechanical seal bellows. First apply a light coating of oil to the mechanical
seal journal then grasp the seal bellows by hand and and try to remove with a combined
pulling and twisting motion. If this method fails, proceed with the steps on the next page
to remove the pump from the transmission. The seal bellows will be forced off the shaft
during this step.

F-1031, Section 4214
Page 4 of 10
Disassembly - Remove Pump from Transmission or Bearing Housing
Removal of End Yoke
Removal of Oil Seal, Throttle Bushing, Mechanical Seal Stationary Ring
1. Stand the pump in a vertical position with the intake adapter flange of the pump
body volute facing down.
2. Note the orientation of the pump discharge flange relative to the transmission as
the pump must be reassembled with the same relation.
3. Remove the eight (8) hex nuts and lock washers attaching the pump volute to the
transmission.
4. With a hoist, lift the pump volute body off of the transmission. If the body does not
break free, tap the body with a soft hammer while lifting until separation is achieved.
5. Once the pump volute body is free of the transmission, remove the O-ring from the
groove in the transmission pump mounting flange.
1. Remove the oil seal from the bore in the volute body.
2. From the transmission side of the body, drive the throttle bushing out of the body
bore. This will also remove the mechanical seal stationary ring.
3. Inspect the throttle bushing per instructions on Page 16 to determine if replace-
ment is required.

F-1031, Section 4214
Page 5 of 10
Inspection and Repair
Impeller and Wear Rings
Check wear rings and impeller hubs for deep grooves or scratches. Spirol
grooves or grooves parallel to the impeller shaft increase leakage. Inspect
for excessive wear ring clearance. Diametric clearances in excess of .027
inches may warrant wear ring replacement. Original factory clearance is
.019 to .023 diametrically. The diametric clearance should be determined
by averaging the results of four measurements taken at 90 degree incre-
ments as follows:
Clean and remove small burrs or other protrusions from the wear ring inner
diameters and the impeller hub O.D. and I.D. Position each wear ring
on the impeller hub on which it was used. Hold the wear ring firmly against
one side of the hub and measure total clearance on the opposite side,
using a feeler gauge. Do not bottom the wear ring against the bottom of
the groove in the impeller.
Ball Bearings
When cleaning bearings, bearing manufacturers recommend placing them
in a basket and suspending the basket in a container of solvent, preferably
overnight. Avoid rotating the bearings before solid particles are removed,
to prevent damaging races and balls.
After cleaning, spin them immediately in light oil and check each one as
described below:
5. Examine bearing for rusted or pitted balls, races or cages.
6. Check cage and races for cracks or other damage. Examine balls and
races for brinelling, abrasion and serious discoloration. If in doubt
about condition of bearing, replace it.
7. Rotate bearing slowly, and check for roughness or excessive internal
looseness. If a rough spot is found, it may be dirt caked on a race.
Try cleaning it again. If endplay is doubtful, compare it with a new
bearing. If the bearings are not to be installed right away, wrap them
in clean, oil proof paper.

F-1031, Section 4214
Page 6 of 10
Inspection and Repair (Cont’d)
Impeller Shaft
Examine shaft for signs of severe scratches, grooves or corrosion, espe-
cially under the oil seal or mechanical seals. If scratches are not severe,
and are not under seals, they can be ignored. Check for cracks, pitting,
twisted splines or damaged keyway.
Scratches in the area of the bellows of the mechanical seal can possibly
be removed by spinning the shaft in a lathe and polishing with a fine
emery cloth.
Installing Oil Seals
Before installing an oil seal in a housing, be sure that the seal, shaft and
housing are clean. Apply force to the outer edge of the seal and press in evenly.
Oil Seal Sleeve
Check for wear and scratches where the seal contacts the sleeve. The
journal may be polished with a fine emery cloth, however; any polishing
that leaves a spiral pattern may lead to an oil leak. If a groove has been
worn in the sleeve, it can be reused by turning it end for end. If question-
able, replace the sleeve or fit with a thin replacement sleeve. This re-
placement sleeve allows use of the same size oil seal. This type of repair
sleeve is available through most sources of oil seals.
Volute Body and Intake Adapter
Examine 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.
Clean out drainage hole in volute body, located between the seat for the
throttle bushing and oil seal.
Throttle Bushing
Note: The bushing serves as a restriction to fluid leakage if the me-
chanical seal fails.
Examine the bore in the bushing for wear due to contact with the shaft.
The size of the bore is 2.760/2.762.

F-1031, Section 4214
Page 7 of 10
Install Mechanical Seal
NOTICE
The mechanical seal primary and stationary rings are made of brittle material.
The material can be cracked or chipped. Extra care must be taken when han-
dling these rings.
Note: If Waterous Mechanical Seal Lubricant part no. 52608 is not available,
P80 rubber lubricant, straight dish soap or glycerin may be substituted.
Reassembly
4. Install the seal stationary ring:
a). Apply a light coating of seal lubricant to the O-ring in the
stationary seal ring.
b). Identify the lapped surface of the seal stationary ring. The un-
lapped face of the stationary ring has a mark. The lapped
surface has no mark,
c). Slide the stationary ring over the end of the shaft with the
lapped face facing out. Push the stationary ring along the shaft
and into the bore in the volute body. If it cannot be seated by
hand, lightly tap into place with piece of wood being careful
not to scratch or mar the lapped face.
d). Wipe the lapped face of the stationary ring with a clean, lint-
free cloth or tissue paper to remove any seal lubricant.
1. Temporarily install the impeller key and impeller on the shaft. Rotate the
impeller. There should be no contact between the impeller and wear ring
in the pump body. If there is contact, correct before proceeding.
Check for the following causes of the contact:
a). Raised burr or nick on either the impeller hub or wear ring.
b). Wear ring was cocked when installed in volute body and is deformed
sufficiently to contact the impeller.
c). Impeller shaft not assembled or installed correctly. Check that correct
spacers and other components were used.
2. Remove the impeller and key.
3. Slide the throttle bushing over the shaft and down into the bore in the
volute body. Tap into position until it is seated in the volute body bore.

F-1031, Section 4214
Page 8 of 10
Install Mechanical Seal (Continued)
5. Install the seal bellows: 6. Install the seal spring over the seal bellows.
a). Apply a piece of tape over the shaft keyway which will protect the seal
7. Install the seal spring retainer on the back side of the impeller.
bellows during installation. Ensure all the tape can be removed once
the bellows is installed.
8. Install the impeller and intake adapter (see next page for instructions).
b). Apply a few drops of seal lubricant on the inside of the seal bellows.
Wipe the carbon ring on the end of the bellows with a lint-free cloth or
tissue paper to remove any seal lubricant.
c). Slide the bellows onto the shaft with the carbon ring end facing inward
taking care when passing over the shaft keyway. Slidethe seal bellows
inward until the carbon ring contacts the seal stationary ring.

F-1031, Section 4214
Page 9 of 10
Install Impeller and Intake Adapter
1. Install the impeller key and impeller on the shaft. Install the impeller
washer and nut. Note that the raised rib on the washer must face the
impeller nut. Tighten the nut finger tight.
2. Rotate the impeller to assure the seal spring is seated in the spring
holder on the back of the impeller. If the seal spring is not properly
seated, rotating the im- peller will cause it to snap into the spring
holder.
3. Finish tightening the impeller nut. Tighten until a slot in the nut is lined-
up with the hole in the shaft. Install and secure the cotter pin.
4. Grease and install the O-ring in the groove on the intake adapter.
5. Position the intake adapter in its original location on the volute body by
aligning the witness marks made during disassembly. Ensure the
intake adapter holes and volute body tapped holes are aligned.
6. Tap the intake adapter into position in the volute body bore.
7. Install the sixteen (16) screws and lockwashers. Tighten the screws until
the flange of the intake adapter contacts the volute body.
8. Rotate the impeller shaft. There should be no contact between the impeller
and wear ring in the intake adapter.
If there is no contact, tighten the screws evenly from side to side.
Torque to 75 lb-ft.
If there is contact, correct before
proceeding: Check for the following
causes of the contact:
a). Raised burr or nick on either the impeller hub or wear ring.
b). Wear ring was cocked when installed in intake adapter and is
deformed sufficiently to contact the impeller.
c). If a new undersize wear ring was installed, the impeller hub
was not re- worked to the correct size.
Once the contact issue is resolved, tighten the screws evenly
from side to side. Torque to 75 lb-ft.

F-1031, Section 4214
Page 10 of 10
Testing
Before the pump is returned to service, it is advisable to give it vacuum,
hydrostatic and operational tests to check it for leaks and to make sure the
pump operates properly.
Vacuum Test
1. Remove all caps except openings without valves. Close discharge,
intake and drain valves and other similar openings. Operated priming
device to create a vacuum of about 22 in. Hg/.735 atmosphere in
pump, then stop primer and engine.
2. Watch the pressure gauge; if vacuum drops more than 10 in. Hg/.334
atmospheres in five (5) minutes, listen for air leaks around the
packing gland, gaskets, valves, etc.
3. Replace gaskets, re-adjust packing, repack or otherwise repair source
of trouble.
4. Repeat test.
Hydrostatic Testing
1. Connect pump to a hydrant or other pressurized water supply.
2. Close all drain lines and open discharge and priming valves.
3. Open hydrant until water runs out through discharge valves and
discharge pipe in priming pump. Close all valves. Be sure to evacuate all
air from pump.
4. Apply water pressure to pump for 15 minutes. Do not exceed 350 psi
(24.2 bar). With a portable light, check pump for leaks. If leaks are
discovered, tighten connections or attaching parts as necessary.
NOTE: If a mechanical seal is used, it may leak under hydrostatic pressure.
However, it should stop leaking after the seal faces are run-in during
operational testing.
5. After all leaks are eliminated, shut hydrant valve, drain pump
completely and disconnect intake hose.
Operational Testing
1. Operate pump at it’s maximum intended service pressure. Do not exceed
350 psi (24.2 bar) (450 psi, 31 bar with positive intake).
2. With a portable light, check pump for leaks. If leaks are
discovered, stop pump and tighten connections or attaching parts
as necessary. Repeat until all leaks are eliminated.
3. While pump is running, check for unusual noises, oil leaks,
overheated bearings, etc. If anything unusual is discovered, stop
pump immediately and determine the cause.
Lubrication
Fill pump bearing housing or transmission with lubricant specified on
pump or transmission Operation and Maintenance instructions.