CH-4 Series Fire Pumps Overhaul Instructions

CH-4 Series Fire Pumps Overhaul Instructions Table of Contents Model CHK-4, Transmission Driven (The pump is turned by a K-Series Transmission mounted directly to the pump.) Introduction... 2 Ordering Repair Parts... 2 Tools Available from Waterous... 2 Safety Information... 3 General Overhaul Information... 5 Pump Overhaul: Complete Disassembly of Pump... See Table A on Page 6 Replacement of Mechanical Seals or Packing without Disassembling the pump... See Table B on Page 6 K Series Transmission Overhaul... See F-1031, Section 4309 Cross-Section Diagrams of Pumps: Pumps with Mechanical Seals: Model CHK-4... 33 Model CHD-4... 34 Pumps with Packing: Model CHK-4... 35 Model CHD-4... 36 Read through the safety information and overhaul instructions carefully before repairing your Waterous CH-4 Series Fire Pump. Model CHD-4, Direct Drive (The pump is turned by a companion flange on the impeller shaft.) NOTE: Instructions subject to change without notice F-1031, Section 4316 (Issued: 07/12/12 ) Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000 www.waterousco.com

Introduction This instruction provides the necessary steps to overhaul CH-4 Series Fire Pumps. If the entire pump is being overhauled, see Table A on Page 6. If only the pump seals are being replaced, see Table B on Page 6. CHK-4 Transmission Drives Only: This instruction covers the removal of K Series Transmission from the pump only. For transmission overhaul instructions, see separate instruction F-1031, Section 4309. Follow the instructions for Extra Heavy Duty Transmissions. Ordering Repair Parts When ordering repair parts, furnish the reference number of the component (from Service Parts List) along with the Pump Model and Serial Number. Refer to the Service Parts List furnished with your pump for identification if individual components. The following repair kits are available for servicing the components identified: Component Pump Model Seal Location Pump Material Repair Kit Includes: Iron K 674 Drive End Bronze K 674-2 CHK-4 Iron K 702-4 Outboard Bearing End Bronze K 702-5 One Mechanical Seal, Mechanical Seal Iron K 674-7 Bearing and Oil Seal Drive End Bronze K 674-8 CHD-4 Iron K 702-4 Outboard Bearing End Bronze K 702-5 (10) Rings, Packing CHK-4 or CHD-4 Drive and Outboard Ends Iron or Bronze K 667-6 (5) for each end F-1031, Section 4316 Page 2 of 36

Special Tools Component Waterous Part No. Includes Mechanical Seal K 628 Tool Kit for Removing and Installing Mechanical Seal Packing 5782 Tool for Removing Packing from Stuffing Box Outboard Bearing K 956 Too Kit for Removing and Installing Outboard Bearing Mechanical Seal Tool Kit K 628 Outboard Bearing Tool Kit K 956 Removal Tool Part No. 62896 (Place over removal tool threads for storage.) Installation Sleeve Part No. 52880 Brush Part No. V2633 Note that these tools may be fabricated by mechanic. Removal Tool Part No. 72385 Packing Removal Tool 5782 IL1931 F-1031, Section 4316 Page 3 of 36

Safety Information Please read through the safety information and operating instructions carefully before using your Waterous Fire Pump.! WARNING! WARNING Death or serious personal injury might occur if proper operating procedures are not followed. The pump operator, as well as individuals connecting supply or discharge hoses to the apparatus must be familiar with these pump operating instructions as well as other operating instructions and manuals for the apparatus, water hydraulics and component limitation. Unexpected Truck Movement. May result in serious 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 serious 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 Scalding Water Hazard. May result in serious burns. When operating the pump, be sure to open at least one discharge valve slightly to prevent the pump from overheating. If the pump runs for a few minutes completely closed, it may heat the water enough to scald someone when the valve is opened. Overheating can damage the packing, seals and other pump parts. If the apparatus builder has installed a by-pass system or other provision designed to prevent overheating, opening a discharge valve may be unnecessary.! WARNING! WARNING Packing Gland and Pump Body Temperature Hazard. 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. F-1031, Section 4316 Page 4 of 36

General Overhaul Information Tools and Equipment The following tools and equipment may be 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 available from the apparatus manufacturer or the Waterous Company. These special items are not absolutely necessary, but they will make the mechanic'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. Excessive 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 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. Pump Bodies and Impellers Flush out these components and related parts with clean water and remove loose scale, caked sediment, etc. Be sure to remove all traces of old gaskets. 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 maintenance, or from freezing. Replace defective parts. Bearings, Gaskets, Seals and O-rings Parts of this nature are frequently damaged during removal or disassembly. 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 longitudinal 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 necessary 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. End Yoke and Companion Flange Nuts Do not reuse self-locking nuts. Apply lubrication oil to the threads before removing. Apply anti-seize to the threads before installing a new self- locking nut. Gaskets To provide added sealing for gaskets between body halves, coat both sides of these gaskets with a suitable sealant. A compound such as Permatex Super 300 is recommended for this application. Be sure all traces of previous gaskets and sealant are removed before installing new gaskets. F-1031, Section 4316 Page 5 of 36

Table A Complete Disassembly of Pump Overhaul Operation See Page CHK-4 CHD-4 Safety Information 4 4 General Information 5 5 Transmission 7 -- Direct Drive End -- 8 Outboard Bearing 9 10 Removal Impeller Shaft 12 12 Mechanical Seals 13 13 Packing 15 15 Impeller and Wear rings 16 16 Undersize Wear Rings 17 17 Impeller and Wear Rings 18 18 Impeller Shaft 21 21 Installation Packing 22 22 Mechanical Seals 23-24 23-24 Outboard Bearing 26 26-27 Transmission 29 -- Direct Drive End -- 30 Final Assembly Steps 31 31 Packing Adjustment 31 31 Vacuum Test (Pumps with Packing) 32 32 Hydrostatic Test 32 32 Dynamic Test 32 32 Table B Replacement of Mechanical Seals or Packing without Disassembly Pump Type of Seal Mechanical Seals Packing Overhaul Operation See Page CHK-4 CHD-4 Safety Information 4 4 General Information 5 5 Transmission 7 -- Removal Direct Drive End -- 8 Outboard Bearing 9 10 Seals 14 14 Seals 23-24 23-24 Installation Outboard Bearing 26 27 Transmission 29 -- Direct Drive End -- 30 Final Assembly Steps 31 31 Hydrostatic Test 31 31 Dynamic Test 31 31 Safety Information 4 4 General Information 5 5 Packing Removal 15 15 Installation 22 22 Final Assembly Steps 31 31 Packing Adjustment 31 31 Vacuum Test 32 32 Hydrostatic Test 32 32 Dynamic Test 32 32 F-1031, Section 4316 Page 6 of 36

Complete Disassembly of the Pump Transmission Removal 1. Remove the four (4) screws attaching the transmission to the pump. 2. Pull the transmission out and away from the pump to disengage the splined shaft connection. (4) Hex Head Screws and Lockwashers F-1031, Section 4316 Page 7 of 36

Direct Drive End Removal 1. Remove the companion flange or end yoke from the shaft. 2. Remove the four (4) screws attaching the bearing cover and remove the cover. 3. Remove the four (4) screws attaching the bearing housing to the pump. 4. Place two (2) 1/2-13 UNC screws in the jacking screw holes. 5. Remove bearing and oil seal from bearing housing. Completely clean bearing housing removing all grease. 6. Remove the V-ring flinger from the shaft. V-ring Flinger Oil Seal Bearing Housing Cover Gasket Bearing Bearing Cover Jacking Screw Hole, One on each side. Oil Seal Companion Flange or End Yoke F-1031, Section 4316 Page 8 of 36

Outboard Bearing Removal (CHK-4) 1. Remove the four (4) screws attaching the bearing cover and remove the cover. 2. Remove the four (4) screws attaching the bearing housing to the pump. 3. Remove the retaining ring in front of the bearing. 4. Remove outboard bearing using hub puller from outboard bearing removal tool kit K 956. See Page 11 for instructions and diagram. 5. Pumps with Mechanical Seals only: a. Remove the retaining ring behind the bearing. Note that this ring is not used on pumps sealed with packing. The bearing seats against a shoulder on the shaft. 6. Remove the V-ring flinger from the shaft. 7. Remove bearing and oil seal from bearing housing. Completely clean bearing housing removing all grease. Bearing Cover Retaining Ring in Front of Bearing Bearing Retaining Ring Behind Bearing (Pumps with Mechanical Seals Only) Bearing Bearing Housing Oil Seal V-ring Flinger F-1031, Section 4316 Page 9 of 36

Outboard Bearing Removal (Model CHD-4) Pump with Mechanical Seals 1. Remove the four (4) screws attaching the bearing cover and remove the cover. 2. Remove the four (4) screws attaching the bearing housing to the pump. 3. Remove the retaining ring in front of the bearing. 4. Remove outboard bearing using hub puller from outboard bearing removal tool kit k 956. See Page 11 for instructions and diagram. 5. Remove the retaining ring behind the bearing. Note that this ring is not used on pumps sealed with packing. The bearing seats against a shoulder on the shaft. 6. Remove bearing and oil seal from bearing housing. Completely clean bearing housing removing all grease. 7. Remove the V-ring flinger from the shaft. Pump with Packing (Hub Puller may not be used) 1. Remove the four (4) screws attaching the bearing cover and remove the cover. 2. Remove bearing locknut and washer from shaft. 3. Remove the four (4) screws attaching the bearing housing to the pump. 4. Place two (2) 1/2-13 UNC screws in the jacking screw holes. Use the screw to remove the bearing housing from the shaft. 5. Remove bearing and oil seal from bearing housing. Completely clean bearing housing removing all grease. 6. Remove the V-ring flinger from the shaft. Bearing Cover Bearing Locknut and Washer Bearing Cover Retaining Ring in Front of Bearing Bearing Retaining Ring Behind Bearing (Pumps with Mechanical Seals Only) Previous Flinger Ring Configurations Bearing Cover Gasket Cover Gasket Bearing Housing Oil Seal V-ring Flinger Bearing Housing Oil Seal Current V-ring Flinger F-1031, Section 4316 Page 10 of 36

Outboard Bearing Removal using Hub Puller from Took Kit K 956 The outboard bearing hub puller is included in Waterous tool kit K 956. The puller may be fabricated. See Page 3 for dimensions. 1. Remove the outer retaining ring from the shaft. 2. Attach hub puller to bearing housing. 3. Tighten the hub puller screw which will cause the bearing housing to pull the bearing off of the shaft. Hub Puller Bearing Housing Do Not Damage Internal Threads in Shaft Hub Puller Screw Remove Outer Retaining Ring F-1031, Section 4316 Page 11 of 36

Impeller Shaft Removal 1. Note the position of the drive and outboard ends of the impeller shaft relative to the pump body as this will aid in the reassembly of the pump. 2. Remove seal chamber covers (pumps with mechanical seals) or packing glands (pumps with packing) from both ends of the pump. 3. Remove the (33) screws attaching the two body halves. Seal Cover / Packing Gland Removal 4. Install two (2) 1/2-13 UNC screws in the jacking screw holes and tighten to separate the body halves. 5. Lift the upper body halve off of the lower body halve. 6. Lift the impeller shaft out of the body. 7. Remove all traces of the gasket from the body halves. 8. Clean out cooling water passageways to body stuffing boxes. Separate Body Halves / Remove Impeller Shaft Seal Chamber (Mechanical Seal Pumps) Seal Chamber Cover (Mechanical Seal Pumps) Upper Body Packing Gland Body Gasket Packing Gland Cleaning Cooling Line Passageways Impeller Shaft Lower Body Clean out these passageways F-1031, Section 4316 Page 12 of 36

Mechanical Seal Removal Complete Disassembly of Pump (Impeller Shaft Removed) 1. Slide the mechanical seal off both ends of the shaft. 2. Thoroughly clean the shaft journals on both ends of the pump. 3. Remove the seal stationary ring, throttle bushing (iron pumps only) and gasket from both seal chamber covers previously removed. Mechanical Seal Impeller Shaft Mechanical Seal F-1031, Section 4316 Page 13 of 36

Mechanical Seal Removal (Continued) Pump was not Disassembled (Impeller Shaft Not Removed) NOTES: a. These instructions are written based on the use of Waterous mechanical seal removal/installation tool kit K 628. See Page 3 for components of tool. b. Always replace both seals on the pump. 1. Remove the eight (8) screws attaching the seal chamber cover to the pump body. See page 12. 2. Remove the seal chamber covers from both ends of the pump. 3. Remove the seal stationary ring, throttle bushing (iron pumps only) and gasket from both seal chamber covers. 4. Clean the impeller shaft using brush included in tool kit K 628. 5. Attach the seal removal tool to the pump body and two of the bearing housing mounting screws and nuts. Tighten the screws finger tight only. The tool plate must be flush with the pump body. 6. Turn the hex head on the tool clockwise until it contacts the seal. Turn an additional 1 to 1-1/2 inches further to slide the tool under the seal. Use sufficient force to force the tool under the seal. Note that the seal may break during this operation. 7. Turn the hex nut on the tool counter-clockwise to pull the seal out of the pump seal chamber. 8. Remove the tool and seal from the pump. 9. Remove the seal spring and spring retainer if they remained in the pump. 10. Clean the pump seal chamber and the face where the seal chamber cover mounts. 11. Repeat the process for seal on other end of the pump, Mechanical Seal Removal Tool Seal Removal Tool Tool Hex Nut F-1031, Section 4316 Page 14 of 36

Packing Removal Complete Disassembly of Pump (Impeller Shaft Removed) 1. Remove the packing rings from both ends of the shaft. 2. Clean the shaft journals. 3. Remove all remnants of the packing from the pump body stuffing boxes. Pump was not Disassembled (Impeller Shaft Not Removed) 1. Remove the packing gland from one end of the pump. 2. Engage the pump per appropriate operating instructions. Gradually increase the discharge pressure until the packing rings are forced out of the pump body stuffing box. Pressure in excess of 300 psi (20.7 bar) may be required. 3. If all the packing is not forced out, the remaining packing must be removed by hand using a pick or similar device. Waterous packing removal tool part no. 5782 may be used. See Page 3. 4. Ensure all remnants of the old packing have been removed from the pump body stuffing box and the shaft journal is clean. 5. Repeat this process for the packing on the opposite end of the pump. F-1031, Section 4316 Page 15 of 36

1. Remove stuffing box ends on each side of the impeller. 2. Remove wear rings on each side of the impeller. 3. Remove retaining rings on each side of the impeller. 4. Slide the impeller off of the shaft. 5. Remove the impeller key from the shaft. Stuffing Box End Wear Ring Impeller and Wear Ring Removal Retaining Ring Impeller Shaft Impeller Key Retaining Ring Wear Ring Stuffing Box End F-1031, Section 4316 Page 16 of 36

Installing Undersize Wear Rings 1. Check wear rings and impeller hubs for deep grooves or scratches. 2. If inspections shows that the wear ring clearances are excessive (diametral clearance in excess of.025 inches), or if the impeller hubs are scored or grooved, use the dimensions in the tables to rework the hubs. 3. The diametral clearance is determined by averaging the results of four measurements taken at 90 increments as follows: c. Clean and remove small burrs and other protrusions from the wear ring inner diameters and the impeller hubs. d. Position each wear ring on the impeller hub on which it was used. e. Hold the wear ring firmly against one side of the hub and measure total clearance on the opposite side using a feeler gauge. 4. Wear ring clearance is restored by turning impeller hubs and installing undersize wear rings. 5. Wear rings are available 0.025, 0.050 or 0.075 inches undersize. The table lists the original hub dimension for the impeller and the rework dimensions for each degree of undersize. Original Hub Dia Original Wear Ring No. Undersize Reworked Hub Dia. New Wear Ring No. 5.459 / 5.493 in. 72474 0.25 in. 0.50 in. 0.75 in. 5.472 / 5.471 72474-25 5.447 / 5.446 72474-50 5.422 / 5.421 72474-75 F-1031, Section 4316 Page 17 of 36

Impeller and Wear Ring Installation 1. Install the impeller key in the shaft. 2. Determine the rotation of the impeller. The direction the impeller rotates differs based on pump drive and input rotation. See Page 19 (CHK-4 Models) and Page 20 (CHD-4 Models) for diagrams to determine impeller rotation. 3. Slide the impeller onto the shaft and over the key. 4. Install one retaining ring on each side of the impeller. 5. Install one wear ring on each side of the impeller. 6. Install one stuffing box end on each side of the impeller. Impeller Stuffing Box End Wear Ring Wear Ring Stuffing Box End Impeller Shaft Key F-1031, Section 4316 Page 18 of 36

Determining Impeller Rotation, CHK-4 Pump Models Impeller and Wear Ring Installation (Continued) The direction the impeller rotates differs based on the input rotation of the drive end. Use the diagram below to determine the proper impeller rotation for your drive configuration. F-1031, Section 4316 Page 19 of 36

Determining Impeller Rotation, CHD-4 Pump Models Impeller and Wear Ring Installation (Continued) The direction the impeller rotates differs based on the input rotation of the drive end. Use the diagram below to determine the proper impeller rotation for your drive configuration. F-1031, Section 4316 Page 20 of 36

Reassembly of the Pump Impeller Shaft Installation 1. Install a new body gasket. Coat both sides with Permatex Super 300 or similar compound. 2. Install impeller shaft in pump body ensuring the drive end is located correctly (See diagrams on Page 19 for CHK-4 Models and Page 20 for CHD-4 Models). 3. Install the upper body half onto the lower body half taking care to align dowel pins in flange and impeller wear rings in the pump body bores. 4. Install the (33) screws, lockwashers and nuts in the body flange. Torque to 85 lb-ft (116 N m). (33) 1/2-20 x 2-1/2 in. Hex Head Screws, Lockwashers and Nuts Upper Body Body Gasket Impeller Shaft Dowel Pin Lower Body Dowel Pin F-1031, Section 4316 Page 21 of 36

Packing Installation 1. Before installation of the new packing, ensure all remnants of the old packing have been removed from the pump body stuffing boxes and the shaft journals are clean. 2. Lightly lubricate the outside diameters of the new packing rings with mineral oil, automotive grease or engine oil. 3. Carefully install one ring in the pump body stuffing box. With the aid of the packing gland, push the ring back into the stuffing box as far as possible. 4. Repeat this process for each succeeding ring staggering the ring joints 90 degrees apart. 5. Install rings until there is a 1/8 to 1/4 inch gap between the rings and the face of the pump body stuffing box. This gap is necessary to allow the packing gland to pilot into the stuffing box. 6. install the packing gland, washers and nuts. Note that the milled slot on the nuts should face the gland. 7. Tighten the nuts one flat beyond finger tight. 8. Repeat Steps 1 through 7 for the stuffing box on opposite end of pump. 9. Adjust the packing per instructions on Page 31. 10. Perform the vacuum test as detailed on Page 32. Gland Nut F-1031, Section 4316 Page 22 of 36

Mechanical Seal Installation NOTICE The mechanical seal stationary ring and cartridge carbon ring are made of brittle material. The material can easily be cracked or chipped. Extra care must be taken when handling. NOTICE If Waterous mechanical seal lubricant part no. 52608 is not available, P80 rubber lubricant, straight dish soap or glycerin may be substituted. NOTES: a. Always replace both seals on the pump. b. Replace the Outboard Bearing End seal first followed by the Drive End seal. c. These instructions are written based on the use of Waterous mechanical seal removal/installation tool K 628. See Page 3 for components of tool. d. Once the installation procedure is started on each end, complete without interruption as delays may cause the seal bellows to improperly seat on the shaft. 1. Inspect the new seal bellows carbon ring and stationary ring sealing surfaces. They should be mirror smooth without any scratches. Seal Bellows (with Spring) Separate Seal Stationary Ring 2. Subassemble the seal chamber cover: a. Install a new throttle bushing in the seal chamber cover (iron pumps only, bushing not used on bronze pumps). b. Apply a light coating of lubricant to the O-ring on the seal stationary ring. Install in the seal chamber cover with the sealing surface facing out. Ensure the stationary ring is seated properly and the sealing surface is parallel with the face of the seal chamber cover. c. Wipe the sealing surface of the stationary ring with a clean lint-free cloth or tissue paper to remove any lubricant. d. Install a new gasket in the seal chamber cover. Seal Chamber Cover Gasket Throttle Bushing IL3149 Seal Stationary Ring IL1276 F-1031, Section 4316 Page 23 of 36

Mechanical Seal Installation (Continued) 3. Install the outboard end seal followed by drive end seal: Outboard End Seal Only: a. Install the installation sleeve from tool kit K 628 on the shaft. This allows the seal to slip over the shaft shoulder without being damaged. b. Liberally coat the shaft and installation sleeve with lubricant. Install Seal (Outboard and Drive End): a. Coat the inside of the seal bellows with lubricant. Wipe the sealing surface of the bellows with a clean lint-free cloth or tissue paper to remove any seal lubricant. b. Place the seal spring retainer on the shaft. c. Slide the seal on the shaft using installation tool from tool kit K 628 until contact is made with the shaft shoulder. d. Continue pushing once contact is made until the seal spring is fully compressed. e. Remove the installation tool slowly allowing the spring to relax. Outboard End Seal Only: a. Remove the installation sleeve from the shaft. b. Install the outboard bearing. See Page 26. Spring Retainer Seal Installation Sleeve (Required on Outboard End Only) Installation Tool F-1031, Section 4316 Page 24 of 36

Mechanical Seal Installation (Continued) NOTE: Before proceeding both the outboard and drive end seals should have been installed as well as the outboard bearing. 4. Install the seal chamber cover: a. Ensure the seal stationary ring is installed and is seated properly and the sealing surface is parallel with the face of the seal chamber cover. b. Install the seal chamber cover on the shaft using the installation tool from kit K 628. Slowly push the seal down the shaft until contact with the pump body is made. c. Install the four (4) seal chamber cover screws, plain washers and lockwashers. Torque to 25 lb-ft (34 N m). 5. Turn the impeller shaft at least two revolutions in both a clockwise and counterclockwise direction. This will seat the seals in the pump. 6. Check the impeller shaft / seal chamber cover and pump body seal chamber cover interfaces for leakage on both ends of the pump. a. Fill the pump with water and pressurize to 150 psig. b. Turn the impeller shaft slowly by hand while checking for leaks. c. If leakage persists after one to two minutes of rotation (10 to 12 revolutions) the seals must be removed and reinstalled. Seal Chamber Cover (4) 5/16-18 Socket Head Screws and Washers Installation Tool F-1031, Section 4316 Page 25 of 36

Outboard Bearing Installation (CHK-4 with Mechanical Seals or Packing / CHD-4 with Mechanical Seals) 1. Install the V-ring flinger on the shaft. Note that the flat side of the ring must face inward. 2. Pumps with Mechanical Seals Only: a. Install the inner retaining ring on the shaft. Note that this ring is not used on pumps sealed with packing. The bearing seats against the shoulder on the shaft. 3. Install a new oil seal in the bearing housing. 4. Install the bearing housing on the pump. Install the four (4) screws, lockwashers and nuts. Torque to 85 lb-ft (116 N m). 5. Install the outboard bearing using installation tool from outboard bearing installation tool kit K 956. See Page 28 for instructions and diagram. 6. Install the outer retaining ring. 7. Install the gasket and bearing cover. Ensure a slot is aligned with lubrication fitting. Install the four (4) screws and lockwashers. Torque to 35 lb-ft (48 N m). 8. Fill the bearing housing with a medium consistency ball and roller bearing grease (such as Amoco Super Permalube). Fill until grease is forced out of the relief fitting. Check that the oil seal has not leaked. NOTE: Do not use a power grease gun to fill bearing housing as the oil seal my be dislodged. Bearing Cover Outer Retaining Ring (4) 3/8-16 x 1 in. Hex Head Screws and Lockwashers Outboard Bearing Inner Retaining Ring (Pumps with Mechanical Seals Only) Cover Gasket Bearing Housing Oil Seal V-ring Flinger (4) 1/2-20 x 2 in. Hex Head Screws and Lockwashers F-1031, Section 4316 Page 26 of 36

Outboard Bearing Installation (Model CHD-4 with Packing) 1. Install the V-ring flinger on the shaft. Note that the flat side of the ring must face inward. 2. Pumps with Mechanical Seals Only: a. Install new inner retaining ring on the shaft. Note that this ring is not used on pumps sealed with packing. The bearing seats against a shoulder on the shaft. 3. Install a new oil seal in the bearing housing. 4. Install the bearing housing on the pump. Install four (4) screws, lockwashers and nuts. Torque to 85 lb-ft (116 N m). 5. Install the outboard bearing using installation tool from outboard bearing installation tool kit K 956. See Page 28 for instructions and diagram. 6. Pumps with Mechanical Seals: a. Install the outer retaining ring. 7. Pumps with Packing: a. Install bearing lockwasher and locknut. 8. Install the gasket and bearing cover. Ensure a slot is aligned with lubrication fitting. Install the four (4) screws and lockwashers. Torque to 35 lb-ft (48 N m). 9. Fill the bearing housing with medium consistency ball and roller bearing grease (such as Amoco Super Permalube). Fill until grease is forced out of the relief fitting. Check that the oil seal has not leaked. NOTE: Do not use a power grease gun to fill bearing housing as the oil seal may be dislodged. Bearing Cover Bearing Locknut and Washer (Pumps with Packing) or Retaining Ring (Pumps with Mechanical Seal) Outboard Bearing Cover Gasket (4) 3/8-16 x 1 in. Hex Head Screws and Lockwashers Bearing Housing Oil Seal V-ring Flinger (4) 1/2-20 x 2 in. Hex Head Screws and Lockwashers F-1031, Section 4316 Page 27 of 36

Outboard Bearing Installation using Installation Tool from Tool Kit K 956 The outboard bearing installation tool is included in Waterous tool kit K 956. The installation tool may be fabricated. See Page 3 for dimensions. 1. Assembly the installation tool. Thread the hex nut onto the screw. Install the thrust washer and then thread the installation tool onto the screw. 2. Apply grease to the bearing journal of the shaft. 3. Slide the bearing into the bearing housing until it contacts the shaft. 4. Thread the installation tool screw into the end of the shaft. 5. Turn the hex nut on the installation tool until the bearing is seated against the shaft retaining ring or shoulder. 6. Remove the installation tool from the shaft. Retaining Ring (Pumps with Mechanical Seals Only) Oil Seal Outboard Bearing Installation Tool V-ring Flinger Lubrication Fitting F-1031, Section 4316 Page 28 of 36

Transmission Installation 1. Install the transmission on the pump engaging the splined shaft connection. 2. Install the four (4) screws and lockwashers. Torque to 75 lb-ft (102 N m). (4) 1/2-13 x 1-1/2 in. Hex Head Screws and Lockwashers Transmission F-1031, Section 4316 Page 29 of 36

Direct Drive End Installation 1. Install the V-ring flinger on the shaft. Note that the flat side of the ring must face inward. 2. Install a new oil seal in the bearing housing. 3. Install the bearing housing on the pump. Install the four (4) screws, lockwashers and nuts. Torque to 85 lb-ft (116 N m). 4. Install the outboard bearing: a. Apply grease to the bearing journal of the shaft. b. Press bearing onto shaft and into bearing housing until seated against the shaft shoulder. 5. Install a new oil seal in the bearing cover. 6. Install the gasket and bearing cover. Ensure a slot is aligned with lubrication fitting. Install the four (4) screws and lockwashers. Torque to 35 lb-ft (48 N m). 7. Install the companion flange or end yoke on the shaft with the castle nut/cotter pin or self-locking nut. Torque self-locking nut to 275-325 lb-ft (374-442 N m). 8. Fill the bearing housing with medium consistency ball and roller bearing grease (such as Amoco Super Permalube). Fill until grease is forced out of the relief fitting. Check that the oil seal has not leaked. NOTE: Do not use a power grease gun to fill bearing housing as the oil seal may be dislodged. V-ring Flinger Oil Seal Bearing Housing Cover Gasket Bearing Bearing Cover Oil Seal Companion Flange or End Yoke (4) 1/2-20 x 2 in. Hex Head Screws and Lockwashers Self-Locking Nut (4) 3/8-16 x 1 in. Hex Head Screws and Lockwashers Castle Nut and Cotter Pin F-1031, Section 4316 Page 30 of 36

Final Assembly 1. Connect pump to intake and discharge piping. 2. Connect propeller or drive shaft(s) to pump. 3. Connect cooling and drain lines, electrical wiring and similar equipment to pump and accessories. 4. Model CHK-4 Only: Fill transmission with lubricant as described in K Series operation and maintenance instructions. 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 maintain 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) packing 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 temperatures during this time, the impeller shaft will be protected from heat damage. CAUTION Pump overheating hazard. May cause damage to the pump. Circulate enough water through the pump to prevent overheating.! WARNING Truck movement hazard. May cause serious personal injury. Stop engine, set the parking brake and chock the wheels before going under truck to adjust packing. 1. Engage pump per appropriate operating instructions. Operate the pump at the capacity pressure shown on the serial plate for ten (10) minutes. CAUTION 3. If drip rate is considered high, stop the engine and tighten the packing gland nuts 1/2 to 1 flat (maximum of 1/6 of a revolution). Make appropriate adjustments 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 leakage during the first hour of operation will result in a better seal over a longer period of time. CAUTION Stopping the leakage entirely at this point will cause the packing to overheat. 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.! WARNING Packing Gland and Pump Body Temperature Hazard. 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. 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. Observe the stuffing box drip rate from the side of the truck. 2. Observe leakage. Normal leakage is 10-120 drops per minute. F-1031, Section 4316 Page 31 of 36

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 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. Testing Before a pump is returned to service, it is advisable to give it both hydrostatic and operational tests to check it for leaks and to make sure the pump operates properly. Hydrostatic Testing Operational 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. 1. Operate pump at its 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. F-1031, Section 4316 Page 32 of 36

Cross-Section Diagrams Model CHK-4 with Mechanical Seals F-1031, Section 4316 Page 33 of 36

Model CHD-4 with Mechanical Seals F-1031, Section 4316 Page 34 of 36

Model CHK-4 with Packing F-1031, Section 4316 Page 35 of 36

Model CHD-4 with Packing F-1031, Section 4316 Page 36 of 36