Waterous E500 Series, Operation, Maintenance And Overhaul Instructions

Page 1: ... 10 Impeller Shaft Components Model E501 C Model E511 C 11 12 Gear Case Removal Model E501 C Model E511 C 13 13 Engine Adapter Removal Model E511 C Model E501 C Model E511 C 14 14 Component Inspection Reassembly 15 Read through the safety information and instructions General Overhaul Information Gear Case and Impeller Shaft Mechanical Seal and Impeller 15 15 16 carefully before using your Waterous...

Page 2: ...pressure by opening drains WARNING Death or serious personal injury might occur if proper operating procedures are not followed The pump opera tor 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 hy draulics and component limitation DANGER ...

Page 3: ... 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 WARNING Moving or rotating ...

Page 4: ...ted Avoid potential rubbing and high heat areas and use adequate connectors and re straints to avoid accidental disconnecting of fuel lines 3 The maximum vertical lift the fuel pump can achieve is two feet 610 mm with any length fuel line On diesel engines be sure the return line reaches the bottom of the fuel tank to prevent air bubbles see pump dimensional drawing for fuel return outlet on engin...

Page 5: ...ing units are permanently mounted in an apparatus and attached to rigid piping connections between the pump and the piping should be made with flexible coupling to avoid applying excessive forces to the pump NOTE Refer to the Kubota Instruction Manual for further details on starting the engine Starting the Engine Turn the ignition switch to the RUN position When the preheat countdown reaches 0 tur...

Page 6: ... the procedures in NFPA 1962 MUST be followed including the use of a fire department gate valve with a 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 r...

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Page 8: ... Repair Pump repair should be done by Waterous authorized service personnel Alternatively pump repair parts can be purchased from Waterous Company and installed by any mechanic familiar with pump overhaul and repair practices and procedures Service Parts Lists are provided which give parts descriptions and reference numbers for ordering Be sure to give the pump model serial number and parts list n...

Page 9: ...om gear case E501 C Volute Body Removal E511 C Volute Body Removal Hex Nut 7 16 20 Lock Washer 7 16 in Lock Washer 7 16 in Hex Nut 7 16 20 Hex Hd Screw 7 16 20 x 2 3 4 in Hex Hd Screw 7 16 20 x 3 in Remove 4 hex head screws from the pump volute body Slide the volute body off the gear case cover Wear ring will come off with volute Remove if required The engine and control panel are shown removed fo...

Page 10: ...etaining ring The stationary ring will remain with the gear case cover 3 Drain oil from gear case Magnetic Pipe Plug 3 8 in Retaining Ring E501 C Gear Case Cover and Impeller Shaft Removal 1 Remove the impeller gasket 2 Remove the 10 hex head screws and lock washers from the gear case cover 3 Remove the gear case cover from the gear case Press out the impeller shaft and bear ing assembly from the ...

Page 11: ...e cover from the gear case Press out the impeller shaft and bear ing assembly from the gear case cover 3 Remove gear case gasket 4 Press out the mechanical seal stationary seal ring oil seal Pull wear ring if required Oil Seal Stationary Ring O ring Impeller Shaft and Bearing Assembly Gear Case Gasket Gear Case Cover Wear Ring Lock Washer 3 8 in Hex Hd Screw 3 8 16 x 1 in ...

Page 12: ...ing a suitable sleeve press the bearing off the impeller end of the shaft _________________________________________________________________________________ E501 C Impeller Shaft Components After August 2 2017 1 The impeller shaft assembly with the ball bearings should not require disassembly unless inspection reveals wear of the ball bearings 2 Using a suitable sleeve press the bearings off the im...

Page 13: ..._____________________________________________________________________ E511 C Impeller Shaft Components After August 8 2017 1 The impeller shaft assembly with the ball bearing should not require disassembly unless inspection reveals wear of the ball bearing 2 If removing the ball bearing grease the shaft surface then using a suitable sleeve press the bearing off the impeller end of the shaft Note T...

Page 14: ...ear case to the engine adapter 7 Removethegearcase Pressouttheoilseal Shaft is already out of case 8 Clean the magnetic drain plug and check to be sure the breather is not plugged E501 C and E511 C Gear Case Removal After to August 8 2017 1 Remove the drive gear shaft assembly 2 Remove bearings from the drive shaft 3 Remove the self locking nut that holds the drive gear to the driveshaft 4 Press t...

Page 15: ...dapter and the drive plate assembly should not require disassembly unless inspection reveals wear of the drive plate 1 Remove the M10 and 5 16 bolts from the engine adapter to separate the engine adapter from the engine 2 Separate the drive plate from the engine by removing the M8 screws ...

Page 16: ... Be sure that the seal shaft and gear case are clean Always install a seal with the seal lip facing in Apply force to the outer edge of the seal and press in evenly b Lubricate all O rings when installing c When installing mechanical seal stationary ring be careful not to scratch the sealing surface that contacts the polished primary ring d If replacing a needle bearing be sure the inner race matc...

Page 17: ...er grease bearing surface of shaft and quickly place bearing onto shaft The bearing should slide onto shaft freely or with a very light force until bearing rests against the shaft shoulder Al low shaft to sit for a few minutes at room tem perature before installing in pump c Warm the bearing with even heat i e hot plate to a temperature of 250 300_F hot to the touch With the shaft surface greased ...

Page 18: ...ows assembly with mechanical seal lubricant Install bellows assembly onto impeller hub with the primary ring facing away from the impeller Make sure the pri mary ring stays in its retainer use a small amount of grease on the backside of the primary ring as needed to keep the ring in place 3 Clean the sealing surface of mechanical seal primary ring with soft cloth and denatured alcohol 4 Place key ...

Page 19: ...to keep the ring in place Clean the seal ing surface of mechanical seal primary ring with soft cloth and denatured alcohol Install the bellows as sembly seal spring and spring collar onto the impeller shaft with primary ring facing the stationary ring Push assembly evenly using collar until primary ring con tacts the stationary ring 2 Install new retaining ring Do not reuse the old retain ing ring...

Page 20: ...oller harness WH00023 Make sure the 3 pin MPU connector is properly connected and the 3 8 ring from the 2 pin MPU connector is grounded to the block This connector provides ground to the controller Check for backed out terminals in 12 pin Deutsch connectors Look closely at pin 1 ground and pin 3 battery If equipped with auxiliary controller check for backed out pins in WH00024 auxiliary controller...

Page 21: ...power and run signal but doesn t energize the W 14 wire replace the timer The timer also is responsible for returning the speed control lever to idle If the timer is bad the speed will not automatically return to idle at shutdown Engine Speed Doesn t Respond To Input Make sure 2 pin speed control connector and 3 pin MPU connector are connected to their mating connectors on engine harness or auxili...

Page 22: ...rank 3 Battery Power protected by 20A fuse 4 Idle Return Signal 5 Run Signal provides power to the following a Energize To Stop Timer b Alternator Ignition Terminal 6 Tachometer Not Used 7 Glow 8 Fuel Level Sender 9 Oil Gauge Sender Signal 10 Oil Gauge Sender Signal 11 Temp Gauge Sender Signal 12 Temp Gauge Sender Signal ...