Waterous HL Series, Overhaul Instructions

Page 1: ...epair Parts 4 General Overhaul Information 5 Pump Components 6 Disassembly Index 7 Reassembly Index 8 K Series Transmission Overhaul See F 1031 Section 4309 NOTE Instructions subject to change without...

Page 2: ...into Disassembly and Reassembly sections see Pages 7 and 8 for indexes HL200K HL300K and HL400K Gear Drive Models Only This instruction covers the removal of the K Series Transmission from the pump on...

Page 3: ...nnections 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 ser...

Page 4: ...156 Optional RTP Foam System SPL83157 SPL83157 SPL83157 SPL83157 SPL83157 SPL83157 Optional Control Panel SPL83158 SPL83158 SPL83158 SPL83158 SPL83158 SPL83158 K Series Transmission SPL83160 SPL83160...

Page 5: ...ediment etc Be sure to remove all traces of old gaskets Examine pump bodies covers adapters and fittings for cracks severe corro sion or other damage Almost all damage to these parts results from impr...

Page 6: ...7 Direct Drive Model HL300D Shown NOTE For clarity diagram does not show fittings installed on the pump intake and discharge openings Location of some components vary slightly based on pump model and...

Page 7: ...with PIV Priming Isolation Valve 21 Pumps without PIV Priming Isolation Valve 21 Piston Primer Disassembly 21 Remove PIV Priming Isolation Valve Remove PIV Priming Isolation Valve 22 Disassemble PIV P...

Page 8: ...ssure Stage Impeller 38 Install Mechanical Seal 39 Install High Pressure Stage Impeller 40 Install Separator Plate 41 Install Main Stage Impeller 41 Install Intake Fitting 42 Install Discharge Determi...

Page 9: ...d HL400D 1 Drain lubricant from Pedestal Primer Housing Models HL200D and HL300D Model HL400D Models HL200K HL300K and HL400K Drain lubricant from Pedestal Primer Housing and K Series Transmission Ped...

Page 10: ...onnect PIV Priming Isolation Valve Air Line 1 Required only if your pump is equipped with optional PIV feature 2 Connection made with push on fitting 3 Push in fitting retaining ring and hold Firmly g...

Page 11: ...ge piping pump and primer drain lines tachometer cable and any accessory equipment connections 2 Remove four bolts attaching the pump to the vehicle frame 3 Lift the pump out of the vehicle using the...

Page 12: ...Remove Intake Fitting Disconnect Hoses 1 Disconnect all hoses attached to the intake fitting NOTE If the hose connection at the intake fitting is not a swivel connection disconnect hose at other end...

Page 13: ...Place two 2 of the screws in the jacking screw holes Alternate tightening the two 2 jacking screws to separate the fitting from the pump body NOTE Impeller wear ring and shaft bushing will remain in...

Page 14: ...ntake fitting to the pump body 2 Place two 2 of the screws in the jacking screw holes Alternate tightening the two 2 jacking screws to separate the fitting from the pump body 3 The outer fitting may r...

Page 15: ...move locknut and washer from end of shaft 3 Remove impeller from shaft The M8 1 75 tapped holes in the impeller may be used to pull the impeller off the shaft 4 Remove the O ring in the groove on the...

Page 16: ...e the twelve 12 socket head screws and washers which attach the separator plate to the pump body 2 Long M12 bolts may be installed in the two M12 1 75 tapped holes and used as handles to guide the sep...

Page 17: ...bore on the back side of the impeller and discard 3 Remove the key from the shaft 4 Remove the shims from behind the impeller If the shims are damaged discard as new shims must be installed If the imp...

Page 18: ...Remove Mechanical Seal Remove Mechanical Seal 1 Grip the lip of the mechanical seal cartridge and pull out of pump 2 Remove the O ring from the groove in the pump body seal bore Mechanical Seal Cartr...

Page 19: ...smission see separate overhaul instruction F 1031 Section 4309 HL200D and HL300D Direct Drive Models Remove Companion Flange 1 Restrain the companion flange to prevent movement 2 Remove the locknut an...

Page 20: ...edestal 4 Remove O ring from groove in pump pedestal 5 If shaft will be removed from pump pedestal remove magnetic tachometer pick up from pump pedestal Disassemble Companion Flange 1 Remove retaining...

Page 21: ...ext page for instructions Pumps without PIV Priming Isolation Valve 1 Remove the four 4 socket head screws attaching primer to pump pedestal 2 Loosen the hex nut on top of the primer until it is disen...

Page 22: ...2 Remove the priming valve cover 3 Remove the wave spring from the internal bore in the valve body 4 Remove the piston from the valve Push out of valve from end opposite of priming valve cover 5 Remov...

Page 23: ...one screw retains the priming tube clip 2 Slide pedestal back until impeller shaft is clear of pump body Remove Pedestal Oil Seal 1 Remove the six 6 hex head screws attaching oil seal housing to pede...

Page 24: ...rce or lightly tapping on drive end of shaft 4 Remove oil seal from drive end of pedestal HL400D Direct Drive HL200K HL300K HL400K Gear Drive 1 Remove the magnetic tachometer pick up from pump pedesta...

Page 25: ...counter weights Keep counterweights and eccentric together as a unit during removal and storage 5 Remove shaft key HL400D Direct Drive HL200K HL300K HL400K Gear Drive 1 Remove the retaining ring 2 Sl...

Page 26: ...peller shaft to prevent movement during locknut removal On HL200D and HL300D models the companion flange may be temporarily installed and used to restrain the shaft 2 Disengage washer tabs from locknu...

Page 27: ...emove Discharge Remove Crossover Valve Actuator 1 Remove the hex nuts attaching the handle assembly to transfer valve and return ball valve 2 Remove the handles Note that the linkage rod connecting th...

Page 28: ...head screws from the return ball valve flange 3 Note that the transfer valve is trapped between the manifolds by the screws and will be loose 4 Lift the interstage manifold off the pump while holding...

Page 29: ...31 Section 4321 Page 29 of 57 Remove Discharge Manifold 1 Remove the four 4 hex head screws which attach the manifold to the pump body 2 Lift the manifold off the pump body Four 4 Screws Pump Body O r...

Page 30: ...l weep passageways in the pump volute as shown below Impellers and Wear Rings Check the wear rings and impeller hubs for deep grooves and scratches Wear rings are located as follows Main Stage Impelle...

Page 31: ...ings on shaft 3 Install the locknut washer 4 Restrain the drive end of the impeller shaft to prevent movement during locknut installation On HL200D and HL300D models the companion flange may be tempor...

Page 32: ...he impeller shaft spacer 5 Press the outboard bearing on the shaft HL400D Direct Drive Models HL200K HL300K HL400K Gear Drive Models 1 Install the shaft key 2 Slide the eccentric counter weights and p...

Page 33: ...applying force or lightly tapping on pump end of shaft 3 Install the oil seal in the drive end of the pedestal HL400D Direct Drive Models HL200K HL300K HL400K Gear Drive Models 1 Stand the pedestal on...

Page 34: ...eter of the oil seal housing 2 With pedestal and pump body in vertical position install the six 6 hex head screws and lockwashers finger tight 3 Mount an indicator dial to shaft and sweep pump body bo...

Page 35: ...l oil seal in pump pedestal 3 Slide companion flange onto shaft spline and into pedestal oil seal 4 Restrain the companion flange to prevent movement 5 Install washer and locknut Torque to 200 300 lb...

Page 36: ...e on pump pedestal 2 Slide companion flange bearing housing back over shaft spline and into bearing housing 3 Install the companion flange hex head screw and washer Torque to 19 lb ft 27 N m 4 Install...

Page 37: ...is not used on HL200D and HL300D models 2 Thread pick up completely into pedestal finger tight 3 Back out 1 2 turn 4 Slowly turn shaft to ensure pick up is not contacting moving parts 5 Repeat process...

Page 38: ...the pump from moving and torque locknut to 140 150 lb ft 190 203 N m 6 Check the gap measurement between the high pressure and volute body with a depth gauge Insert the gauge through one of the holes...

Page 39: ...y bore with the raised carbon ring side facing out Gently tap the outside metal ring of the cartridge until seated 4 Wipe the exposed face of the seal cartridge with a clean lint free cloth or tissue...

Page 40: ...e with a piece of wood being careful not to scratch or mar the polished face 3 Wipe the exposed face of the seal mating ring with a clean lint free cloth or tissue paper to remove any seal lubricant 4...

Page 41: ...e Torque to 40 45 lb ft 54 61 N m 1 Install the small O ring on the impeller shaft and the larger O ring in the back side of the impeller 2 Install the impeller on the shaft engaging the key 3 Install...

Page 42: ...ews and lockwashers and tighten evenly from side to side Torque to 67 lb ft 91 N m b If there is contact correct before proceeding Check the following causes of the contact 1 Raised burr or nick on ei...

Page 43: ...2 The input rotation of the drive end of the pump determines the direction the pump impeller rotates 3 If you are unsure of the impeller rotation of your pump the cast rotation arrow on the pump body...

Page 44: ...e interstage manifold on the discharge manifold Install the four 4 hex head screws and lockwash ers Torque to 25 lb ft 34 N m Note that the transfer valve is trapped between the interstage and dischar...

Page 45: ...e interstage manifold on the discharge manifold Install the four 4 hex head screws and lockwash ers Torque to 25 lb ft 34 N m Note that the transfer valve is trapped between the interstage and dischar...

Page 46: ...the volute body bores 4 Install the four 4 hex head screws and lockwashers Torque to 25 lb ft 34 N m Volute Body O ring 3 5 8 x 3 7 8 in 2 O rings 1 3 4 x 2 in 4 M12 1 75 x 120 mm Hex Head Screws and...

Page 47: ...handles on transfer valve and return ball valve with the hex nuts and lockwashers 3 If the linkage rod was removed reconnect to handles Adjust handle travel by decreasing or increasing the thread enga...

Page 48: ...andles on transfer valve and return ball valve with the hex nuts and lockwashers 3 If the linkage rod was removed reconnect to handles Adjust handle travel by decreasing or increasing the thread engag...

Page 49: ...lve body 6 Install the priming valve cover with the two button head screws and washers 1 Install O rings in the internal grooves in the pump body and PIV body 2 Install priming tube in the PIV body 3...

Page 50: ...3 Repeat process for primer on opposite side of pump 1 Install O ring in external groove in primer 2 Install primer on pump flange while engaging the primer elbow with the tube 3 Install the four 4 s...

Page 51: ...F 1031 Section 4321 Page 51 of 57 Reasassembly Install Hoses on Intake Fitting 1 Connect all hoses in their original location on the intake fitting Reconnect all hoses...

Page 52: ...F 1031 Section 4321 Page 52 of 57 Reassembly Cross Section Views HL200D and HL300D Direct Drive Models...

Page 53: ...F 1031 Section 4321 Page 53 of 57 HL200K and HL300K Gear Drive Models...

Page 54: ...F 1031 Section 4321 Page 54 of 57 HL400D Direct Drive Model...

Page 55: ...F 1031 Section 4321 Page 55 of 57 HL400K Gear Drive Model...

Page 56: ...s fill to the marking on dipstick pedestal or bottom of plug labeled Oil Level K Transmission 3 K Transmission breather may be removed and the hole used as the lubricant fill 4 Synthetic oil substitut...

Page 57: ...overed tighten connections or attaching parts as necessary Repeat until all leaks are eliminated NOTE The mechanical seal may leak under hydrostatic pressure however it should stop leaking after the s...