Fire Pumps CG Series Centrifugal Fire Pumps Installation Instructions IL3214 Table of Contents Safety Information... 2 Introduction... 3 Pump Mounting: CGVG Series Pumps: With C20 Series Transmission: Drop Dimensions and Driveline Angles... 4 Mounting Bracket Attachment Points... 5 With WB Series Transmission: Drop Dimensions and Driveline Angles... 6 Mounting Bracket Attachment Points... 7 Oil Pressure Gauge... 7 With K Series Transmission: Driveline Angles... 8 Mounting Bracket Attachment Points... 8 With PA Series Transmission: Driveline Angles... 9 Mounting Bracket Attachment Points... 9 Pump Mounting Holes in Angle Brackets for CGVG Pump Models... 10 CGV, CGVN CGVR Series Pumps: With C20 Series Transmission: Mounting Bracket Attachment Points:........................................................ 12, 13 With K Series Transmission: Mounting Bracket Attachment Points... 14 Optional Suspension Pin Mounting... 15 With PA Series Transmission: Mounting Bracket Attachment Points... 16 With T Series Transmission: Mounting Diagram... 17 Installation of Shift Unit; C20 and WB Series Transmissions Only: See Instruction F-1031, Section 3030 Optional Corrosion Protection... 18 Electronic Tachometer: Optional on C20 Series, Standard on PA Series Transmissions......................................... 19 Optional Mechanical Tachometer Drive (K and T Series Only)... 19 Final Checks: Lubrication... 19 Testing... 19 Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000 www.waterousco.com F-1031, Section 3019 (Revised: 9/5/17)
Safety Information Read through and communicate safety information to the end user of this Waterous Fire Pump. 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 and manuals for the apparatus, water hydraulics and component limitations. WARNING Pressure Hazard. May result in personal injury. Pressure 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 serious burn. 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. WARNING Rotating Parts Hazard or Unexpected Truck Movement. May result in serious personal injury or death. Stop the engine, set parking brake and chock the wheels before going under the truck to adjust packing or to check packing gland temperature. OEM Installation Warnings WARNING Unexpected Truck Movement. May result in serious personal injury or death. Failure to properly install the pump shift control and pump shift indicator system in the apparatus or failure to incorporate in the Pump Operator s Panel Engine Speed Interlock System may result in unexpected truck movement which may result in serious personal injury or death. WARNING Inability to Pump Water. May result in serious personal injury or death. Failure to properly install the pump shift control and pump shift indicator system in the apparatus or failure to incorporate in the Pump Operator s Panel Engine Speed Interlock System may result in unexpected truck movement which may result in serious personal injury or death. WARNING Exceeding Power Train Torque Ratings. May result in inability to pump water causing serious personal injury or death. This fire pump may have the capability under certain pumping conditions to exceed the torque rating of the power train. A means to control the engine output to a torque level no greater than the power train s continuous-duty torque rating must be considered when specifying power train components and engine control system parameter. F-1031, Section Page 2 of 19
Introduction This instruction covers the installation of Waterous CG Series single stage fire pumps. The CG Series can be rated at 500, 750 or 1000 GPM. Four different CG models are available as follows: Model Intake Discharge CGVG Crosspipe which is mounted directly to the frame rails. CGV 5 in. Victaulic CGVN 4 in, 4-1/2 in. or 5 in. NH Thread CGVR 5 in. Keystone Flange 3 in. Flange or Optional 4 in. Victaulic Adapter C20 Series: The C20 transmission is an aluminum, split-shaft, chain driven transmission that transmits power from the truck's transmission to either the fire pump or the drive axle of the truck. K Series: The K transmission is an iron, two-gear speed increaser designed primarily to be driven by a power take-off (PTO) or power divider. T Series: The T transmission is an iron, two-gear speed increaser designed to be mounted directly to an engine bell housing. The CG pump is available with the following transmissions: PA Series: The PA transmission an aluminum chain driven transmission designed to be driven off the ten-bolt power take-off (PTO) provision available on the left side of the Allison MD or HD automatic transmission. WB Series: The WB transmission is an iron, split-shaft, chain driven transmission that transmits power from the truck's transmission to either the fire pump or the drive axle of the truck. Instruction Name The following installation instructions are available: Instruction Number Monarch Intake Valve (BFV) F-1031, Section 2318 Drain Valves F-1031, Section 3008 Pressure Control System F-1031, Section 3010 Overheat Protection Manager (OPM) F-1031, Section 3015 FoamPro System F-1031, Section 3012 Foam Manager Systems Advantus System F-1031, Section 3026 Aquis System F-1031, Section 3031 Parking Brake F-1031, Section 2304 Priming Systems F-1031, Section 3023 Shift Unit F-1031, Section 3030 Before proceeding with the installation of your pump, read the following instructions carefully. Check the appropriate dimensional drawings in the Engineering Manual as necessary. F-1031, Section Page 3 of 19
CGVG Series Pumps with C20 Series Transmission Table 1. C20 Series Transmission Drop Ranges Model Dim A. (IN/mm) C20B 12.240 / 310.90 C20C 13.811 / 350.80 C20D 14.856 / 377.34 C20E 16.920 / 429.77 C20F 18.971 / 481.86 *NOTE: 2.27 ratio drop values shown. Drop values vary for other output ratios, see dimensional drawings for specific drops by ratio. Drop Dimensions NOTE: Remove shipping brackets and discard. Do not use for mounting pump. Select a mounting location which will make the pump and its accessories readily accessible for maintenance and which will make the pump driveshaft parallel with the output shaft of the chassis transmission or transfer case. Also, select the location so that when the apparatus is loaded, the universal joints on the propeller shaft will have a proper working angle. Note that the C20 Series transmission is available with a range of drop sizes (see Table 1 and Figure 1, Dimension A ). Figure 1. Drop Size Dimensions Drive Line Angles Table 2 gives maximum universal joint angles for installation where propeller shaft flanges are parallel and yokes are aligned. Refer to this when positioning a pump to determine proper shaft angles. Be sure to keep at least a minimum of 1 U-joint operating angle, but do not exceed those specified 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 Installation Techniques. CAUTION Be sure the propeller shafts used are of the slip-joint design. Frame deflection, temperature changes and similar factors may cause a propeller shaft without slipjoints to produce severe axial loads on the bearings and damage the pump / transmission. 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 the table above are the maximum U-joint operating angles recommended by Waterous and are directly related to the speed of the driveshaft. Any U-joint operating angle greater than 3 will lower the U-joint life and may cause vibration 1. 1 From Spicer Driveshaft Installation Techniques, Form J-3311. F-1031, Section Page 4 of 19
CGVG Series Pumps with C20 Series Transmission Figure 2 shows a typical installation of a CGVGC20 where the pump is mounted on angle brackets attached to the outside of the chassis frame rails. To mount the pump, create angle brackets that will attach the pump to the vehicle's chassis. The CGVGC20 is equipped with two (2).563 (9/16) in. through holes on each side of the crosspipe. To help create the angle brackets, Figure 13, Pump Mounting Holes in Angle Brackets, shows the locations of the holes in the crosspipe. Drill a suitably sized hole in the angle bracket where the corresponding hole in the crosspipe is located. Using only one tapped hole on each side of the adapter, fasten the angle bracket to the pump. Repeat this procedure for each side of the pump. Fasten the angle brackets to the chassis frame rails using a 3-point mounting technique shown in Figure 3. This mounting technique allows for slight truck frame twist. NOTE: Tighten the mounting screws to standard torque specifications. Figure 3. Three-Point Mounting Diagram Adjust pump angle to achieve proper driveline angles (See Table 2). 1/2 Mounting Screws, Grade 5 Minimum (One bolt on each side of adapter - 4 per pump) CAUTION Do not use the 4-bolt mounting pads on the output shaft side of the C20 case for mounting CGVG model pumps to prevent excess stress on the transmission case. Figure 2. CGVGC20 Mounting Chassis Frame Rail Angle brackets on both sides (See Figure 13 on Page 10 for Mounting Holes). Anti-seize should be applied to the shaft threads before installing end yoke or companion flange. Do not reuse self-locking nuts. Torque to 475-525 lb-ft. 3/4 Mounting Screws, Grade 5 Minimum For Three-Point Suspension. Use single screw on driver's side. 3/4 Mounting Screws, Grade 5 Minimum F-1031, Section Page 5 of 19
CGVG Series Pump with WB Series Transmission Drop Dimensions Select a mounting location which will make the pump and its accessories readily accessible for maintenance (see Figure 4) and which will make the pump driveshaft parallel with the output shaft of the chassis transmission or bearing housing. Also, select the location so that when the apparatus is loaded, the universal joints on the propeller shaft will have a proper working angle. Note that the WB Series transmission drop dimensions varies by ratio (see Table 3 and Figure 5, Dimension A ). Figure 4. Required Working Space for Removal of Oil Pump Table 3. WB Series Transmission Drop Ranges Ratio Dim A. (IN/mm) 1.19 12.251 / 311.18 1.29 11.852 / 301.04 1.39 11.964 / 303.89 1.52 11.934 / 303.12 1.62 12.175 / 309.25 1.74 11.795 / 299.59 1.87 11.895 / 302.13 2.04 11.847 / 300.91 2.57 12.179 / 309.35 Figure 5. Drop Size Dimensions Drive Line Angles Table 4 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 determine proper shaft angles. Be sure to keep at least a minimum of 1 U-joint operating angle, but do not exceed those specified 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 Installation Techniques. CAUTION Be sure the propeller shafts used are of the slip-joint design. Frame deflection, temperature changes and similar factors may cause a propeller shaft without slipjoints to produce severe axial loads on the bearings and damage the pump / transmission. Table 4. 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 the table above are the maximum U-joint operating angles recommended by Waterous and are directly related to the speed of the driveshaft. Any U-joint operating angle greater than 3 will lower the U-joint life and may cause vibration 1. 1 From Spicer Driveshaft Installation Techniques, Form J-3311. F-1031, Section Page 6 of 19
CGVG Series Pumps with WB Series Transmission Figure 6 shows a typical installation of a CGVGWB where the pump is mounted on angle brackets attached to the outside of the chassis frame rails. To mount the pump, create angle brackets that will attach the pump to the vehicle's chassis. The CGVGC20 is equipped with two (2).563 (9/16) in. through holes on each side of the crosspipe. To help create the angle brackets, Figure 13, Pump Mounting Holes in Angle Brackets, shows the locations of the holes in the crosspipe. Drill a suitably sized hole in the angle bracket where the corresponding hole in the crosspipe is located. Using only one tapped hole on each side of the adapter, fasten the angle bracket to the pump. Repeat this procedure for each side of the pump. Fasten the angle brackets to the chassis frame rails using a 3-point mounting technique shown in Figure 7. This mounting technique allows for slight truck frame twist. NOTE: Tighten the mounting screws to standard torque specifications. Figure 6. CGVGWB Mounting Chassis Frame Rail Oil Pressure Gauge An oil pressure gauge may be used to show that the transmission lubrication pump is working. Following are guidelines on installing an oil pressure gauge. 1. Mount the gauge away from the operator's panel and preferably at the right hand side panel (passenger or curb side). This will prevent a pumper from being shut down due to a failed pressure gauge. NOTE: Do not use a gauge with a low pressure zone marked in red or wording on the gauge face indicating that operation in the low pressure zone is dangerous. 2. The gauge should be identified as: FOR MAINTENANCE CHECKS ONLY. 3. The end user should be instructed to use the gauge only as part of monthly maintenance checks. These checks should be done while the lubricant is not hot and with the pump turning fast enough to give a good pressure indication on the gauge. 4. No specific pressure value should be given to prove the lubrication pump is working, but instead, a range from 3-30 PSIG is satisfactory. Note that any movement of the pointer on the gauge with a change in pump speed indicates that the lubrication system is working. Figure 8. Oil Pressure Gauge Angle brackets on both sides (See Figure 13 on Page 10 for Mounting Holes) Anti-seize should be applied to the shaft threads before installing end yoke or companion flange. Do not reuse self-locking nuts, Torque to 475-525 lb-ft. Figure 7. CGVGWB 3-Point Mounting Technique Oil Pressure Gauge Tap 1/2 NPT Adjust pump angle to achieve proper driveline angles (See Table 4). 1/2 Mounting Screws, Grade 5 Minimum (One bolt on each side of adapter - 4 per pump) 3/4 Mounting Screws, Grade 5 Minimum For Three-Point Suspension. Use single screw on driver's side. 3/4 Mounting Screws, Grade 5 Minimum F-1031, Section Page 7 of 19
CGVG Series Pumps with K Series Transmission Drive Line Angles Select a mounting location which will make the pump and its accessories readily accessible for maintenance and which will make the pump driveshaft parallel with the output shaft of the chassis transmission or transfer case. Also, select the location so that when the apparatus is loaded, the universal joints on the propeller shaft will have a proper working angle. Table 5 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 determine proper shaft angles. Be sure to keep at least a minimum of 1 U-joint operating angle, but do not exceed those specified 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 Installation Techniques. CAUTION Be sure the propeller shafts used are of the slip-joint design. Frame deflection, temperature changes and similar factors may cause a propeller shaft without slipjoints to produce severe axial loads on the bearings and damage the pump / transmission. Figure 9 shows a typical installation of a CGVGK where the pump is mounted on angle brackets attached to the outside of the chassis frame rails. To mount the pump, create angle brackets that will attach the pump to the vehicle's chassis. The CGVGK is equipped with two (2).563 (9/16) in. through holes on each side of the crosspipe. To help create the angle brackets, Figure 13, Pump Mounting Holes in Angle Brackets, shows the locations of the holes in the crosspipe. Drill a suitably sized hole in the angle bracket where the corresponding hole in the crosspipe is located. Using only one tapped hole on each side of the adapter, fasten the angle bracket to the pump. Repeat this procedure for each side of the pump. Fasten the angle brackets to the chassis frame rails using a 3-point mounting technique shown in Figure 10. This mounting technique allows for slight truck frame twist. NOTE: Tighten the mounting screws to standard torque specifications. Figure 9. CGVGK Mounting Diagram Table 5. 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 the table above are the maximum U-joint operating angles recommended by Waterous and are directly related to the speed of the driveshaft. Any U-joint operating angle greater than 3 will lower the U-joint life and may cause vibration 1. 1 From Spicer Driveshaft Installation Techniques, Form J-3311. Figure 10. CGVGK 3-Point Mounting Technique Adjust pump angle to 1/2 Mounting Screws, achieve proper Grade 5 Minimum driveline angles (One bolt on each side of (See Table 4). adapter - 4 per pump) 3/4 Mounting Screws, Grade 5 Minimum For Three-Point Suspension. Use single screw on driver's side. 3/4 Mounting Screws, Grade 5 Minimum F-1031, Section Page 8 of 19
CGVG Series Pumps with PA Series Transmission Drive Line Angles Select a mounting location which will make the pump and its accessories readily accessible for maintenance and which will make the pump driveshaft parallel with the output shaft of the chassis transmission or transfer case. Also, select the location so that when the apparatus is loaded, the universal joints on the propeller shaft will have a proper working angle. Table 6 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 determine proper shaft angles. Be sure to keep at least a minimum of 1 U-joint operating angle, but do not exceed those specified 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 Installation Techniques. Figure 11 shows a typical installation of a CGVGPA where the pump is mounted on angle brackets attached to the outside of the chassis frame rails. To mount the pump, create angle brackets that will attach the pump to the vehicle's chassis. The CGVGPA is equipped with two (2).563 (9/16) in. through holes on each side of the crosspipe. To help create the angle brackets, Figure 13, Pump Mounting Holes in Angle Brackets, shows the locations of the holes in the crosspipe. Drill a suitably sized hole in the angle bracket where the corresponding hole in the crosspipe is located. Using only one tapped hole on each side of the adapter, fasten the angle bracket to the pump. Repeat this procedure for each side of the pump. Fasten the angle brackets to the chassis frame rails using a 3-point mounting technique shown in Figure 12. This mounting technique allows for slight truck frame twist. NOTE: Tighten the mounting screws to standard torque specifications. Figure 11. CGVGPA Mounting Diagram CAUTION Be sure the propeller shafts used are of the slip-joint design. Frame deflection, temperature changes and similar factors may cause a propeller shaft without slipjoints to produce severe axial loads on the bearings and damage the pump / transmission. Driveshaft RPM Table 6. Maximum U-joint Operating Angles 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 the table above are the maximum U-joint operating angles recommended by Waterous and are directly related to the speed of thedriveshaft. Any U-joint operating angle greater than 3 will lower the U-joint life and may cause vibration 1. 1 From Spicer Driveshaft Installation Techniques, Form J-3311. Anti-seize should be applied to the shaft threads before installing end yoke or companion Angle brackets flange. on both sides Do (See not Figure reuse 13 selflocking Holes) nuts. Torque on Page 10 for Mounting to 275-325 lb-ft. Anti-seize should be applied to the shaft threads before installing end yoke or companion flange. Do not reuse self-locking nuts, Torque to 275-325 lb-ft. Figure 12. CGVGPA 3-Point Mounting Technique Adjust pump angle to achieve proper driveline angles (See Table 4). 1/2 Mounting Screws, Grade 5 Minimum (One bolt on each side of adapter - 4 per pump) 3/4 Mounting Screws, Grade 5 Minimum For Three-Point Suspension. Use single screw on driver's side. 3/4 Mounting Screws, Grade 5 Minimum F-1031, Section Page 9 of 19
Figure 11. Pump Mounting Holes in Angle Brackets for CGVG Pump Models The pump has two mounting hole locations on each side of the crosspipe. Drill suitably sized holes in angle brackets for 1/2 in. Grade 5 screws. Angle Bracket CL Intake C L Chassis Chassi s Frame Rail 1/2 in. Cap Screws (Grade 5 minimum) (Two required on each side) Mounting Hardware Used to Attach Pump to Chassis Frame Rails NOTE: Waterous does not provide hardware to mount the pump to frame rails. OEM must provide mounting hardware as follows: 1. Use two (2) 1/2 in. (Grade 5 minimum) cap screws on each side of the pump. 2. Provide a method to restrain cap screw (lock washers and / or thread-locking compound). 3. Tighten cap screws to standard torque specifications for 1/2 in. cap screws. F-1031, Section Page 10 of 19
CGV, CGVN, CGVR Series Pumps with C20 Series Transmission Table 7. C20 Series Transmission Drop Ranges Model Dim A. (IN/mm) C20B 12.240 / 310.90 C20C 13.811 / 350.80 C20D 14.856 / 377.34 C20E 16.920 / 429.77 C20F 18.971 / 481.86 *NOTE: 2.27 ratio drop values shown. Drop values vary for other output ratios, see dimensional drawings for specific drops by ratio. Drop Dimensions NOTE: Remove shipping brackets and discard. Do not use for mounting pump. Select a mounting location which will make the pump and its accessories readily accessible for maintenance and which will make the pump driveshaft parallel with the output shaft of the chassis transmission or transfer case. Also, select the location so that when the apparatus is loaded, the universal joints on the propeller shaft will have a proper working angle. Note that the C20 Series transmission is available with a range of drop sizes (see Table 7 and Figure 14, Dimension A ). Figure 14. Drop Size Dimensions Drive Line Angles Table 8 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 determine proper shaft angles. Be sure to keep at least a minimum of 1 U-joint operating angle, but do not exceed those specified 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 Installation Techniques. CAUTION Be sure the propeller shafts used are of the slip-joint design. Frame deflection, temperature changes and similar factors may cause a propeller shaft without slipjoints to produce severe axial loads on the bearings and damage the pump / transmission. Table 8. 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 the table above are the maximum U-joint operating angles recommended by Waterous and are directly related to the speed of the driveshaft. Any U-joint operating angle greater than 3 will lower the U-joint life and may cause vibration 1. 1 From Spicer Driveshaft Installation Techniques, Form J-3311. F-1031, Section Page 11 of 19
CGV, CGVN and CGVR Series Pumps with C20 Series Transmission Figures 14 and 16 shows the mounting areas on CGV, CGVN and CGVR pumps. There are mounting holes on the output side of the transmission as well as the pump intake. To mount the pump/transmission to the vehicle chassis, attach brackets (not supplied by Waterous) on either side of the transmission. Position the pump/transmission within the vehicle frame rails, blocking temporarily to provide correct shaft angularity. With the pump/transmission in the correct position, secure the brackets (not supplied) to the vehicle frame using a three point mounting technique. The bracket on one side of the transmission shall use only one bolt when attaching to the rail. The bracket on the other side of the transmission should be attached to the chassis rail using two bolts. This three point technique will allow for slight vehicle frame twist without undue stress on the pump/transmission assembly. The transmission cap also contains five (5) mounting holes for further support of the CGVC20, CGVNC20 or the CGVRC20. Support the pump by fashioning a bracket (not supplied by Waterous) and mount it to the intake side of the pump using the existing intake mounting screw holes. NOTE: You will need to remove one or more intake mounting screws from the intake side of the pump and replace them with longer screws to compensate for the thickness of the bracket. NOTE: Tighten the mounting screws to standard torque specifications. Connect shift unit per installation instruction F-1031, Section 3030. Figure 15. CGVC20, CGVNC20, CGVRC20 Dimensions F-1031, Section Page 12 of 19
CGV, CGVN and CGVR Series Pumps with C20 Series Transmission Figure 16. CGVC20, CGVNC20, CGVRC20 Mounting Mounting Holes on Transmission Five (5) Mounting Holes (3/8-16 UNC-2B x.563 Deep) Four (4) Mounting Holes (5/8-11 UNC-2B x.938 Deep) (2 Holes on each side of tranmission) Mounting Holes on Pump Intake Remove the screw(s) and install bracket (not supplied by Waterous). Tighten bracket to intake of the pump using 7/16 screw(s). NOTE: Use longer 7/16 in. screws to secure bracket to the pump than were originally supplied with the pump to compensate for the thickness of the bracket. IL1932 Anti-seize should be applied to the shaft threads before installing end yoke or companion flange. Do not reuse self-locking nuts, Torque to 475-525 lb-ft. Sixteen (16) 7/16-14 UNC Intake Mounting Screws (Torque to 50 ft-lb) F-1031, Section Page 13 of 19
with K Series Transmission CGV, CGVN and CGVR Series Pumps with K Series Transmission Figure 17 shows the mounting areas on a CGV, CGVN and CGVR pumps. To mount the pump/transmission to the vehicle chassis, fashion a bracket that will span the frame rails of the vehicle and attach to the transmission mounting holes (several locations are provided). NOTE: Before installation, make sure your pump has the right rotation as compared to the driveshaft rotation (see dimensional drawings for correct rotation configurations). Support the pump by fashioning a bracket (not supplied by Waterous) and mount it to the intake side of the pump using the existing intake mounting screw holes. NOTE: You will need to remove one or more intake mounting screws from the intake side of the pump and replace them with longer screws to compensate for the thickness of the bracket. NOTE: Tighten the mounting screws to standard torque specifications. Position the pump/transmission within the vehicle frame rails, blocking temporarily to provide correct shaft angularity. With the pump/transmission in the correct position, secure the brackets (not supplied) to the vehicle frame. Finally, provide adequate support for any intake and discharge piping assemblies. Figure 17. CGVK, CGVNK and CGVRK Mounting Diagram Mounting Holes on Pump Intake Remove the screw(s) and install bracket (not supplied by Waterous). Tighten bracket to the intake of the pump using 7/16 in. screw(s). NOTE: Use longer 7/16 in. screws to secure the bracket to the pump than were originally supplied with the pump to compensate for the thickness of the bracket. Mounting Holes on Transmission IL1932 Sixteen (16) 7/16-14 UNC Intake Mounting Screws (Torque to 50 ft-lb) F-1031, Section Page 14 of 19
with K Series Transmission - Optional Suspension Pin Mounting (K520) An optional mounting technique on the CG Series Pumps is the Suspension Pin Mounting Kit. The kit consists of a bracket, two 7/16 screws, two lock-washers, two cotter pins and the suspension pin. To mount the transmission using the kit, follow the instructions below: 1. Mount the bracket to the transmission using the top two mounting holes. Secure the bracket with the two 7/16 screws and lockwashers. 2. Insert the suspension pin into the bracket. 3. Line up hole in the bracket with the hole in the suspension pin and insert a cotter pin. 4. Fashion a bracket that will span the vehicle s chassis. Cut out a hole in the bracket that will allow the suspension pin to pass through. 5. Install the bracket on the suspension pin and hold in place by inserting a cotter pin through the hole on the suspension pin. Figure 18. Optional Suspension Pin (K520) F-1031, Section Page 15 of 19
CGV, CGVN and CGVR Series Pumps with PA Series Transmission Figure 19 shows the mounting areas on a CG Series Pump. To mount the pump/transmission to the vehicle chassis, fashion a bracket that will span the rails of the vehicle and attach to the transmission mounting holes. Position the pump/transmission within the vehicle frame rails, blocking tempoprovide correct shaft angularity. With the pump/transmission in the position, secure the brackets (not supplied) to the vehicle. Support the pump by fashioning a bracket (not supplied by Waterous) and mount it to the the intake side of the pump using the existing intake mounting frame screw holes. NOTE: You will need to remove one or more intake mounting screws rarily to from the intake side of the pump and replace them with longer screws to correct compensate for the thickness of the bracket. NOTE: Tighten the mounting screws to standard torque specifications. Finally, provide adequate support for any intake and discharge piping assemblies. Figure 19. CGVPA, CGVNPA and CGVRPA Mounting Diagram Mounting Holes on Pump Intake Remove the screw(s) and install bracket (not supplied by Waterous). Tighten bracket to the intake of the pump using 7/16 in. screw(s). NOTE: Use longer 7/16 in. screws to secure the bracket to the pump than were originally supplied with the pump to compensate for the thickness of the bracket. Mounting Holes on Transmission Eight (8) Mounting Holes Intake Side of CG pump IL1932 Sixteen (16) 7/16-14 UNC Intake Mounting Screws (Torque to 50 ft-lb) Anti-seize be applied to the shaft threads before installing end yoke or companion flange. Do not reuse self-locking nuts. Torque to 275-325 lb.-ft. F-1031, Section Page 16 of 19
CGV, CGVN and CGVR Series Pumps with T Series Transmission Figure 20 shows the CG Series Pump equipped with a T Transmission. The CGVT, CGVNT or CGVRT is a direct-engine mounted pump. The bellhousing attaches to the vehicles flywheel housing. NOTE: The design of the T transmission relies on the engine flywheel to control the axial and radial movement of the drive shaft. Prior to installation on the engine, the allowable axial movement of the pump drive (input) shaft is.273 in. (7 mm). NOTE: Before installation, make sure your pump has the right rotation as compared to the driveshaft rotation (see dimensional drawings for correct rotation configurations). To install the CGT pump, perform the following: 1. Supply input shaft support bearing. 2. Install the drive plate assembly according to the manufacturer s instructions. 3. With a suitable hoist, guide the pump drive shaft into the drive plate and pilot bearing. Align screws holes in the pump mounting flange with those in the flywheel housing. Install the twelve (12) screws and tighten security. 4. Finally, provide adequate support for any intake and discharge piping assemblies. NOTE: Tighten the mounting screws to standard torque specifications. Figure 20. CGVT. CGVNT and CGVRT Mounting Diagram Eight (8) 3/8-16 UNC- 2B Tapped Holes in Flywheel. Use Class 8 Screws. 8 X 3/8-16 UNC-2B TAPPED HOLES IN FLYWHEEL, USE GRADE 8 SCREWS Flywheel for Driving-Ring Type over center clutch per SAE J620. Bearing 1-3/4-10 SAE Spline Drive Plate Bell Housing Adapter Bell Housing Adapter F-1031, Section Page 17 of 19
Optional Corrosion Protection Zinc Intake Screens Waterous offers zinc intake screens that fit 4, 4-1/2, 5 and 6 inch intake fittings sizes. The screen is designed to fit in the counter bore in the inside diameter of the fittings. There must be a strong electrical contact between the screen and the intake fitting. Remove any corrosion, debris or paint from the counter bore that will insulate the screen from the intake fitting. If the screen does not fit tightly, adjust the gap of the slot on the outside diameter of the screen to ensure a tight fit. NOTE: Zinc intake screens are die-cast which results in a slight taper from one side to the other. Install the screen with the thinner cross-section facing out to minimize flow restriction. Zinc Anodes Zinc anodes may be mounted in the intake piping or, if no intake pads are available, in the discharge piping. NOTE: The zinc must make contact with water to be effective. Do not paint or use any other coating on the zinc elements. Zinc anodes are available for the following: Pads machined with 2-1/2 in., 4-bolt mounting patterns Pads machined with 2-1/2 in. or 3 in. NPT taps. Zinc Anodes - Bolt On Pads Machined with 2-1/2 in., 4-bolt Mounting Pattern Pads Machined with 2-1/2 in., 4-bolt Mounting Pattern Zinc Anodes - Threaded Pads Machined with 2-1/2 in., or 3 in. NPT Taps F-1031, Section Page 18 of 19
Tachometer Electronic Tachometer Drive (Optional on C20 Series, Standard on PA Series Transmissions) The magnetic pick-up in the transmission mates with an Amphenol connector (P/N MS3106A-10SL-4S). This connector should be wired to a wall mount receptacle on the operator's panel. Cable assembly 63033 available from Waterous. C20 Series Transmissions: To verify the rotational speed of the drive shaft, the frequency (Hz) reading from the tachometer sensor should be multiplied by 10. Hz x 10 = RPM PA Series Transmissions: To verify the rotational speed of the drive shaft, the frequency (Hz) reading from the tachometer sensor should be multiplied by 6. Hz x 6 = RPM Frequency reading can be measured with hand held multimeter. Cable connector assembly V 3398 available for connecting wall mount receptacle to multimeter. Optional Mechanical Tachometer Drive (K and T Transmissions Only) Install a cable from the tachometer take-off on the driveshaft (front housing of the transmission). Tachometer cable furnished by customer. Stewart Warner or equivalent sealed cable..88 18 USF Thread 0.213/5.41 x.88/22.35 Deep Final Checks After the pump, accessories, piping and miscellaneous connections are completely installed, check the items listed below: Lubrication CAUTION Failure to properly lubricate the pump and transmission may result in serious damage to the equipment. C20 Series Transmission Add any type of automatic transmission fluid (ATF) through the fluid level hole or by removing the breather. Approximately 6 quarts is required to fill the transmission when completely drained. The fluid should be level with bottom of the fluid level hole. WB Series Transmission Add any type of automatic transmission fluid (ATF) through the fluid level hole or by removing the breather. Approximately 6 quarts is required to fill the transmission when completely drained. The fluid should be level with bottom of the fluid level hole. K Series Transmission Add any type of SAE 80W-90 gear oil through the fluid level hole or by removing the breather. Approximately 1 quart is required to fill the transmission when completely drained. The fluid should be level with the bottom of the fluid level hole. PA Series Transmission Add any type of automatic transmission fluid (ATF) through the fluid level hole or by removing the breather. Approximately 1 quart is required to fill the transmission when completely drained. The fluid should be level with bottom of the fluid level hole. T Series Transmission Add any type of SAE 80W-90 gear oil through the fluid level hole or by removing the breather. Approximately 1 quart is required to fill the transmission when completely drained. The fluid should be level with the bottom of the fluid level hole. Testing Tachometer connection driven gear runs at 1/2 propeller shaft speed. Stewart- Warner drive joint of the proper ratio must be used unless tachometer is calibrated for this ratio. Drive rotates clockwise facing connection on transmission. from DPL82074 Perform the tests listed in F-1031, Section 1000, Centrifugal Fire 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. Transmission Temperature Specifications The maximum temperature permitted at transmission external surfaces is 250 F (121 C). F-1031, Section Page 19 of 19