Waterous CX Series Manual

CX Series Centrifugal Fire Pumps
Operation and Maintenance Instructions
Table of Contents
F-1031, Section 2109.1 (Rev: 7/14/20)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com
NOTE: Instructions subject to change without notice
Read throughthe operationinstruc-
tions carefully before using your
Waterous Fire Pump.
Safety Information----------------------------------------------- 2, 3
Introduction------------------------------------------------------------- 4
General Description:
Components------------------------------------------------------------ 4
Options---------------------------------------------------------------- 4, 5
Operating Instructions:
Pumping from Water Tank------------------------------------------ 6
Pumping from Hydrant or in Relay-------------------------------- 7
Pumping from Draft--------------------------------------------------- 8
Fire Hose Testing----------------------------------------------------- 9
Maintenance:
Corrosion Protection------------------------------------------------ 10
Optional Intake Screens------------------------------- 10
Optional Anodes----------------------------------------- 10
Mechanical Seal------------------------------------------------------ 11
Packing----------------------------------------------------------------- 11
Packing Removal---------------------------------------------- 11
Packing Installation-------------------------------------------- 12
Packing Adjustment------------------------------------------- 12
Vacuum Test---------------------------------------------------------- 13
Overheat Protection Manager (OPM)--------------------------- 13
Butterfly Valve (BFV)------------------------------------------------ 13

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.
!
WARNING
Scalding Water Hazard. May result in seriousburns.
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 com-
pletely 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.
!
WARNING
Rotating Parts Hazard or Unexpected Truck Move-
ment. Mayresult inseriouspersonalinjury ordeath.
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 Haz-
ard. May result in serious burns.
Heat is dissipated through the cross-section of the
packing, transferring the heat to the packing gland
and pump body.
!
WARNING
F-1031, Section 2109.1
Page 2 of 13
Unexpected Truck Movement. May result in seri-
ous personal injury or death.
Failure to properly shift transmission in accordance to
the transmission operating instructions may result in
unexpected truck movement which may result in seri-
ous personal injury or death.
!
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
discharge hoses to the apparatus must be familiar
with these pump operating instructions as well as
other operating instructions and manuals for the ap-
paratus, water hydraulics and component limitation.
!
WARNING
SafetyInformation
Read throughthe safety information and operating instructions carefully before using your Waterous Fire
Pump.

F-1031, Section 2109.1
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.
Page 3 of 13
Read throughthe safety information and operating instructions carefully before using your Waterous Fire
Pump.
SafetyInformation

F-1031, Section 2109.1
Page 4 of 13
Introduction
This instruction contains the information needed for operation and maintenance of CX Series centrifugal pumps. Since
there are several types of transmissions available for these pumps, they are covered in separate instructions.
GeneralDescription
The CX series pumps are single stage centrifugal pumps.
Depending on the type of transmission used, the pump may be
used as a front-mounted pump (driven from the engine
crankshaft), power take-off driven, direct-engine driven
(bellhousing mounted) or midship mounted. They are available
in capacities up to 1250 gpm (4750 l/m).
OPERATION LIMITS: Do not operate pump beyond max. pressure (350 psi) or max. speed (5200 rpm).
Fail to do that may result in personal injury or premature pump failure.
Body Assembly
Components
Impeller Shaft Assembly
This assembly includes the body, head, intake adapter and
related parts. The body and adapters are either cast iron or
bronze.
Heater Jacket (CXR Only)
A heater jacket consists of two 1/2” NPT tapped holes in the
intake adapter. This allows a piping connection from the engine
coolant system to connect to the tapped holes. Engine coolant
then flows through a hollowed out area in the intake adapter.
The engine coolant helps prevent the water flowing into the
pump from freezing.
This assembly consists of a bronze impeller mounted on a
stainless steel shaft, wear rings, mechanical seal or pack- ing
and related parts. The impeller is balanced and the im- peller
shaft is supported by ball bearings.
Mechanical Seal
The mechanical seal consists of a flat, highly polished
(lapped), spring-fed carbon ring that is sealed to and ro- tates
with the impeller shaft. It presses against a highly polished
(lapped) stainless steel, stationary ring that is sealed in the
pump head. This seals the shaft and pre- vents air from
entering and water from leaving. A me- chanical seal does
not leak or drip water, even when pumping.
Intake Screens
Options
consistently outwear hard chrome plating, tool steel and solid
tungsten carbide.
Zinc die cast screens are normally used in the intake fit-
tings, with brass screens available optionally. Although the
screens are chemically treated (coated) to inhibit cor- rosion,
the water being pumped may still corrode the screens. Such
corrosion is ‘‘sacrificial’’; that is, it will help prevent corrosion in
the rest of the pump the same way the magnesium anodes
protect the metal parts of a water heater.
Anodes
As additional corrosion protection for iron body pumps,
Waterous has anodes available to fit any unused opening in the
intake fitting.. Anodes provide an additional sacrificial surface to
the water to supplement the intakescreens.
Flame Plated Impellers
Approximately 75% of the pump wear due to pumping sand,
occurs on the impeller hubs. For this reason, the Waterous
Company adopted the policy of offering a flame plated impeller
as an option. The flame plating process consists of adding
tungsten carbide to the surfaces to be protected from wear.
This unique process produces ex- tremely hard, well bonded,
wear resistant coatings which
Overheat Protection Manager (OPM)
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.
Monarch Intake Valve
The Monarch intake valve is a package including an extra short
intake fitting, an intake butterfly valve and an intake nipple with
integral relief valve mounting pad, all designed to fit behind the
pump panel. The Monarch intake valve also features a provision
for a pre-valve relief valve and choice of manual worm gear or
pneumatic actuator. For operation and maintenance instructions
for the Monarch intake valve, see the following instructions:
• F-1031, Section 2318, Operation, Maintenance and
Installation Instructions for Butterfly Valves
• F-1031, Section 2319, Operation, Maintenance and
Installation Instructions for Butterfly Valve Pneumatic
Actuator
Model
Intake
CXN
DIN PN10 150
CXR
5 in. or 6 in. NH Thread
CXS
6 in. Victaulic Tee with a Front Facing
5 in. Victaulic Connection
CXV
Single 6 in. Victaulic

F-1031, Section 2109.1
Page 5 of 13
Figure1.CXN Models 6 in. ANSI Flange & DIN PN10 150 Flange Figure2.CXRModels
Figure3.CXSModels Figure 4.CXVModels
Figure5.CXDModels Figure6. CXSDModels

F-1031, Section 2109.1
Page 6 of 13
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.
!
WARNING
Scalding Water Hazard. May result in seriousburns.
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 com-
pletely 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.
!
WARNING
Unexpected Truck Movement. May result in seri-
ous personal injury or death.
Failure to properly shift transmission in accordance to
the transmission operating instructions may result in
unexpected truck movement which may result in seri-
ous personal injury or death.
!
WARNING
OperatingInstructions
Transmission Operation
Because of the variety of transmissions available for these pumps, the methods of operating them are not explained in
this section. For information on Waterous transmissions, refer to transmission operation instructions.
Pumping from Water Tank
CAUTION
Do not attempt to pump more water than is available
from the water tank. Always make sure the intake
pressure compound gage reading stays above zero.
5. Set relief valves or other pressure governing de-
vice to desired pressure.
After Pumping
1. Open valve(s) 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 because
of air trapped in piping.
3. Engage pump. If pump is equipped with a Water-
ous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
4. Open discharge valves and accelerate engine to
obtain desired discharge pressure and capacity.
1. Disengage pump. If pump is equipped with a Wa-
terous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
2. If pumping anything but clean water, remove all in-
take and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh wa-
ter for several minutes to remove all traces of im-
purities.
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.
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 dis-
charge pipe. Also check fluid level in priming tank,
and refill if necessary.
CAUTION
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.
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.
!
WARNING
NOTICE
NOTICE

F-1031, Section 2109.1
Page 7 of 13
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.
!
WARNING
Scalding Water Hazard. May result in seriousburns.
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 com-
pletely 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.
!
WARNING
Unexpected Truck Movement. May result in seri-
ous personal injury or death.
Failure to properly shift transmission in accordance to
the transmission operating instructions may result in
unexpected truck movement which may result in seri-
ous personal injury or death.
!
WARNING
CAUTION
If pump has a mechanical seal, limit intake pressure
to 100 psi if possible. Although the pump will operate
properly with higher intake pressure, such operation
will greatly accelerate mechanical seal wear.
Pumping from Hydrant or in Relay
3. Open discharge valves and accelerate engine to
obtain desired discharge pressure and capacity.
4. Set relief valves or other pressure governing de-
vice to desired pressure.
CAUTION
Do not attempt to pump more water than is available
from the water tank. 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.
After Pumping
1. Engage pump. If pump is equipped with a Water-
ous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
2. Open intake, hydrant and other valves as neces-
sary to allow water to enter the pump.
NOTE: Bleeder valves should be used while filling
a hose connected to an intake with water.
1.
Disengage pump. If pump is equipped with a Wa-
terous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
2. If pumping anything but clean water, remove all in-
take and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh wa-
ter for several minutes to remove all traces of im-
purities.
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).
CAUTION
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 dis-
charge pipe. Also check fluid level in priming tank,
and refill if necessary.
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.
!
WARNING
NOTICE
NOTICE
NOTICE

F-1031, Section 2109.1
Page 8 of 13
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.
!
WARNING
Scalding Water Hazard. May result in seriousburns.
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 com-
pletely 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.
!
WARNING
Pumping from Draft
1. Prime the pump (see separate instructions sup-
plied with primer).
2. 2.Engage pump. If pump is equipped with a Water-
ous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
3. 3.Open discharge valves, and accelerate engine to
obtain desired discharge pressure and capacity.
4. 4.Set relief valves or other pressure governing de-
vice to desired pressure.
After Pumping
NOTE: To get full capacity, quick prime and maintain
pumpefficiency:
a) Position vehicle as near as possible to water sup-
ply.
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
pumpcapacity.)
c) Make sure all intake connections are tight and dis-
charge 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 bot-
tom to prevent sand, gravel and other foreign mat-
ter from being drawn into the pump.
1. 1.Disengage pump. If pump is equipped with a Wa-
terous transmission (C10, C20, K, PA, T, Y), follow
transmission operation instructions.
2. 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. 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).
CAUTION
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.
1. 4.Close all drains and install intake and discharge
caps.
2. 5.If truck is equipped with a priming pump, operate
it until fluid is discharged from priming pump dis-
charge pipe. Also check fluid level in priming tank,
and refill if necessary.
Unexpected Truck Movement. May result in seri-
ous personal injury or death.
Failure to properly shift transmission in accordance to
the transmission operating instructions may result in
unexpected truck movement which may result in seri-
ous personal injury or death.
!
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.
!
WARNING
NOTICE

F-1031, Section 2109.1
Page 9 of 13
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.
NOTICE

F-1031, Section 2109.1
Page 10 of 13
Optional Intake Screens Corrosion Protection
Onceper month checkto makesure the intakescreens are
notcloggedor damaged.Alsocheck forcorrosion,andre-
place screens if damageis severe.For the screento ad-
equately control corrosion, there must be a strong electrical
contactbetweenthe screen and the fitting.Removeany cor-
rosion, debris or paint from the counter bore that will insulate
the screenfrom the intakefitting.If thescreendoes not fit
tightly, adjust the gap of the sloton the outside diameter of
the screento ensure a tight fit.
NOTE: These screens are die-cast which results in a
slight taper from one side to the other. Install the screen
withthe thinner cross-section facing out to minimize
flow restriction.
Figure 5. Intake Screens
Optional Anodes
Twiceper year,remove the anodes and check for erosionof
the replaceable elements. Replace the elements if more than
half of eitherof the elements has eroded. Anodes are
normallymounted onthe pumpintakepiping, but theymay
alsobe installed in the discharge pipingif no intakemounting
locations were available. Physical mounting of the anode
may be via anNPT tap or bolt-on flange as described below.
NOTE: The replaceable elements must make contact
with water to be effective. Do not paint or use any other
coating on the replaceable elements.
Bolt-on Anodes
Unscrewthe (4) hex head screws from the pump. If ele-
ments requirereplacement, unscrewthe hex head cap
screw.
NOTE: There is no need to remove the threaded anode
adapter from the anode flange for element replace-
ment.The screw was installed using thread sealant so
higher force than normal may be necessaryto remove.
Replace one or both elementsas necessary.Installthe hex
headscrew using Loctite 242 (blue) on the screwthreads.
Mount the anode assembly back on thefitting.
Figure 6. Bolt-on Anodes
Threaded Anodes
NOTE: The 2-1/2 in. hex is threaded into a bushing that
should remain on the pump. Be sureto restrain the
bushing when removing the 2-1/2 in. hex.
Unscrewthe 2-1/2 in. hex from the pump. If the elements
require replacement, unscrew the hex head cap screw.
NOTE: The screw was installed using thread sealant so
higher force than normal may be necessaryto remove.
Replace one or both elementsas necessary.Installthe hex
headscrew using Loctite 242(blue) on the screwthreads.
Removeany paintor corrosion from the face around the
NPT tap on the pump. Apply thread sealant to the threads
and screw the 2-1/2 in.hex intothe pipe tap until tight.
Figure 7. Threaded Anodes
Maintenance

F-1031, Section 2109.1
Page 11 of 13
CAUTION
Prolonged dry pump operation or operating a dry
pump at high speeds will reduce the life of the me-
chanical seal.
Packing Gland and Pump Body Temperature Haz-
ard. May result in serious burns.
Heat is dissipated through the cross-section of the
packing, transferring the heat to the packing gland
and pump body.
!
WARNING
CAUTION
Pump overheating hazard. May cause damage to
the pump.
Circulate enough water through the pump to prevent
overheating. Do not pressurize the pump over the
maximum discharge pressure of the pump.
Mechanical Seal
If a mechanicalshaftseal is used,no adjustment is required.
Whenthe pump operates,the water being pumped cools
and lubricates the shaft seal to preventit from overheating.
Waterous uses a braided graphite fiber, with reinforced
flexible graphite yarns and high purity graphite filament
yarns that appear on the corners as well as throughout
the body of the packing. The graphite reinforcement al-
Packing
1. Remove the unbalanced nuts, flat washers and
packing gland halves.
2. Engage the pump per appropriate operating in-
lows the flexible graphite yarns to provide greater tensile
strength.
This type of packing reduces the frictional heat created
between the shaft and the I.D. of the packing. By dissipat-
ing the heat through the cross section of the packing, the
heat is transferred to the packing gland and the pump
body.
structions.Operatethe pump, gradually increasing
the discharge pressure until the packing is forced
out of the stuffing box. Pressure in excess of 300
psi (20.7 bar) may be required.
Packing Removal
3. If all the packing is not forced out, it may be neces-
sary to remove the remaining packing by hand, us-
ing a pick or similar device. Waterous has a packing
removal tool (P/N 5782) available for this purpose,
seeFigure 8.
4. Replace packing per instructions below.
1.
IL1931
Figure 8. Packing Removal Tool
Truck movement hazard. May cause serious per-
sonal injury.
Stop engine, set the parking brake and chock the
wheels before going under truck to remove packing.
!
WARNING
NOTICE
NOTICE

F-1031, Section 2109.1
Page 12 of 13
Packing Installation
1. Before installing the new packing, be sure that all
ofthe old packing is removed from thestuffingbox.
2. Be sure that the stuffing box and the shaft are
clean and free of any packing residue.
3. Lightly lubricate the packing ring I.D. and O.D. with
mineral oil, automotive grease or engine oil for in-
stallationpurposes.
4. Make sure the packing is clean.
5. Carefully install one ring of packing. With the aid of
packing glands, push the packing into the stuffing
box as far as possible. Repeat this operation with
each ring, staggering the joints at least 90 apart.
Install the packing rings until the top of the last ring
is about 1/4 inch from the end of the stuffing box
(at least 1/8 inch is required for the packing gland
nose entrance into the stuffing box). See Figure 9.
Note: Be sure that the packing joints are stag-
gered at least 90 apart.
6. Install packing glands, nuts and washers. Tighten
gland nuts one flat beyond finger tight, see Figure
9.
Note: The milled slot on the nut should face the
gland.
7. Adjust packing as required per instructions on the
next page.
Figure9. PackingandGlandInstallation
Packing Adjustment
The pump packing is designed and adjusted to drip
slightly during operation. This is to cool and lubricate the
packing. It is desirable to adjust the stuffing box to main-
tain a leakage rate of 10 to 120 drops per minute when
operating at a discharge pressure of 150 psi (10.3 bar).
Leakage through the braided flexible graphite (BFG) pack-
ing may be at zero or diminish to zero leakage and may
not respond to loosening of the packing nuts to restore
leakage, see Adjustment Step 3. While the packing gland
and stuffing box and pump body may reach high tempera-
tures during this time, the impeller shaft will be protected
from heat damage.
1. Engage pump per appropriate operating instruc-
tions. Operate the pump at the capacity pressure
shown on the serial plate for ten (10) minutes.
2. Observe leakage. Normal leakage is 10-120 drops
per minute.
3. If drip rate is considered high, stop the engine and
tighten the packing gland nuts 1/2 to 1 flat (maxi-
mum of 1/6 of a revolution). Make appropriate ad-
justments starting with 1 flat, when approaching
the final adjustment reduce to 1/2 flat. This reduces
the possibility of over tightening. Tighten the
gland nuts equally to ensure that the packing
gland goes on straight. Gradually reducing leak-
age during the first hour of operation will result in a
better seal over a longer period of time.
4. Operate the pump at the capacity pressure shown
on the serial plate for two (2) minutes to let packing
run in, then observe the drip rate.
CAUTION
Stopping the leakage entirely at this point will
cause the packing to overheat.
CAUTION
Observe the stuffing box drip rate from the side
of the truck.
!
WARNING
Truck movement hazard. May cause serious per-
sonal injury.
Stop engine, set the parking brake and chock the
wheels before going under truck to remove packing.
CAUTION
Pump overheating hazard. May cause damage to
the pump.
Circulate enough water through the pump to prevent
overheating.
NOTICE
NOTICE
NOTICE

F-1031, Section 2109.1
Page 13 of 13
Packing Gland and Pump Body Temperature Haz-
ard. May result in serious burns.
Heat is dissipated through the cross-section of the
packing, transferring the heat to the packing gland
and pump body.
!
WARNING
5. Repeat steps 3 and 4 until the drop rate is
acceptable.
Note: After adjusting the packing, the pump must
pass the following vacuum test described below.
Vacuum Test
1. Remove all caps except openings without valves.
Close all discharge, intake and drain valves and
other similar openings. Operate priming device to
create a vacuum of about 22 in. Hg/.735 atmos-
phere 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 oth-
erwise repair source of trouble.
4. Repeat test.
Overheat Protection Manager
Check the electrical circuit by pressing the test button lo-
cated on the panel plate every 100 hours of pump opera-
tion 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).
Butterfly Valve (BFV)
Operate valve once a week for optimal performance.