Waterous HL Series User manual

HL Series Centrifugal Fire Pumps
Installation Instructions
Table of Contents
Introduction . . . . . . .. . . . . . . . . . . . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . 2
General Description . . . . . . . . . . . . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . 2
Operational Limits....................................................................................2
Available Pump Models ...........................................................................2
Installation Instructions...........................................................................3
Pump Lifting Points................................................................................3
Pump Mounting......................................................................................4
Pump Intake . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . . 5
Low Pressure Discharge........................................................................5
High Pressure Discharge.......................................................................5
High Pressure Inlet Strainer . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . . 5
High Pressure Relief Valve ....................................................................5
Read through the installation Thermal Relief Valve . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . 5
instructions carefully before
installing your Waterous HL
Series Fire Pump.
Piston Primers .......................................................................................6
Lubrication.............................................................................................7
Pedestal (Primer Housing) Fill and Drain...........................................7
K Series Transmission Fill and Drain . . . . .. . . . . .. . . . . .. . . . . .. . . 7
Pump Water Drains . . . . . . . . .. . . .. . . . . .. . . . . .. . . . . . .. . . . . . . . . . . 9
NOTE: Instructions subject to change without notice Tachometer Connection . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . 9
Optional Items......................................................................................10
Solenoid Valve for PIV (Priming Isolation Valve) . . . . .. . . . . .. . . . 10
RTP Foam Systems: .......................................................................11
Installed on Pump at Factory.......................................................11
Mounted Remotely from Pump....................................................11
Control Panel . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . 12
Final Checks...........................................................................................13
Lubrication...........................................................................................13
Testing . . . . . . . . .. . . . . .. . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . 13
F-1031, Section 3032 (Rev: 6/7/19)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com

F−1031, Section 3032
Page 2 of 13
Introduction
This instruction covers the typical installation of any HL Series pump regardless of the model or intake and discharge.
General Description
The HL series are pedestal mounted fire pumps designed to operate in to modes:
Low Pressure Mode
Pump only low pressure water.
High Pressure Mode
Simultaneously pump low and high pressure water.
Three performance levels are available:
Before operating the HL pump, read the following instructions carefully.
OperationalLimits
Maximum Low Pressure
Control the speed of the pump so that the maximum low
pressure is limited to 17 bar.
Maximum High Pressure
The maximum high pressure is internally limited by the high
pressure relief valve not to exceed 55 bar.
Maximum Angle of Inclination
The maximum angle of inclination for pump operation is 15
degrees.
Maximum Pump Speed
The pump has a maximum operating speed of 3450 rpm.Do
not exceed this speed.
Maximum Priming Speed
When priming, the pump speed should be limited to 2600
rpm.
Low Pressure
High Pressure
Model
Series
2000 L/min @ 10 bar
400 L/min @ 40 bar
HL200
3000 L/min @ 10 bar
400 L/min @ 40 bar
HL300
4000 L/min @ 10 bar
400 L/min @ 40 bar
HL400
Available Pump Models

F−1031, Section 3032
Page 3 of 13
Installation
Pump Lifting Points
Direct Drive Models HL200D, HL300D, HL400D
Gear Drive Models HL200K, HL300K, HL400K

F−1031, Section 3032
Page 4 of 13
Pump Mounting
Select a mounting location that will make the pump and its accessories readily available for maintenance. Provide room around
the pump for all intended piping, instrumentation and drive system.
Pump Mounting Flange
For mounting holes are located on the pump pedestal that
are to be used to secure the pump to a mounting plate (plate
not supplied by Waterous). The mounting plate should be
designed with the four mounting holes (see diagram below
for dimensions).
The plate should also provide clearance for the volute flange
as identified in the diagram below.
Attach the pump to the mounting plate and secure to the
vehicle with M16 bolts.
Driveline Connection
The pump mounting location should be such that the drive-
line shaft length and angles are in accordance with the drive-
line manufacturer's specification.
Connect the driveline to the companion flange provided on
the pump input shaft. use appropriate fasteners and torque
following the driveline manufacturer's specification.
NOTICE
Tighten fasteners to the following specifications:
176-190 • (130-140 lb-ft).
N m
Pump Mounting

F−1031, Section 3032
Page 5 of 13
NOTICE
Install a suitable 1/2 in. fitting and tube or hose as-
sembly and route to one of the following locations:
To the holding tank, vehicle tank or to atmosphere
(ground).
Pump Intake
If piping is to be attached to the pump intake, provisions must
be made to allow the removal of the pump intake adapter
while the pump remains in the vehicle. This is necessary to
provide access to the pump for repairs and maintenance.
Low Pressure Discharge
Any piping connected to the low pressure discharge open-
ings on the pump discharge manifold must be properly sup-
ported and secured.
High Pressure Discharge
Any piping connected to the high pressure discharge open-
ing on the pump discharge manifold must be suitable for high
pressure and properly supported and secured.
High Pressure Inlet Strainer
Pump installation should provide access as this is a main-
tenance item.
High Pressure Relief Valve
Pump installation should provide access as this is a main-
tenance item.
Thermal Relief Valve
The valve is designed to discharge water if the temperature
of the pump water reaches 49° C. The discharged water
must be diverted away from the pump operator.
Installation of Components
NOTICE
The piping must not be restricted in any way.
NOTICE
A suitable strainer should be installed in each intake
opening on the pump.

F−1031, Section 3032
Page 6 of 13
Clearance for Service Piston Primers Primer Discharge
The pump has (2) two automatic piston primers located on
each side of the pump pedestal. Pump installation must
provide 50 mm (2 in.) of space behind the primers to allow
them to be removed for servicing.
During operation, the primers can discharge water. This wa-
ter exits through the primer discharge outlets. It is important
that this water is not restricted in any way. Typically the water
is discharged to the ground.
A suitable hose may be used to assist in directing the water
to the ground, however, it is not recommended that any
angled fittings be used as they will restrict the flow.
Piston Primers
NOTICE
The piping or hose must not be restricted in any way.

F−1031, Section 3032
Page 7 of 13
Lubrication
Models HL200 and HL300D
Pedestal (Primer Housing) Fill and Drain - HL200D, HL300D
Models HL200K, HL300K, HL300D, HL400D
Pedestal (Primer Housing) and K Series Transmission Fill and Drain
See next page for K Series Transmission requirements.
NOTICE
Pump installation must provide for access to the lubrication fills and drains.

F−1031, Section 3032
Page 8 of 13
Lubrication
Models HL200K, HL300K and HL400K Only
Transmission Mounted Vertically
NOTICE
Pump installation must provide for access to the lubrication fills and drains.

NOTICE
All piping, fittings and valves must be suitable for pres-
sures that are present in the low and high pressure
stages.
Pump Water Drains
The pump is provided with a 3/4 NPT water drain. The drain
should be fitted with piping, valve and routed to suitable
draining location.
Tachometer Connection
If Optional Control Panel was not furnished:
The pump includes a magnetic pick-up installed in the pump
pedestal which allows a tachometer to be connected. A 10
meter cable is included with the pump which mates with the
magnetic pick-up (Amphenol connector part no.
MS3106A-10SL-4S).
Wire the cable to the tachometer. Note that the magnetic
pick-up produces four pulses per revolution of the pump
shaft.
If Optional Control Panel was furnished:
The tachometer is included in the control panel and the wir-
ing to the magnetic pick-up was completed at the factory.
Optional Items
F−1031, Section 3032 Page 9 of 13
Solenoid Valve for PIV (Priming Isolation Valve)
Pump Water Drain

F-1031, Section 3032
Page 10of 13
Solenoid Valve for PIV (Priming Isolation Valve)
2.750
69.85
1.188
30.16
MOUNTING FLANGE
:
1.563
i
·'":f-
19.84
39.69
2XM4MOUNTING HOLE
I
SOLENOID DIMENSIONS
AllDIMENSIONS SHOWN
INCH )
AS INCH/MILLIMETER
(
MILLIMETER
GROMMET
TWO 16 OR 18
AWG WIRES
CONNECTOR
HOUSING
SOLENOID
VALVE
TERMINAL
SCREWS
NOTE: SOLENOID IS NOT
POLARITY SENSITIVE
SOLENOID WIRING
AIR INLET CONNECTOR ON PUMP
PRIMING ISOLATION VALVE IPIVI.
CONNECT 6mm TUBING TO
PUSH-ON FITTING
TO PTO ACTUATOR
PTO SWITCH
6mm TUBING
16 OR 18 AWG WIRE
PRIMING VALVE SOLENOID,
REMOTELY MOUNT IN CHASSIS
ISEE DIMENSION AND WIRING DETAILS!
FROM CHASSIS
AIR SUPPLY
6mm TUBE X 1/4
BSP FITTINGS
IL:9561

F−1031, Section 3032
Page 11 of 13
RTP Foam System
(RTP Foam System is Optional)
Installed on Pump at Factory:
Install the Foam Suction Hose:
Install the barbed fitting in the tap located on the bottom of
the Proportioner Valve.
Attach the hose and wand to the barbed fitting using the
clamps provided.
Mounted Remotely from Pump::
See separate Installation Instructions F-1031, Section 2321.
RTP Foam System (Installed at Factory)

F−1031, Section 3032
Page 12 of 13
Control Panel
(Control Panel is Optional)
Complete Electrical Connections for the fol-
lowing:
•Tachometer / Hourmeter
•Pump Overheat Module
•Pump Engaged Module
Complete Electrical Connections and Tank
Connections for the following:
•Optional Tank Level Monitors
Control Panel

F−1031, Section 3032
Page 13 of 13
Final Checks
Lubrication
Before operating the pump, add the lubricants specified below (see Pages 7 and 8 for fill locations.)
Models HL200D, HL300D and HL400D
Lubrication required for Pedestal (Primer Housing) Only
Pedestal (Primer Housing)
Lubricant
Capacity
SAE 10W-30 Motor Oil
.95 Liter (1 Quart)
Models HL200K, HL300K and HL400K
Lubrication required for Pedestal (Primer Housing) and K Series Transmission
Pedestal (Primer Housing)
Lubricant
Capacity
SAE 10W-30 Motor Oil
.95 Liter (1 Quart)
K Series Transmission
Lubricant
Capacity
SAE 80W-90 Gear Oil
.95 Liter (1 Quart)
Testing
Before operating the pump, check and verify all fasteners
and connections (mounting, driveline, piping, etc.) are se-
cure.
To run the pump, follow instructions F-1031, Section 2408,
HL Series Fire Pump Operation and Maintenance Instruc-
tions.
During the running of the pump, monitor for smoothness of
operation, listen for unusual noises and check for leaks.
NOTICE
Failure to properly lubricate the pump may result in serious damage.
NOTICE
1. Capacities shown are approximate. Quantities listed vary based on ratio and /or
mounting orientation.
2. Always fill to the marking on dipstick (pedestal) or bottom of the plug labeled “Oil Level”
(K Series Transmission).
3. K Transmission breather may be removed and the hole used as the lubricant fill.
4. Synthetic oil substitutes are acceptable.