This manualis for CHAMPION FIRE PUMP:
PumPNumber Model
RECOMMENDEDPERFORMANCE: PumPPressure Method of Pump CaPacitY Operation GPM PSI.
- DESCRIPTION: series-parallel, Type S & SE fire pump is a high speed,two.stage centrifugal PUfrP, The or in parallel with the designedto operati *itr, itr i*o i.p.ttrtsltt a'srties as a two-stagePumP, characteristicsof a single stagepump' pressuresor lower engine The pump is operated in seriesat restricted capacitiesfor higher at lower pressures' .pr.ai p-u;llif op.-tulion is employed for maximum capacities the capacity reducedby one- If a two-stagepump operating in parallel is-switched to series; pressurewill be doubled' half and the engine-rp.Ja kept thJsame, then the output first two stagesare identical The Type sH & SEH fire pump is a three-stagepump i1.1tri9!r the it to operatesimultaneously to the Type S. The third stagehas a tlp"iurrrlutitr geaiwhich allows as a two-stage' with the iirst two stages,or stand idle while the pump runs pressuresrequired for fog with the three stagesoperating in seriesat low volume, very high streamsare delivered. underwriter requirements, The two-stageunit of this pump will gen^erallydeliver class A third stage' while simultaneourfy-Iai*tittg ttigtt pressuiefog streamsfrom the page' External featuresof this pump are illustrated on the next
l7oooll "' TYPE SE & SEH FIRE tsUMP 11 L2
I 1 2 2 3 L3 5 4 L4 5 15 6 16 2L L7 7 23 18
10
22 7
1 Discharge Gate Valves L5 Third Stage Outlet 2 Drain Valves 16 Discharge Pressure Tap 3 Pressure Relief Valve L7 Suction Screen - Third Stage 4 Re1ief Valve Shutoff 18 Purrp Drain Valve 5 Suction Inlet 19 Pump Power Shift 6 Exhaust Heater Connection 20 Tachometer Drive 7 Packing Gland Adjustment Screw I Booster Discharge Outlets LUBRICATION POII,ITS 9 Booster Suction Inlets 10 Third Stage Power Shift 2L Impeller Shaft Grease Zerk L1 Double FLoat Primer Assembly 22 Transmission Oil Level- Plug L2 Discharge Check Valve 23 Rear Drive Shaft Grease Zerk L3 Staging Control Valve 24 Transmission Case Oil FiII Plug L4 Cooling Line Strainer
sE-2 1{1 lSut;p1t W.S. DARLEY & CO.
REPAIR SERVICE INSTRUCTIONS TYPE SESOO/SE75O/SEIOOOMIDSHIP FIRE PTJMPS
Type SE T9ship fire pumpsare assembledin two main sectionswhich separateon a horizontalplane at the top of the pump casing. The lower section of the assembly(comprising all moving parts of the pump and transmission)can be unbolted from the upper sectionand lowered for removaland repair. It is not necessaryto removethe uppersection of the pumpassembly from the truck chassisor to disturb the manifold, valves,piping, accessoriesor body deails whenonly the pumpand transmission need repair or overhaul.
TO REN,IOVE PTJMP CASING AND TRANSMISSION OI\ILY FROM TRUCK CHASSIS Refer to Drawing 5825
l. Disconnectcasing drain valverod, coppertubing lines, clutch shift rod, brakelever rod or cable, tachometerdrive cable, and removedrain valve. 2. Disassembleuniversal joint at front of pumpby removingcap screwsto freeone yoke, and remove drive shaft betweenpump and truck transmission. 3. Disassembleuniversal joint at rear of pump to free propellerdrive shaft. 4. Placeblocking of floor jacks undei both pump casingand transmissioncase to supportits weight. 5. Removetop support stud nuts from cross membersat front and rear of pump. 6. U"lglt pump cqgingfrom manifoldb.y rgmoving sixteen V2"NC nutsunderneath the pump casing and dischargeelbow flange,one l/2"NC nut undermiddle of dischargeelbow, and three-l/2"Ne nuts on top side of manifold on drivers side. 7. Tapnedholes for jack screwsare provided in pumpcasing flange to facilitateseparation of gasket joint. $e 8. Alwayskeep casing flange parallel with bottomof manifoldwhile separatingto avoidinterference. 9. Lower pumpand transmissionassembly to the floor and slideout from underthe truck. Truck may haveto be jacked up for clearance.
TO REMOVE COMPLETE SE PTJMPFROM TRUCK CHASSIS Refer to Drawing 5825
l. Disconnectthe following from the pump: Suctionand dischargebooster piping Heaterpiping Gageline tubing Primer tubing Relief valve or pressureregulator tubing Auxiliary cooler tubing Drain valve and extensionrod Clutch shift rod Thchometerdrive cable Dischargevalve operating linkage Control valveoperating rod Brake lever control rod or cable 2. Separateuniversal joint at truck transmissionand removejack shaft. leeaTl 3. Separateuniversal joint at rear of pump and drop propeller shaft. 4. Removetop support stud nuts from cross membersat front and rear of pump. 5. Block up underpump and transmissioncases to supportis weight. 6. Unbolt dischargeextensions (113) from dischargehead (lCI) and pull out throughopenings in body panels. 7. Unbolt suctionextensions (D0) and (109)from pump manifold(52). Loosenset screwsin suction extensionsupport bracketsand pull out through body panels. 8. Lift pump out of chassiscarefully with hoist of not less than t/z ton capacity.
PT]MP DISASSEII,IBLYFOR OVERHATJL Refer to Drawings 5972 and 5825
l. Setpump and transmissionassembly on a benchwith bottom side up.
REAR DRTVE SHAFT DISA^SSEMBLY
If disassemblyof rear drive shaftis not required,complete steps lQ ll, and D to removerear drive shaft assemblyfrom pump. 2. Cut and removesafety wire from brake drum Qq. Removesix 3/8"NF cap screwsand remove brake drum from brake drum flange Qls). 3. Removecotter keys from clevis pins (208) and removeclevis pins from yoke ends (210)and (2ll). 4. Removecotter key from bell crank pin QA|) and slide washerQl7) andbell crank Ql3) otr of bell crankpin. 5. Pry tabof lock washer(218) out of groovein lock nut (214).Remove lock nut andlock washer-from rear drive shaft (48). 6. Slide brakedrum flange Qls) off of rear drive shaft (48). 7. Removefour U2"NC capscrews and remove mechanical brake assembly (216) from brakeyoke (50) and removebrake lever (209). 8. Removefour 3/8"NC cap screwsand removebrake yoke (50). 9. Pressbrake drum oil seal (22) out of brake yoke (50). 10. Removetwelve 1/4"NC Fillister headcap screwsand removetransmission case cover (45). ll. Loosensix 3/8"NC capscrews holding transmission bearing cap (39) to allow removalof rearbear- ing bracket(49). 12. Removetwo 3/8"NC capscrews holding bearing bracket (49) to pumpcasing (l). Removefour 3/8"NC capscrews holding bearing bracket to transmissioncase 09). A 9116"stafter wrench with a curved handle,such as Duro Chrome#2081, is necessaryfor two of thecap screws. Slide the bearing bracket to the rear and awayfrom the transmissioncase. 13. Pressrear drive shaft(48) out of rear bearingbracket (49). Removebearing backup washer (226) and presstransmission shaft bearing (47) ott of rear drive shaft. 14. Tapoil seals(205) and (219)out of rear bearingbracket (49).
nnu89 l)uazt CLUSTER GEAR DISASSEMBLY
If disassemblyof clustergear is not required,complete step 15 to removecluster gearltransmission shaft assemblyfrom transmissioncase. 15. Removesix 3/8"NC cap screwsfrom transmissionbearing cap (39). Slidetransmission shafl/drive gear assemblyout of transmissioncase (D). 16. Slide bearingcap (39) off of bearing(38). Pressoil seal(37) out of bearingcap. n. Bump pilot bearing(51) off of transmissionshaft (35) with sliding clutch gearQ9).. 18. Removesix l/4"NC graqe8 cap screwsholding pump clutch gear(31), transmission drive ge,ar(162), and bearing retainer (25) together. 19. Pressor tap transmissionshaft (35) out of pump clutch gear (31)and transmissiondrive gear(162). 20. Pressrear bearing(203) otr of transmissionshaft (35). 21. Pressfiont bearing QO3),bearing retainer (25), bearingspacer (87), and bearing(38) offof transmis- sion shaft (35) together. 22. It may not be necessaryto removeclutch shift bar (33) and shift yoke (30) from transmissioncase. (19).To disassemble:Remove four retainingrings (223) from clutchshift bar (33). Slideshift yoke (30) off of shift bar and slide shift bar out of transmissioncase (19). NOTE: Models after July 1988have a lock bolt shift yoke. Cut safetywire and removelock bolt (227) to removeshift yoke from shift bar.
PIJMP DISASSEIVIBLY
23. Removetwelve. 1/2"NC heavynuts from studsand removeoutboard head (8) with outboardstuffing box (174),bearing cap(177), bearing (176), bearing cap cover (173), and waterslinger Q24) attachd. Tlvo 5/l6"NC tappedholes in flangewith facilitate separation.Maintain headsquare with impeller shaft during removal to avoid damageto parts. 24. Removefour 1/4"NC caq scrervsand removeoutboard bearing cap cover(173) and bearing cap (lZ7) with bearing (176).Tap bearing out of bearing cap. 25. Make alignmentmar}s on the outboardstuffing box (174)and the outboardhead (8) with a cent€r punchor a cold chisel. 26. Removetwo 5/l6"NC cap screwsand removepacking plunger guide (163)from outboardstuffing box (174). n. Removesix l/4"NC slotted flat head brassmachine rrrri, and removeoutboard head (8). 28. Removecotter key (4), impellernut (5), andimpeller washer (6) from pumpshaft (18). Place a hard- wood block againstpinion gear (20) to preventshaft from rotating. 29. Pull secondstage impeller (3) off of pumpshaft (18). T\r,o 1/4"NC tapped holes are provided in back of impeller for puller bar studs.Use a heavy,flat puller bar with two 9132"clearance holes l-ll2" apart and a 3/8"NC tappedhole in centerfor shaftdrive bolt. 30. Removesix 1/2"NC heavynuts and two 1/2."NCjam nuts from inboardhead (12) and separatepump c-asing(l)from inboardhead. TWo 5/16"NC apped holes in flangewill facilitateseparation. Support the weightof transmissioncase (19) and head and keep it squarewith casingbore while separating theseparts. 31. Pry first stageimpeller (11)off of pumpshaft (18) using a pair of flat barsbetween back of impeller and headat oppositeslides. Bear againstimpeller wherevanes provide support. Inspectseal rings (10),and impellers(3) and (11).(See PARIS INSPECTIONAND MEASURE- MENT.) If sealrings (10)are not worn, removalis not necessary.If removalis necessarycontinue with steps33 and 34. 33. Removefour l/4"NC slottedflat headbrass machine screws and removeseal rings (10) from pump casing(l). 3 Aw-c:LL 34. Removefour l/4"NC slottedflat headbrass machine screws and removeintersage seal ring (2) from pump casing(1). 35. It shouldnot be necessaryto removeinboard head (12) from transmissioncase (19). These pans are held togetherwith two 3/8"NC cap screwsand four 1/2"NC cap screws. 36. Removetwo 5/16"NC cap screwsand removepacking plunger guide (163)from inboardstuffing-box (157). 37. Removefour 1/4"NC slottedflat headbrass machine screws and removeinboard stuffing box (157) from inboardhead (12). 38. Removeall old packing (160)from stuffing boxes(67) and (174)and packingplunger guides (163). 39. Removetwo 3/8"NC- cap screwsand two 3/8"NC sockethead cap screwsfrom bearingcap (23) and force cap away from transmissioncase (19) using rwo 5/16"Nt tappedpuller holeJ. N. Pushpump shaft (18) assembly with bearings(16), and pinion gear(2O) out of transmissioncase (19). 41. Presspinion gear (20), pinion spacer(22), and bearing (lO off of pump shaft (18) rogether. 42. Pressrear bearing 06) otr of pump shaft (18). 43. If necessarypress tachorneterdrive gear (210)otr pump shaft (18). 4. Removefour l/4"NC cap screwsand removetachometer gear case (24) from bearing cap (23).
PARIS INSPECTION AND MEAST]REIVIENT
1. Clean all parts and examinecarefully for wear or delerioration. Replaceany questionableparts. 2. Y*tu_* the impeller sealrings and sealrings for wear.Use the following tableof originaldimen- sionsfor comparison. INNERRING OUTER RING Impeller SealRing O.D. 5.t24- 5.125" 6.189- 6.190" Impeller SealRing I.D. 4.750- 4.',15r" 5.887- 5.ggg" SealRing O.D. 5.134- 5.t35" 6.199- 6.2m', SealRing I.D. 4.7N- 4.74r" 5.877- 5.879" ClearanceO.D. - original 0.009- 0.011" 0.009- 0.011"' ClearanceI.D. - original 0.009- 0.011" 0.009- 0.011" 3. If clearanceexceeds 0.025" on diameterof outsidering, impeller sealrings canbe restoredto original sry ry soldering a ring over trued surfacewhich retainsat least 0.090" ualt thickness.Stationary sealrings (10) shouldalso be replaced. 4. Measu-rethe impeller shaftand stuffing boxes for wear.Use the following tableof originaldimen- sionsfor comparision. OUTBOARD INBOARD Impeller Shaft.diameter at packing area 0.870- 0.871" 1.372- 1.373" Stuffing Box bore - orig 0.875- O.876" t.375- t.377" Clearance- original 0.004- 0.006" 0.002- 0.005" Clearance- max. allowable 0.01I" 0.010"
Byytt 5. MeasureFqing !9u$n-gEt:t fo_lpropersize. Use the follorving table for comparison.If anybore exceedsthe high limit by 0.0005", thepart shouldbe replaced. PART REP.NO. ORIGINALBORE DIA. OutboardBearing Cap r77 2.0472- 2.0479" Inboard Head 12 3.1496- 3.1503" Pump Shaft Bearing Cap 23 3.1496- 3.1503" Rear Bearing Bracket 49 front 3.7&2 - 3.7411" rear 3.9370- 3.9379" TransmissionBearing Cap 39 3.9370- 3.9379" TransmissionDrive Gear t62 3.5433- 3.5442" Rear Drive Shaft 48 2.0472- 2.04'19" 6. Measureshaft bearing journals for proper size. Use the following table for comparison.The low limit under bearing is required to insure a press fit with inner ball bearing race. ORIGINAL JOURNAL. REP NO. DIAMETER Pumpshaft. 18 front 1.3781- 1.3785" center 1.3781- 1.3785" rear 0.7875- 0.7879" Transmissionshaft " 35 front 2.1655- 2.1ffi" center 2.1655- 2.1ffi" pilot 0.7875- 0.7879" Reardrive shaft 48 front 2.3623- 2.3628" rear 2.1655- 2.16fr0" 7. The original plTp shaftdiameter under the pinion gearis 1.5615- 1.5620". The originalpinion gearbore is 1.5620- 1.5625", providinga 0.0000to 0.0010" clearance.Pinion gear may b€reversea to work other side of gearteeth. 8. The original pump shaft diameterunder the tachometergear is 0.3763 - 0.3768". The original - - tachometergear bore is 0.3750 0.3755", providinga 0.0012 0.0018" pressfit. Sincea fress fit is required,tachometer gear bore may not be exceeded.
ASSEIVIBLYOF SEsOO/SE7sO/SEIOOOPT]MP AND TRANSIVtrSSIONS Refer to drawings 5972 and 5825 l. Cleanall partsto removedirt, grease,and oil. Cleanall gasketsurfaces to bare metal. 2. Pr-esspump shaft inboard oil seal(15) into inboardhead (12) with lip springof sealfacing bearing. Fill greasecavity with greaseand lubricateoil seallips. 3. If they havebeen separated, attach inboard head (12) to transmissioncase (19) with two 3/8"NC x l'114",cap screws and lock washers(center), one l{2"NC x l-114"cap screwand lock washer(up- per right), and three l/2"NC x l-112"cap screwswith lock washers. 4. Apply No. 2 Permatexto inboardstuffing box (67) flangesurface. Place stuffing box gasket(l5) on inboardstuffing box againstPermatexed surface. Apply a thin layer of No. 2 Permitexto the stuffing box gasket. 5. Apply threadtape and No. 2 Permatexto the threadsof six l/4"NC x 314"slotted flat headbrass machinescrews. Attach inboardstuffing box (157)to inboardhead (12) with thesescrews. t*)&r7l nnot89 Apply a light coatingof greaseto pumpshaft (18). Place pinion key (21)in pumpshaft keyway, align with keyslotin pinion gear (20), and presspump shaftinto pinion gearbore until shaft shoulder is tight againstside of gear. 7. Slide pinion spacerbushing (22) onn pump shaft (18). 8. Apply a light coatingof greaseto bore of pump shaftbearing (16). Press bearing onto pump shaft (18)until pinion gear,spacer, and inner race of bearingare tight together. NOTE: Both bearings(16) may be pressedonto the pumpshaft in a singlestep with an arborpress. Apply a light coatingof greaseto bore of secondpump shaftbearing (16). Press bearing onto pump shaft (18) until bearing is tight againstshaft shoulder. 10. Grease'inboardwater slinger (225) to hold it in place,and place it in positionon the inboardstuffing box. ll. Wrap the splinedend of pump shaft (18)in shim stockto preventdamage to the oil sealsas the shaft is inserted. t2, Insert pump shaft (18)into transmissioncase/inboard head/stuffing box assembly. 13. Thpon end of impeller shaft(18) with a rubbermallet until bearing(16) is seatedagainst shoulder of its bearingpocket. Check with a straightedgethat front bearing(16) is flush with faceof gearcase. t4. Apply No. 2 Permatexto flangesurface of pump shaftbearing capQ3). Attach to transmissioncase (19)with two 3/8"NC x l" sockethead cap screwswith high collar washers(near tachometer gear caselocating pins) and two 3/8"NC x l" cap screwswith lock washers. 15. Checkaxial clearanceof pumpshaft (18). Insert pump shaft bearing cap gaskets (189) under bearing cap flange,if necessaryto insure0.005" minimum to 0.06" clearance. 16. Apply a light coatingof greaseto bore"ofachometer drive gear (40) and pressonto pump shaft (18)until tight againstshaft shoulder. t7. Apply No. 2 Permatexto tachometergear case (24) gasketflange. Place tachometer gear case gasket (26) againstPermatexed surface. 18. Locatetachometer gear case Q4) w bearingcap Q3) with two U4" x 5/8" dowelpins. Attachwith four l/4"NC x 1" cap screws.
CLUTCH SHIFT BAR ASSEMBLY
19. Apply greaseto two clutch shift bar o-rings (86) and fill o-ring groovesin transmissioncase (19) with grease.Insert o-rings into transmissioncase. 20. Apply oil to clutch shift bar (33). Insert clutch shift bar half-wayinto transmissioncase (19) from the front. 21. Placeone retaining ring (223) inthe front-mostgroove on the clutchshift bar (33). Referto drawing X3494, which showssharp corner side of retainingring in properposition !o takethrust load. Ail retainingrings shouldbe tight in groove.Replace any looserings. 22. Placea secondretaining ring (223) on the clutch shift bar (33) insidethe transmissioncase (19). SeeDrawing X3494. 23. Slide the shift yoke (30) onto the clutch shift 5ar (33) with the rib of the yoke to the rear. Place the third retainingring Q23) on the clutch shift bar. SeeDrawing X3494. 24. Pushthe clutch shift bar (33) completelyforward. Place remaining retaining nng (223)in the rear groove. 25. Placethe secondretaining ring (223) in the groovesecond from front. Slide the shift yoke (30) to the front, againstthe retainingring. Placethe third retainingring in the remaininggroove. NOTE: Models sinceJuly 1988have a lock bolt shift yoke.To assemble:Slide clutch shift yoke (30) onto clutch shift bar (33). Align bolt hole in shift yoke with groovein shift bar. Apply Loctite No.242 Threadlockerto the threadsof lock boft Qn) and install in shift yoke. Torqueto 20-23 ftlbs. Attach safety wire through hole in head of lock bolt and around groove in end of shift bar. finw89 ld*wtJ- 26. In::,l,*rruUrrr4jog Q) iry9 r:ff"fitffiJ"utboard end.Attach topump casine (r) wittt four Y4"NC x U2" flat headbrass machine screu/is. Sake the machinescrews with a centerpfi"it: 27. Insert impeller sealrings (10)into pump casing0) and attachwith four l/4"NC x3l4".flat head brassmachine screws each. Stake the machinescrews with a centerpunch. 28. Apply_asilicon lubricant,such as Dow CorningCompound lll (or equiralent)to inboardhead o- ring (9) and place on inboardhead (12). 29. Slide fint stageimpeller (11)onro pump shaft (18). 30. Slide pump ca:ing (l ito position and spin on two l/2"NC jam nurs (on flat edgeby rear bearing bracket)and six l/2"NC heavynuts, but do not tighten. 31. Line up machinedvertical surfaceof pump casing(l) with transmissioncover gasketsurface on transmissioncase (19) so theyare parallel. (A bubbletype level works well for this.) Tightenall nurs. 32. Slide secondstage impeller (3) onto pump shaft (18)and slide on impeller washer(6). 33. gPun u4 dry sh1ftthread and impeller nut (5), removingdirt grease,and.oil. (I-octiteKlean N' Prinie, Part No. 2556, can be used to clean parts and shortenCure time.) 34. Apply Loctite 242 Threadlockerto shaft thread and nut thread. 35. IgLt"lilP"ller nut (5) until it contactsimpeller washer (6), thenturn to nextconer key hole.(DO .NOT OVER TTGHTEN.) 36. Install a ll8" x l-314" STAINLESSSTEEL cotterkey (4) in impeller shaftcotter key hole. 37. Run a l/4"Nc tap into stuffing bbx screwholes on outboardhead (8). 38. Apply a thin layer of No. 2 Permatexto the gasketflange of the outboard stuffing box (174).put stuffing \1 Casket(68) againstPermatexed surface. Apply anotherthin layer of No. Z bernnatex to the stuffing box gasket 39. Insert outboard$uffing box (7a) into outboardhead (8). Line up alignmentmarks. Apply thread tape and No. 2 Permatexto the threadsof six U4" x 314" flat h&d brassmachine scrirs. Fasten outboardstuffing box to outboardhead with thesescrews q. Apply a silicon lubricantto the outboardhead-o-ring (9) and place on outboardhead (8). 41. Slideoutboard head/stuffing box assemblyonto pump shaft (18) and into positionin pumpcasing (l). 42. Attachoutboard head (8) to pump casing(1) with twelve 1/2"NC heavynuts on studs. 43. slide outboardwater slingerQ24) into its grooveon pump shaft (18). 44. Plesspymp shaft oil seal (175)into'outboard bearing cap(177) flush with inside,with lip spring of seal lging bearing.Fill greaseTuiq with greaseind lubricateoil seallips. Tapthe beaiingcap into positionon the outboardstuffing box (l7a). 45. Thp outboardbearing (176)onto pump shaft (18)tight againstshoulder. 46. Apply No. 2 Permatexto outer flanggsurface of outboardbearing cap cover (173).Fill cavity with grease.Attach through outboard bearing cap (177) to outboardstuffing box Q74)with four li4"NC x 718" cap screwswith lock washers. 47. Insert oil fill plug (222) 48. Repackstufhng boxes with approximately8-9 pelleeof packingeach. (See FILLING THE STUFFING BOX WrTH PACKING)
notn7f 'iuii,is REAR BEARING BRACKET ASSEII{BLY 49. Pressoil seals(205) and (219)into bearing bracket (49) againstshoulder, with lip spring of seal " facing bearing. Fill greasecavity with greaseand lubricateoil seal lips. 50. Pressbearing (47) onto rear drive shaft (48) tight againsttruck gear shoulder. 51. Wrapsplined end of shaftin shimstock in orderto preventdamage to theoil sealsas the shaftis inserted. 52. Insert rear drive shaft (48) into bearing bracket (49). 53. Place bearing backup washerQ26) onto rear drive shaft (48) againstshoulder. 54. Removeone shield from the rear drive shaft bearing (38). Pressbearing onto rear drive shaft (48) tight againstwasher Q26) with shield side to the rear.
CLUSTER GEAR ASSEIVIBLY 55. Fit sliding-ilutghggar Q9) t" transmissionshaft (35) with pins touarddrive gear.Make alignment marks with indelible marker and removesliding clutch gear from shaft. 56. Apply a light coatingo{Breaseto bores of bearings(203). Press bearings (203). Press bearings (203) onto transmissionshaft (35) tight againsteach side of shoulder. 57. Put bearingretainer (25) onto transmissionshaft (35) and slide it into positionon bearing e03). 58. Slide transmissionbearing spacer (87) onto transmissionshaft (35) until it contactsbearing eO3). 59. Ap_plya light coating of greaseto bore of bearing (38) and pressbearing onto transmissionshaft (35) until inner race is tight againstspacer. 60. Presstransmission shaft (35) with bearings(203) into transmissiondrive gear (162). 61. Placepump clutch gear (31)into positionon transmissiondrive gear(162). 62. Cleanthe threadsof six l/4"NC x 3" grade8 hex headcap screws.Apply Loctite 242Threadlocker to the threads.Insert throughpump clutch gear (31)and transmissiondrive gear(162). Thread into bearing retainer (25) and torque to l0 ft.-lbs. 63. Slidesliding clutch gearQ9) onto transmissionshaft (35) with oil slingerpins touarddrive gear(162). &. 4nnJV a_1ightcoating of greaseto bore of pilot bearing (51) and pressbearing onto transmission shaft (35) until tight againstshaft shoulder.
FINAL PI]MP ASSE}TBLY
65. fres"soil seal(37) into transmissionbearing cap (39), faceflush with outsideof bearingcap, with lip springof sealfacing bearing. Fill greasecavity l/3 full with greaseand lubricateoil seailips. 66. 4pply No. 2 Permatexto bearingcap (39) gasketflange surface.Put bearing cap gasket(188) on bearing cap againstPermatexed surface. 67. Put bearingcap (39) over transmissionshaft (35) and slide onto transmissionshaft bearing (38). 68. Ill:n drive gearltransmissionshaft_assembly into positionin transmissioncase (19) with shift yoke (30) engagingsliding clutch gear(29). Pushbearing cap (39) into positionand inserttrno 3/8;NC I l-y4" cap screwswith lock washers.Leave cap screwsloose until rear drive shaft and bearing bracketassembly has beentightened into position. 69. Ap.plyNg. 2 Permatexto bearingbracket (49) flangesurface and placebearing bracket and rear drive shaftassembly into positionat rear of transmissioncase (19). Move transmision shaft so pilot lealing (51)enters without binding. Attach with two 3/8"NC x 1" cap screwsand lock washerson the inside,two 3/8"NC x l-114"cap screwsand lock washerson thi outside,and two 3/8"NC x l'112"cap- screws and lock washerson thepump casing (1). Make sure bearing bracket is tight against pump-caSing,then tighten two capscrews into pumpcasing first. Inboardhead flange bolts miy re- quireloosening to allor pumpcasing mwement if necessary.The tu,o inside cap screws on thetranimis- sioncase require the useof a9ll6" starterwrench with curvedhandle, such as Duro Chrome#2081. l}txntt 70. Insert remaining four 3/8"NC x l-114"cap screwsand lock washersinto bearing cap (39). 71. Pressbrake drum oil seal (206) into bearingcap and braker9f9 (SO)with lip spring of seal frcing bearing. Fill greasecavity with greaseand lubricate oit seal lipi. 72. Slide.bearingcap (50) wer rear drive shaft(48). Attachto rear bearingbracker (49) with four 3/g"NC x l-114" cap screwsand lock washers. 73. lPt up flat edgeof baaring cap (39) with transmissioncase cover (45) mountingsurface. Tighten all six cap screwsholding bearing cap to transmissioncase (19). 74. Check transmissionshaft (35) for end play. hper gaskets(188) can be addedor subtractedunder the transmissionbearing cap (39) to give-oesiieaJnd pla5rorb.oos - 0.06". 75. ApPly {o. 2 Permatexto transmissioncase cover (45) gasketsurface. Place gasket(46) on cover againstPermatexed surface. 76. Attach transmissioqcpver (45) to transmissioncase (19) with twelve U4"NC x 314,,Fillister head cap screwsand lock washers.
MECHAMCAL BRAKE ASSNN,NT,Y
77. Apply gfeasgto rognd pivot pin on brakelever (209) and insert pin into hole on bottom side of rear bearing bracket (49). 78. $1te_tpping brake thT!3pgt, slide mechanicalbrake assembly (216) inro positionon brakeyoke (50). Make sure lever (209) is engagedin slot betweenshoes. 79. Attach mechanicalbrake assembly(21Q with four l/2"NF x 1" cap screwswith lock washers. 80. Apply greaseto bell crank pin eAl. 81. Slide bell crank (2lil) and washer(217) onto bell crank pin eUl). 82. Insall a3132" x 1" cotter key in hole in bell crank pin eAD. 83. Insert clevis pin (208) through plain yoke end (2ll) and bell crank (2lii) 84. Insert secondclevis pin (208) through adjusable yoke end (210)and brake lever (209).-' 85. Install l/8" x l-114"cotter keysin holesin clevispins (20g). 86. Slide brakedrum flange (26) ono rear drive shaft (48). Slide on lock washer(218) and install lock nut (214)-Ttghten lock nut until a tab of lock washeraligns with a slot on lock nut. press ab oi lock washerinto slot on lock nut. 97. Attachbrake drum Q12)to brakedrum flange(26) with six 3/8"NF x314" cap screwsdrilled for safety wire, and lock washers.Install safetywire in cap screws.
FILLING TIIE STI'TTING BOX WTrII PACKING
Use only plasallic packingsupplied by W.S. Darley & Co. It is importalt that the.stuffing-boxbe completelyfilled solid with packing.If voidsare present, pump Pressuremay force packing out betweeps$ft a!d- box opening,enlaging lhe void until no pu.tirig t"- mains.This will not occur when packingis solid. P pu"t the stuffingbox whenemPty and assembled in thepump, it is convenientto usepellet packing 3n{ fee! with packing screw qsing a qpeedwrench. At the sa*e time the pump shaft shouldbe^ turned by handuntil resistalceto turningisfeli whenalmost full. Continueturning paciitg ,"r"* Uyhand using a standard9/16" end wrench until about? b 4-pgun!sforce is felt at end6f wrerich.Contlnue turnin! until a few flakes of packing are extrudedout of shaft opening.-wtritJpumping,Rotate pump shaft by tranauniii iiturnt freely. The gland is now ready for further adjustment
/f,txszl nnu89 INSTALLING PUMP IN TRUCK CHASSIS
Reversethe proceduresoutlined under removialinstructions. Lubricate universaljoint slip yoke on pump drive shaft. Fill gear casewith SAEI0W/40SF grade motor oil to the bottom of the 3/8" NPT fill plug located in front frce of gear case.
PACKING ADJUSTMEI{T
While pumping at 50 psi dischargepressure, obserue that 10to 20 drops per minute of water comes out of stuffing box. Increasepump dischargepressure to normal operatinglevel and checkthat drip rate remainswithin samelimits. A slight additionaltrghtening of packingscrew may be necessaryto achieve a stable drip rate. For pumpsthat havebeen in service,it is importantto periodically checkthat drip rate remainscons- tant at normal operatingpressures and at 50 psi. To insurethat packingactually is solid, we recommend that the packingscrew be turnedwhile pumpingat 50 psi until the.normal2 to Alb. resistanceis felt at end of standard9116" end wrench. Alternatepumping at both normalpressure and 50 psi level andobserve that drip rate remainsconstant betrveenl0 to 20 drops per minute. It may be necessaryto repeatthis procedureseveral times to achieve a stabledrip rate if the packing has not been attendedto over a long period of time.
SOME CA,REAND HANDLING INSTRUCTIONS
l. Avoid unnecessaryforce and rough handlingof parts in disassemblingand reassembling. 2. Clean parts thoroughly and maintain free from abrasiveforeign matter. 3. Keep bearingsin original containersuntil ready to insall. 4. Work with clean tools in cleansurroundings during reassembly. 5. Do not bump or abrademachine finished surfaces,giving special care to wearing surfaces,shaft shoulders,gear and impeller hub faces,gear teeth,etc. 6. Use an arbor pressfor forcing pressfits wheneverpossible. If necessaryto use a hammer,use one having soft plastic heads. 7. Use suitablemachined and fitted sleevesor bars for forcing or driving ball bearingsand other parts havingpress fits. o 8. Do.not pressball bearingonto a shaftby forcingagainst the outer race.Heavy pressure or impact againstbearing balls will damagethe bearing and causepremature failure. 9. If necessaryto removea ball bearing from a shaft by forcing againstthe outer race, the bearing shouldbe discardedand replaced. 10. When pressingor driving a bearingor other part onto a tight fitting shaft the part must be started dead squarewith the shaft and forced on squarelyall the way. ll. Clean and oil bearingseats and other parts havingpress fis to preventgalling. 12. Keep looseparts markedor otherwiseindentified to avoiderors in assembly. :
rF FURTITER TNFORMATION IS NBEDED, CALL W.S. DARLEY CO. AT CHIPPEWA AA.LLS,WI AT 8fi)-634-7812or T15-7234216
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a- o E:I litxn"lr PARTS LIST - TYPE SE CHAMPION FIRE PI,'MP DRAWINGS S972snd SS25
Rep. Rep. No. Name of Part No. Name of Parl I Pump Casing 67 Control Rod 2 InterstageSeal Ring 77 Drain Valve Assembly 3 Impeller - 2nd Stage 78 Primer Cover 4 Cotter Key 79 Primer Shut Off Gasket 5 Impeller Nut 80 Primer Valve Body 6 Impeller Washer 8l Safety Float Housing 8 Outboard Head 82 Primer Cover Gasket 9 Pump Head C)'ring 84 Relief Valve Assembly t0 Impeller Seal Rings 85 Oil Seal - Tachometer Shaft ll Impeller - lst Stage 86 Clutch Shift Bar O'ring t2 .Inboard Head 87 TransmissionBearing Spacer l5 Oil Seal-InboardPump Shaft 88 Drain Valve Gasket 16 Pump Shaft Bearings 89 SleeveO'ring l8 Pump Shaft 9l Control Valve Cover O'ring l9 TransmissionCase 92 Control Valve O'ring ?T Pump Driven Pinion Gear 95 Cooling Line Strainer 2l Pinion Key 99 DischargeHead Gasket 22 Pinion SpacerBushing 100 DischargeHead 23 Bearing Cap - Pump Shaft 102 DischargeExtension Gaskets 24 Tachometer Gear Case 103 Discharge Head Cover Gasket 25 Bearing Retainer 104 Disch. Check Valve Guide Bushing 26 Tachometer CaseGasket 105 DischargeHead Cover Plate 28 Oil Slinger Pins 106 Suction ExtensionGaskets 29 Sliding Clutch Gear 107 Primer O'ring 30 Clutch Shift Yoke 108 Primer Body 3l Pump Clutch Gear 109 Suction Extension 33 Clutch Shift Bar ll0 Suction Nipple Gasket 35 TransmissionShaft lll SuctionCap 36 Universal Joint ll2 Primer Gasket 37 Oil Seat 113 DischargeExtension 38 TransmissionShaft Bearing ll4 DischargeValve O'ring 39 Bearing Cap - Transmission l15 DischargeCap 40 TachometerDrive Gear l16 DischargeWye 4lq TachometerDriven Gear ll8 Control Rod Pivot Screw 42 TachometerDrive Shaft ll9 Suction Strainer 43 Tach. Drive Shaft Bushing 157 Inboard Stuffing Box 45 TransmissionCase Cover 158 Stuffing Box Gaskets 46 TransmissionCover Gasket 159 Packing Gland Screws 47 TransmissionShaft Bearing 160 Pump Shaft Packing 48 Rear Drive Shaft 16l Gland Nut 49 Bearing Bracket 162 TransmissionDrive Gear 50 Bearing Cap or Brake Yoke 163 Packing Plunger Guide 5l TransmissionPilot Bearing l& Control Valve Sleeve 52 Pump Manifold 167 Cleanout Cover Plate 53 Control Valve 168 Cleanout Cover Gasket 54 Control Valve Stop Pin 173 Bearing Cap Cover 55 Control Valve Cover 174 Outboard Stuffing Box 56 Control Valve Lever 175 Oil Seal Outboard Pump Shaft 57 Control Valve Bushing 176 Outboard Bearing 58 Manifold Gasket 177 Outboard BearingCap 6l DischargeCheck Valve Seat 178 Remote Control Bracket @ DischargeCheck Valve Assy. 179 Remote Control Valve Lever 65 DischargeGate Valve 180 Remote Control Rod 66 Suction Nipple l8l LeverWasher lAXn I t
sE-9 PARTS LIST - TYPE SE CHAMPION FIRE PLIMP(Continued) DRAWINGS5972 and 5825 Rep. No. Name of Part 182 RemoteControl Irver Pin 188 Bearing Cap Gasket 189 Pump Shaft Bearing Cap Gasket 190 Suction Extension l9l SuctionCheck Valve Assembly lY2 CheckValve Cover 193 Check Valve Guide Bushing 194 FlangeO'ring 195 Relief Valve Extension 196 ExtensionO'ring 197 Flange Gasket 198 CheckValve Spring 199 Check Valve Cover O'ring 203 Bearing - Trans. Shaft 205 Oil Seal - Front Drive Shaft 206 Oil Seal - Brake Drum 2W Bell Crank Pin 2OB Clevise Pin Assembly 2W Brake lrver 2lO AdjustableYoke End 2ll Plain Yoke End 212 Brake Drum 213 Bell Crank 214 Fla+ge RetainingIocknut 215 Brake Drum Flange , 216 MechanicalBrake Assembly 217 Flat Washer 218 'Loclavasher ztg Oil Seal - Rear Drive Shaft 22O GreaseZerk 221 GreaseVent Pipe 222 Oil Fill Plug 223 Shift Bar RetainingRing 224 OutboardWater Slinger 225 Inboard Water Slinger 226 BearingBackup Washer .:.1 227 Shift Fork Iock Bolt
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H F !!p U OL E a; p c. 3r { Fo, -Z ;: ;H l3ooo;l PartsList For PowerGear Shift Assembly TypeSE & SEH Pumps - DrswingGlt64
Rep. No. Name of Part I Valve Body 2 O'Ring Seal 3 Connectors 4 Valve Plug 5 Mounting Plate 6 Shift Control Plate 7 Panel Nut 8 Stop Nut 9 Latch Knob l0 Pilot Light ll Lever Latch Pin :12 Latch Lever 13 Spring l4 Cotter Pin l5 Clevis Pin 16 Lockwasher t7 Cylinder Rod & Nut t8 Lever - Maln Pump l9 Sliding Clutch Position Switch - Main Pump 20 Switch Mounting Screw 2l Link 22 Sliding Clutch Position Switch - 3rd Stage 23 Clevis Pin 24 Clevis Pin - Switch Activator 25 Clevis Pin 26 Yoke End 27 Flat Washer 28 Yoke Rod 29 Jam Nut 30 Yoke End 3r Nut 32 Wiper Ring 33 Cylinder Head 34 Rod O'Ring 35 Cylinder O'Ring 36 Cylinder End 37 Piston 38 Cylinder Pivot Post 39 Cotter Pin N CastleNut 4l Piston Rod / 42 Piston Quad Seal 43 Cylinder M Shift Bar 45 Cylinder Bracket - 3rd Stage 46 Lever - 3rd Stage 47 Switch Spacer 48 Switch - 4-Way Valve 49 SwitchBracket 50 Switch Mounting Screw, Nut & Washer
t3uX)71 PARTS LIST FOR G229+1
Rep. Rep. No. Name of Part No. Name of Part I Valve Body 36. Cylinder End 2 Valve Plug O'ring 37 Piston 4 Valve Plug 38 Cylinder Pivot Post 5 Mounting Plate 39 Cotter Pin 6 Shift Control Label 40 CastleNut 7 PanelNut 4l PistonRod 8 Stop Nut 42 QuadRing 9 Latch Knob 43 Cylinder l0 Pilot Light Lens 44 Lockwasher tl Lever Latch Pin 45 Cylinder Bracket - 3rd Stage 12 Latch Lever 46 Shift Lever - 3rd Stage 13 Spring 48 Micro Switch 14 Cotter Pin 49 Micro Switch Bracket 15 ClevisPin 50 RoundHead Screw 16 Lockwasher 51 CylinderRod t7 Hex Nut 52 Oilite Bushing 18 Shift Irver - Main Pump 53 Pilot Lamp 2l Links 54 filot Light Base 24 Shift Bar Pin 55 Hex Nut 25 Clevis Pin 56 Lockwasher 26 AdjustmentYoke 57 RoundHead Screw 27 Flat Washer 60 Spring Pin 28 Yoke Rod 61 Micro Switch Bracket 29 Jam Nut 62 Cotter Pin 30 Yoke End 63 Lockwasher 3l Hex Nut & Hex Head Cap Screw 32 Wiper Ring 65 Hex Nut 33 Cylinder Head 66 Link Spacer 34 PistonRod O'ring 67 Offset Bar 35 Cylinder O'ring 68 Shift Bar
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l1aqgz (-69R t 2-9I W.S. DARLEY & COMPANY REPNR SERVICE INSTRUCTIONS Tlpe SE & SEH trlre Pumps
Tlpe SEand SEH midship fire pumpsare assembled in two mainsections which separateon a horizon- tal planeat the top of the pump casing. The lower sectionof the assembly(comprising all movingparts of the pump and transmission)can be unboltedfrom the upper section and lowered for removaland repair. It is seldomnecessary to removethe upper sectionof the pump assemblyfrom the truck chassisor to disturbthe manifold, valves,piping, accessoriesor body details.
TO REIVIOVE PI.JMP CA.SING TRANSMISSION ONLY FROM TRUCK CHASSIS
l. Disconnectcasing drain valverod, coppertubing lines, clutch shift rod, brakelever rod or cable, tachometerdrive cable, and removedrain valve. 2. Disassembleuniversal joint at front of pumpby removingcap screwsto free oneybke, and remove drive shaftbetween pump and truck transmission. 3. Disassembleuniversal joint at rear of pump to free propellerdrive shaft. 4. Placeblocking under both pumpcasing and transmissioncase or floor jacks to supportits weight. 5. Removetop supportstud nuts from crossmembers at front and rear of pump. 6. Unbolt pump casingfrom manifold-byremoving stud nutsunderneath casing flange. Models 51000 & Sn50 have23 studnuts under the casingflange. Models 58750 & SEl000have 16 stud nuts under the casingand elbov flange,one under middle of dischargeelbow and 3 on top of manifoldon driver's side. 7. Fpp"O holesfor jack screwsare provided in pumpcasing flange to facilitateseparation of thegasket joint. 8. Alwayskeep casing flange parallel with bonomof manifoldwhile separatingto avoidintelference. 9. LowerplmP andtransmission assembly to the floor andslide out from underthe truck. Truck may haveto be jacked up for clearance.
TO REMOVE COMPLETE SE PI,JMPFROM T"RUCK CHASSIS Refer to Drawing 5751
l. Disconnectthe following from the pump: Suctionand dischargebooster piping Heaterpiping Gageline tubing Primer tubing Relief valveof pressureregulator tubing Auxiliary coolertubing Drain valve and extensionrod Clutchshift rod Thchometerdrive cable Dischargevalve operating linkage Control valve operatingrod Brakelever control rod or cable 2. separateuniversal joint at truck transmissionand removejack shaft. 3. Separateuniversal joint at rearof pumpand drop propellershaft. 4, Removetop supportstud nuts from crossmembers at front and rear of pump. taux)7t
I 1-1974 5. Block up under pump and transmissioncases to supportits weight. 6. Unbolt dischargeextensions (ll3) from dischargehead 000) andpull out throughopenings in body panels. Unbolt suctionextensions (190 & 109)from suctiondischarge manifold (52). Loosenset screws in suctionextension support brackes and pull out throughbody panels. Lift pump out of chassiscarefully with hoist of not lessthan ll2 ton capacity.
TO DISASSE}IBLB SE75O& SE1OOOPT]MP AI{D TRANSMISSION ASSEMBLY WIIEN SEPARATEDTROM MAIVIFOLD Refer to Drawing S75l l. Set the pump and transmissionassembly on a benchwith bottom side up. 2. Unbolt and removetransmission cover (45). 3. Removelocknut (214) lockwasher (218) brake drum flange(214) and brake drum Ql2) fromtail shaft (48). 4. 'Removefour capscrews holding bearing bracket (49) to transmissioncase (19). One screw requires useof a 9116"closed end curvedhandle "starter" wrenchsuch as Duro Chrome#2081 or P & C #D1730.Remove 2 capscrews holding bearing bracket to pump casing(l). Loosensix cap screws andmove bearing cap (39) about3116" to allow transmissionshaft (35) assemblyto moveforward as far as possible.Pull bracketand drive shaftassembly to rear and awayfrom transmissioncase. 5. Removefour screwsholding bearing cap brake yoke (50) to bearingbracket (a9) andpull offbrakeyoke. 6. Pushtail shaft (48) out of bearingbracket (49). 7. Removeball bearings(38) and (47) andoil seals(219) and (205). Bearingscannot be reusedafter removal. 8. Removesix cap screwsholding bearing cap (39) to transmissioncase and pull off bearingcap. 9. Slide drive gear(162) and transmissionshaft (35) assemblyout of transmissioncase. 10. Bump pilot bearing(51) off from transmissionshaft with sliding clutch gear(29). Bearingcannot be reused. ll. Removesix cap screwsthrough drive gear(162) to freebearing retainer (25) andpump clutch gear (31). 12. Presstransmission shaft (35) throughdrive gear (162)touard bearingretainer end. 13. Pressbearing (203) retainer (25) spacer (87) and bearing (38) off togetherfrom transmissionshaft (35). 14. Loosencap screwin split hub of shift yoke(30) and unscrewshift bar (33) to removethese parts. 15. Unbolt and removeoutboard head (8) with bearing076) stuffingbox (174)and waterslinger (175) attached.Two 5/16''NCtapped holes are provided to assistflange separation. Maintain head square with impeller shaft during removalto avoiddamage to parts. 16. Removebearing cap (177) and extract ball bearingwith hookedpry bar behindinner race. An alter- nativemethod is to turn a woodplug to fit bearingbore, fill cavity with greaseand hammerplug into bearingbore. 17. Relnoveimpeller retaining nut (5) andwasher (6) from impellershaft. Place a hardwoodblock against pinion gear (20) to keep shaftfrom turning. 18. Pull secondstage impeller (3) off shaft.Two l/4"NC tappedholes are provided in backof impeller for puller bar studs.Use a heavyflat pullerbar with two 9132"clearance holes I 3/4" apartwith a 3/8" tappedhole centeredin betweenfor shaftdrive bolt. 19. Removepump casing stud nuts from inboardhead (12) and separate casing from head.Two 5/l6"NC tappedpuller holesare provided to assistflange separation. Support the weightof transmissioncase (19)and headand keepit squarewith casingbore while separatingthese parts. 20. Pry first stageimpeller (ll) off shaft,using a pair of flat barsbetween back of impellerand head at oppositesides. Bear against impeller where vanes provide support.
4-1911 lAnot t 21. Impeller seal rings (10), interstageseal plate (2) and stuffing boxes(l57 and 174)are easily tapped out after removalof fasteningscrews. 22. Removecap screwsfrom bearingcap (23) and force cap awayfrom transmissioncase using two 5/16" NC tappedpuller holes. 23. Pushimpeller shaft (18) assembly with bearings(16) pinion gear(20) waterslinger (15) and bearing closure(l5l) out of inboardhead casting (12). 24. Unscrewwater slinger (15) with a spannerwrench. THIS PARTHAS A LEFT HAND THREAD. 25. Presspinion gear(20) spacer(22) andball bearing06) otr impellershaft (18) together; or remove bearingonly with puller engagingouter race--inwhich casebearing must be discarded. 26. Pressoff bearing(16) and removespacer (17). 27. Thchometergear case(24) is disassembledby removingfour cap screwsand two dowelpins. 28. Impellerand sealring tolerances:The diametralclearance between the impellerhub and sealring when new is from 6 to l0 thousanthsof an inch. This clearancewill increasein time, depending on cleanlinessof watersupply, and should not be exceed25 to30 thousandthsto maintainreasonable pump performance. 29. Stuffingbox tolerances:The endsof the plasticmetallic packing chamber have 4 to 8 thousandths diametrialclearance on the impeller shaft which will last indefinitelyproviding packing pressure is maintainedto keepleakage within normal limits of from l0 dropsper minuteto 2 dropsper se- cond.Excessive clearance will causepacking loss and frequentadjustment to maintainlow leakage and propervacuum seal for priming. Sucha conditionindicates repair is needed.
TO REASSEMBLE SE75O& SEIMO PIJMP AND TRANSMISSION Refer to Drawing SE750
l. If stuffingbox assemblies(174) and (67) havebeen removed, replace in inboardhead (D) andoutboard- head(8). Flangesurfaces must be cleanand smooth,and non-hardeningPermatex applied on both sidesof stuffing box gaskets(158) before assembling 2. Build impellershaft assembly as follows:Place gear (20) key (21)and spacer (22) on impellershaft (18)and press on bearing(16) (bear against inner raceonly). Placespacer (17) and bearing (16) on shaftand pressinto place.Place bearing closure (l51) o'ring (150)and waterslinger (15) on shaft andtighten slinger (left handthreads) firmly with a spannerwrench. Push bearing cap (23) on bear- ing (16). Pushimpeller shaft assembly into transmissioncase and inboardhead. Insert cap screws in bearing cap(23) finger tight andcheck the axial clearanceofshaft. Insertpaper gasket (189) under beAring cap flange,if necessaryto insure.005" minimum to .015"clearance before tightening cap screws. 4. Fastentachometer gear case (24) andshaft assembly to bearingcap with locatingdowel pins and cap screws. 5. Placelst stageimpeller (ll) on impellershaft and applyoil to sealring. 6. Installpump casing (1) with sealrings (10) and interstage seal ring (2) boltedin place.Replace damaged o'rings.Flange surfaces must be cleanand smooth. Apply oil to sealring grooveswhen assembling impellers.Tighten casing nuts. 7. Install2nd stage impeller (3) washer(6) impellernut (5) andbrass cotter pin. Tightenimpeller nut very lightly.Excessive tightening may spring impeller shaft. Lock positionwith brasscotter pin. 8. Installoutboard head (8) and stuffingbox (174)assembly and tighten casing nuts. 9. Presswater slinger (175) and bearing (176) on impellershaft. 10. Pushon bearingcap (177) and tighten cap screws. Lubricate bearing with a few dropsof light oit. ll. If packing(160) has been replaced, tighten packing screw (159) while rotatingpump shaft by hand until someresistance is noted.Final adjustment is accomplishedwhen pumping water. See Opera- tion MaintenanceInstructions. fJmc? J-t97.1 '12. Build transmissionshaft (35) assemblywith ball bearing(38) spacer(87) bearing retainer (25) bear- ings (203) drive gear (162)clutch gear (31) sliding clutch gear(29) and pilot bearing(51). 13. Tightensix drive gear(162'l assembly cap screwsfirmly andrivet the endsto insureagainst working loose. 14. Installshift nd (33)and shift yoke(30) with lockingset screw head toward transmission case opening. 15. Placedrive gearassembly into transmissioncase with clutchshift fork (30) engagingsliding clutch gear(29). Pushbearing cap (39) into positionand insertcap screws-- leaveslack until rear drive shaft and bearingbracket assembly has beentightened in position. 16. Pressoil seals(205) and (219) into bearingbracket (49) with lip springfacing bearing side. Fill grease cavitieswith grease. 17. Pressbearing (47) into positionon rear drive shaft (48) tight againsttruck gear shoulder. 18. Pushrear drive shaft (48) into bearingbracket (49). 19. Pressbearing (38) at other end of rear drive shaft into positiontight againstshaft shoulder. 20. Permatexflange face and placebearing bracket and rear drive shaftassembly into positionbehind transmissioncase. Move transmission shaft so pilot bearing(51) enteis without binding. Use a 9/16" starterwrench with curvedhandle such as Duro Chrom #2081to tightenfour cap screwsholding bracketto transmissioncase. Make surebracket is tight againstpump casing before tightening two capscrews into pumpcasing. Inboard head flange bolts may require loosening to allow pumpcasing movement. 21. Fastenbearing cap brake yoke (50) to rear bearing bracket (49) with four screws.Oil seal (206) lip springmust face bearing (38). Bearingshould be openand cavity packed with grease.Lubricate oil seallips. 22. Install brakeassembly (216) and securebrake drum flange(215) tight againstbearing with locknut (214)arrd lockwasher. Bend lockwasher tab into locknutrecess or securewith washer,nut andcotter pin. 23. Checktransmission shaft (35) for axial clearance.Use paper gasket (188) if necessaryto provide .005" to .015"end play. Tightenbearing cap (39) screws. 24. Sleeve(86) provides a positivestop for slidingclutch gear(29) in "pump" position,and is factoryiet. 25. Adjust clutch $rift bar (33) by screwingit into shift yoke (30) to original factory set positioni or until shoulderat threadedend stops against inside wall of transmissioncase while the slidingclutch gearis held in full engagementwith the truck drive gear.Continue turning shift bar (33) clockwise until sliding.clutch gear backs off approcimately1132" so that shift yokewill not bearagainst the sliding clutchgear. Rotate shift bar l/4 turn or lessso that flat at end of bar linesup with shift rod connection.Tighten cap screwin shift yoke (30). 26. Fastentransmission case cover (45) and gasket(46). 27. Replacegaskets using a soft settinggasket cement such as black Permatexon both sidesof gaskets that are subjectedto hydraulicpressure. 28- Use lockwashersunder all fasteningsthat are subjectto vibrationor reversingloads. 29. Refilltransmission case with heavyduty SAE20 motoroil to levelof oil levelplug before operating pump.
PRECAUTIONARY MEASURES
l. Avoidunnecessary force and roughhandling of partsin disassemblingand reassembling. 2. Keepparts clean and free from abrasiveforeign matter, using special care in the handlingof ball bearings. 3. Do notbump or abradefinished surfaces, giving special care to wearsurfaces, shaft shoulders, gear and impellerhub faces,gear teeth, etc. lilw"tt 1-t971 r!?oo r r n s g I B g t3 t B E E H n 3
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I INSTRUCTIONS FOR REPLACING SHAFT SEAL ON DARLEY CHAMPION S PUMP
l. Dismantlefront and rear universaljoint and disconnectboth the propellershaft and thejack shaft from the pump assembly.Disconnect shift lever linkageat the pumb. 2. The bottomhalf of the pump-is securedby nil_ele,etstuds through the casing#l andelbow flange andthree studs passing through the centermanifold. Remove the nineteen l/2'-nuts from underneaih the truck and three 1/2" nuts from the top of the centermanifold. 3. Droppump assembly straight down until thethree long studs in theassembly clear the center manifold casting,and removefrom under the truck. 4. Unscrewthe twelve ll4" capscrews on the third stagegear case at point "A' indicatedon drawing and removethe assembly. 5. Removethe six-3/8" cap screwsfrom the bearingbracket #49 andremove this assembly.Use ex- tremecare in this operationso the pilot bearing#51 is not damaged. 6. Removethe outboardhead #8. 7. Unscrewthe impellernut #5 andremove the lockwasher#6. lb hold the impellershaft from turning while removingthe nut, placeshift rod in pumpposition, pulled out to is limit, and insert a bar into the universaljoint. 8' The first impellercan be pulledby employingthe two ll4" puller holeson the rear of the impeller. 9. Removethe eight l/2" nuts on thd inboardhead #1. 10. The secondimpeller #ll mustnow be takenoff the shaft.Impeller key mustbe removedbefore this canbe accomplished. ll. With the removalof the secondimpeller, the sealis exposed.Slide the bellowsassembly #82 off andusing a small screwdriver or wire, pry out the floatingseat assembly from the inboird head. 12. Checkthe shaft sealto be sure it has not beendamaged. 13. Cleanall dirt andrust from the sealpocket in the inboardhead. The Darleyshaft seal is a precision product.Treat it with care.In handfingdo not let the carbonsealing *urli"t drop or fall;'and ake particularcare not to scratchthe lappedfaces on the washerand floating seat. 14. Oil the outer surfaceof the seatring (uselight oil, NOT grease)and pushthe assemblyinto the cavity,seating it firmly and squarely.Use finger pressureonly. 15. Beforecompleting the shaftseal installation,wipe the lappedsealing wash& faces of the floating seatand sealingwasher perfectly dry. 16. Oil the shaft (uselight oil, NOT grease)to allow bellowsto be pushedeasily into position. 17. Put the washerand bellowsassembly on the shaft(but not the spring) and slide the assemblyin as far as it will go- Be surethe sealingwasher is in the proper- position. The notcheson the ;dge of the sealingwasher should mate with the retaininglugs. 18. Slip the spring into place, making sure it is seatedproperly over bellowsassembly. 19. Replacethe lst s-tageimpeller #ll on shaftmaking sure the springis seatedproperly in counterbore at rear of impeller. 20. Holding-theimpeller in this position,insert the key and reassemble the pumpby reversingthe pro- ceduredescribed above.
W. S. DARLEY & COMPANY MelrosePark, Illinois - ChippewaFalls, Wisconsin
lArcot r INSTRUCTIONS FOR REPLACING REAR WATER SLINGER
l. Removebearing cap. 2. Pry off bearingand waterslinger with screwdriver. 3. Place_newslinger in placeand tap or pressto the shoulderof shaft.We adviseusing a sleevewith an l.D-slightly largerthaa the O.D. of the impellershaft, to installthe slinger.This-will avoidany possibility of distortingthe slinger. 4. Replacethe bearingand bearingcap.
INSTRUCTIONSFOR REMOVING TACHOMETERGEAR & SHAFT ON M, S OR SH PT,]MPS
l. RemoveThchometer Cover. 2. Loosenset screwsin 2 centerholes. 3. Drive taperedpin out of tachometergear. 4. Removeeuter brassbushing and pull shaftout of gear.
INSTRUCTIONS FOR REPLACING REAR DRIVE SHAFT OR BEARINGSONM&SPTJMP
1. Dismantlerear universaljoint. 2. Thkeout 6 cap screwsholding drive shaftbracket - 4 on gear case,2 on casing. 3. Pull entireassembly touard rear of pumptill releasedfrom bearing#47.lJtmost care musf be taken so as not to damagethis bearing. 4. Shaft can be pressedout from the assemblyand bearingsreplaced. 5. Removebrake drum - 4 capscrews holding rear bearingcap and brake anchor. Removal of this cap uncoversthe rear bearing#52. 6. Presson new bearingsand reverseprocedure for re-assemblying. Extremecaution must be exercisedupon assemblying the unit to thepump to protectthe pilot bearing.
INSTRUCTIONSFOR REPLACING 3RD, STAGEVOLUTE
l. Place volute in place on head, fastentemporarily. 2. Use suction flange as templateand mark volute for drilling and tapping. 3. Removevolute, drill and tap four 3/8 NC tappedholes - ll2" full thread. 4. Reassemblepump. 5. Fasteninlet flange to volute and replacepacking nut.
la&b 7l INSTRUCTIONS FOR REPLACING DRTVE SHAFT & CLUTCH GEAR l. RemoveGear Case Cover, #60. 2. RemoveThchometer Gear Cover #64. Using a smallpunch, drive taperpin from Thchometergear. After releasingAllen Set Screwholding outsidetachometer bushing, pull shaftand bushingfree, then removetachometer gear. An Allen Set Screwis locatedin the centerhole of the Thchometer Gear CoverBolting pattern. Remove6 cap screwsin #62 bearing cap. The gear cluster can now be removedby pulling entire assemblyforward until pilot bearingis free from rear drive shaftbearing bracket. 4. A_fterthe gear-cluster.is removed, push bearing cap off andusing a bearingpuller, pull pilotbearing #54 andthe front drive shaft bearing#51. Usinga 5116"drill, very carefullydrill rivited endof the 6 capscrews holding gear together so they canbe removedfreely. After thesesix cap screwsare removed,entire assembly can be dismantled. 6. After havingchecked for chipsor anyother foreign material, carefully reverse procedure until entire unit is reassembled.
ATTENTION SLIDINGCLUrcH GEARMUST BE ON SHAFTBEFORE PILOT BEARING IS PRESSEDON.
INSTRUCTIONS FOR REPLACING TRUCK DRTVE SHAFT ON SH PT'MP l. Remove4 cap screwsfrom #L23Inlet Flangeand all pipesconnected to 3rd stagecasing. 2. DisconnectBy-Fass Tlrbe between 3rd stageand Pump Manifold. 3. Removethe twelve ll4" capscrews holding the 3rd stageQear Case to the Main GearCase. Using one of the cap screwsrembved from the 6ear CaseFlanje, insertinto the tappedholes provided on the top and bottom of the Gear Case,and turn in until the Gear Caseseparates. 4. Removethe six 3/8" cap screwsfrom the BearingBracket #49 andremove this assembly.Use ex- tremecare in this operationso the pilot bearing#51 is not damaged. 5. Replacewith new assemblyand reverseprocedure described above.
lAtx:otI Power Shift Linkage Adjustment Type SE Pump Main Transmission Shift Bar Drawing GlE64 l. With lever(18), links(21), pins (23 &24), andclevis assembled as shownin DrawingG1864, extendlever (18) completelyforward until shift bar snapring hits rear of transmissioncase. 2. Extendcylinder rod (41) until piston(37) contactscylinder end (33). 3. Loosenclevis locknut (31). 4. Adjustyoke end (30)to position3/8" holein yokeend l/16" to l/8" beyondhole in lever(18). 5. Tightenyoke end locknut(31). 6. Installall clevispins and cotterkeys. 7. Cycle cylinder in and out while observingthe locationof the shift bar. If linkageis correctly ad- justed, shift bar travel shouldbe stoppedat eachend of its strokeby the retainingrings contacting theoutside of transmissioncase. The resultingreserve travel in cylinderrod will keepconstant pressure on retainingrings providing positive locationof the shift bar.
Bwzt TO REASSEIVIBLESEH 3RD SIAGE PTJMPAND GEAR CASE Refer to Drawing 5754
1. Build impeller shaftassembly as follows:Place ge,ar(147) and spacer(148) on impellershaft e43) and presson bearing 049) Oear againstinner race only). Place spacer(183) and bearing(139) on shaft and pressinto place. Securebearing (149) with lockwasher(62) and locknut (150).Bend lockwashertab into locknutnecess. Place bearing closure 037) andwater slinger (lil8) on shaftand tighten with a spannerwrench (right hand threads). 2. Pushimpeller shaft assemblyinto positionthrough gear case. 3. Pushidler shaft bearing(155) into placeat pump side of gear case. 4. Fositionidler gear (144)and spacer (142) in gearcase and push idler shaft(l5a) in until resistance is felt. Rotategear on shaftto line up keyways. 5. Insertkey (l53) ' to hold keywaysin line andpress shaft all the way into bearing.Thp key all the way into keyway. 6. Pressother idler shaft bearing(155) on shaftand into gear casehousing. 7. Checkaxial clearanceand insert paper gasket (l8l) underbearing cap (146) to provide.005" minimum up to .015"for both pump and idler shafu. Tightenbearing cap screws. 8. Placeshift bar (61) throughside of gearcase and into locknut(182) lockwasher and shift collar (l4O) which is engagedwith groovein pinion gear(147) and insert end of bar into gearcase hole at otherside. 9. Screwshift bar (l5l) into shift collar (140)until abouttwo threadsshow beyond collar. Rotateshift bar to line up lug andinsall shift bar stop(180) and locknut 091). Shoulder at endof threadsserves as a stop for 'but" position. 10. Tightenlocknut (182)against lockwasher and shift collar (140). 11. Engagepinion gear(147) with idler gear(144) until gearstops against spacer (148). Move shift collar until bladein grooveof piniongear is centered,or has l/8" clearanceon eachside of bladB.Screw shift bar stop (180)in to contactlug on shift bar at this point to serveas stopfor "purr4- position and tightenlocknut (l9l). Helical gearthrust holds pinion againstspacer (148) when pumping. 12. Installgasket (136) and stuffrng box (135).Flange surfaces must be clean.andsmooth. Permatex both sidesof stuffing box gasket.Apply oil to seal ring groovesbefore placing impeller. 13. Install spacer(188) impeller (132) washer (129) locknut (128) and brass cotter pin. Tightenimpeller retainingnut very ligfuly as excessivetighlening may springimpeller shaft. 14. If packing(134) has been replaced, tighten packing screw (159) while rotatingpump shaft by hand until someresistance is noted.Final adjustmentis accomplishedwhen pumping water. See Opera- tion and MaintenanceInstructions. 15. Apply oil to seal ring grooveand install pump casing(122). 16. Install gasketand dowelpins to properly locategear caseto main pump transmissioncase. 17. Replacepiping. 18. Reconnectshift bar linkage.
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4-tt tq- INSTRUCTIONS FOR REMOVING SEH 3RD STAGE PT]MP ASSEIVIBLY Refer to Drawing 5754
l. Disconnectshift bar linkage. 2. Removefour cap screwsfrom inlet flange(123). 3. Removetwelve cap screws and tno do'rvelpins holding3rd stagegear case 045) to mainpump transmis- sioncase. Use gear case cap screws in tappedpuller holeson top andbottom of geariase io separate flanges. 4. If 3tqstagepump-is to be-returnedto factoryfor repairs,then disconnect suction tube, plug opening in mainpump discharge elbov, andcover transmission case opening with the blankcwer ptateprd,viaeA.
CAUTION: If the puTp is returnedto servicewithout the 3rd stagepump, do not forgetto refill transmissioncase with heavyduty SAE 20 oil to the level plug.
TO DISASSEMBLB SEH 3RD STAGE PT.]MPAiYD GEAR CA.SE Refer to Drawing 5754
l. Remove16 stud nus holding pump casing(D2) to gear case(145) and separateflanges. 2. Removeimpeller retaining nut (128)and washer (129) from impellershaft. Place a hardwoodblock againstidler gear (144)engaged with pinion gear (147)to keepshaft from turning. 3. Pry impelleroflfrom shaft,using a pair of flat barsbetween back of impellerand stuffingbox at oppositesides. Bear againstimpeller wherevanes provide support.Remove spacer (188). 4. Removesix flat headscrews holding stuffing box (135)to gear caseand separate. 5. Loosenshift collar locknut (182)and removestop screw080). Unscrewshift bar (l51)fiom shift collar (140)and removeparts from gearcase. 6. Removesix screwsand bearingcover plate (146). 7. Usea heavyflat puller bar with two tappedholes 3-ll4" apartwith a 13132"clearance hole centered in betweento pull idler gearshaft (154) and bearing(155) out of idler gear(144) and gear case using the 3/8"NC tappedpullerhole in endof idler shaft.Bearing (155) at pumpend can be removedwit[ a hookedpry bar. 8. Pushimpeller shaft (143)assembly complete through gear case toward bearing cap end. 9. Unscrewwater slinger (138) with a spannerwrench and removebearing closure. 10. Pressoff bearing(139) and spacer(183) using pinion gear to bear against. ll. Removelocknut (l50) and lockwasher(152) to removebearing (149) and spacer(148) using pinion gearto bearagainst.
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TYPE SEH CHAMPION FIRE PI,IMP
Rep. Rep. Rep. No. Name of Part No. Name of Fart No. Name of Fart 101 Inlet Elbow 136 Pump CasingGasket 153 Idler Gear Key 102 Gland Stud Piston 137 BearingClosure Assy 154 Idler Gear Shaft 120 Inle.tNipple 138 WaterSlinger 155 Idler Shaft Bearings l2I RetainingCollar Stud 139 Pump ShaftBearing 159 PackingScrew 122 Pump Casing 140 Shift Collar 16l Gland Nut 123 Inlet Stuffing Box 142 Idler GearSpacer 180 Shift Bar Stop 124 Stuffing Box Nipple 143 PumpShaft l8l BearingCap Gasket 125 SealRing 144 Idler Gear 182 Shift Collar Lock 126 Inlet Gland Nut 145 PumpHead & GearBox 183 Oil Slinger 127 Inlet Gland Packing 146 BearingCap 184 GlandYoke 128 ImpellerNut 147 PumpDrive Pinion 185 GlandScrew-Plunger 129 Impeller Washer 148 PumpGear Spacer 187 RetainingCollar 130 Inlet Gasket 149 PumpShaft Bearing 188 Impeller Spacer 132 Impeller 150 BearingLocknut 189 StrainerSleeve 134 ShaftPacking l5l ShiftBar 190 StrainerFitting 135 StuffingBox 152 BearingLockwasher
l*tur71 INSTRUCTIONS FOR REPLACING SHAFT SEAL oN DARLBY SH PtrivIR THIRD STAGE
l. Removefour cap screwson suctionflange - #123.. 2. Back off nuts on adjustingstuds - #r2l - and removesame. 3. Unscrewbrass suction pipe - #124- from rralve- #101. 4. Removepump casing - #122. 5. Removeimpeller - #128. Impeller is removedfrom shaftby exertingpressure from two oppositepoints on rear of impeller. Extreme.care mustbe exercisedso pressureison the ranesof the iririe[ei dr i-p"ll;r;il 6" *iourry damaged. 6. Removchead plate - #1f.S. 7. Removespring retainer- #133. 8. Removeshaft seal spring, bollorvsand floating seat. 9. Make surethat Fe syntheticrubber..seat ring iq tig[ againstthe shoulderof the floatingseat, with , rounded outer edgeat the rear to facilitateinsertiori ThJring is assembledin this t*i*f,?" ,t-i,i,p"O. 10. Oil theouter surface.of the seatring (uselight oil, not grease)and push the assemblyinto thecavity, seatingit firmly and squarely. ll. If.it is not possibleto insert floating s9a!y{h the fingers,use the size of tubing or sleevewhich will makecontact on the outer edg- of the floating s&t, wCn oo th" lappedrJding f".g. 12' CLEAN AND oIL SEALING FAcEs completin-gthe shaftseal installation, wipe the lapped sgaling.faces ffore of the floatingseat and sealing washer periectly clean. ffren oiiUoth fr;;:-;il JLn, light oil. 13' (use Oil shaft lightoil,.not grease)to allorv bellowsto be pushedeasily into position.The should 'ou", shaft be clean and polishedsmooth. If shaft haskeyway in diamete, wirich sealassembly passes'hone edges of keywayand insertwooden key-fluih with shaft circumference. 14' Put the sealingwasher and bellows assembly on thesha{, (but not the.spring)and slide the assembly in as far as it will go. Be surethe sealingwasher is in the propglposition.itre notcheson tt. of rog" thesealingwasher should mate with the lugson the retain.i. lf it ir noipossibleto sUaeassembly iruo placewith the fingers,use a sleeveof lroper diameter.A smoothsleeve is suiable. 15. Slip the spring into place, makingsure that is is seatedproperly. 16. Replacespring retainer- #133- and reverseprocess in replacingparts. (If impractival to work with Third Sageon pump,entire assembly can be removedfrom maingear case- #19.)
lDocn-rr INSTRUCTIONS FOR REPLACING DRTVE GEAR ASSEIVIBLY AND IMPELLER SHAT'T ASSEMBLY ON SH PI.]MP
l. Remove4 capscrews from #123inlet flangeand all pipesconnected to 3rd sage casing. 2. Removethe 12- ll4" cap screwsholding the 3rd stagegear case to the main gearcase. Using one of the cap screws,removed from the gear caseflange, insert into the tappedholes prwided on the top and bottom of the gear case,and turn it evenly until the gear casesseparate. 3. Disconnectfront and rear universaljoints from pump shafts. 4. Removetachometer gear cover#83. Using a small punch,drive taperpin from tachometergear. After releasingAllen set screwholding outsidetachometer bushing #43, pull this bushingand tachometershaft #42 out of opening,then removethe tachometergear. The Allen setscrew is located in the centerhole of the tachometergear coverbolting pattern. 5. Remove6 cap screwsin #39 bearingcap. #162 drive gearcluster can no\il be removedby pulling entire assemblyforuard until pilot bearing#51 is free from rear drive shaftpocket. 6. Tirkeout the 6 cap screwsholding rear drive shaftbracket #49 - 4 on gearcase and,2 on casing. Pull entire assemblytouard rear of chassistill releasedfrom gear case. 7. Removebearing cap #177. Bearing #176 should come off with cap.If not it will comeoff when #8 headis pulled off. 8. Remove12 capscrews from outboardhead #8. Using 2 screwdrivers as priesdirectly oppositeof eachother, push straightback until shaft has passedthrough'stuffing box. 9. Remove#5 impeller nut. 10. Pull #3 2nd stageimpeller usingthe puller holesprovided. ll. Removethe 4 cap screwsfrom #23 bearingcap. 12. Using a lead hammer,tap #18impeller shaft towardsfront of chassisuntil bearingshave cleared bearingpocket. Shaft shouldnow slide forward out of impeller splines. 13. Insertnew pump shaft with all partsassembled to the shaftas removed.Extreme care must be used at this point to align the splineof the shaft with the lst stageimpeller.
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\! \! OF !. $ >o I E lf -l o I 9{ il? 0r orfie -{I B -to (o Hp DUNTI OPERAING TIIE TYPE SH PTJMP The sliding gear clurch which drives the third sage is operatedI a shift lever marked "Eog" for pumping position and "Out" for disengagedposition. Ttre shift lever must be locked in one or the other of thesepositioni before the pump can be started. The third stageclutch must not be shifted while the main pump is running. When the main pump is in operation, it must alwaysbe stopped(engine clutch disengaged)for shifting of the third sage clurch either in or out. ' The third stageis alwaysprimed @ prcssurefrom the main pump. The third stagehas a small by-passline with valve to boostertank. Open by-passvalve when rirnning with 3rd stagedischarge lines completely shut off. PARIS LIST FOR TYPE SH CIIAMPION FIRE PT]MP DRAWING NO. S1O7I Rep. No. Name of Part Quantity Rep. No Name of Prrt Quantity 101 InletTee ...... 1 r44 Idler Gear r02 GlandStud Piston ...... 1 145 Pump Head . 103 CouplingPipe O-ring ...... 1 t46 BearingGap. . 104 ShiftBar O-ring ...... 1 t47 PumpDrive Pinion.... 105 Strainer Plug . 148 Pinion Spacer 106 Impeller Nut Key t49 Bearing ...... 1 t20 Inlet Pipe 151 ShiftBar ...... 1 r2l RetainingStud. 153 IdlerGear IGy ...... 1 122 Pump Casing 154 IdlerGearShaft ...... 1 123 Inlet Flange 155 IdlerShaft Bearings ...... -...2 n4 Coupling Pipe . r59 PackingScrcw ...... :..1 125 Seal Ring l6l GlandNut ...... ^....1 r28 ImpellerNut .. 181 BearingCap Gasket ...... 1 r29 Impeller Washer r82 RetainingRing.. :...... 2 BO Inlet Flange Gasket 184 Facking Plunger Guide ...... 1 132 Impeller 186 CollarMjusting Nuts...... -2 t34 Facking .10 t87 ReainingCollar ...... 1 135 Stuffing Box . ..1 188 ImpellerSpacer ...... 1 136 Pump Casing Gasket ..1 189 StrainerSleeve ...... 1 138 Oil Seal ..1 190 StrainerFitting ...... 1 89 PumpShaft Bearing ... ..,. ..1 t92 WaterSlinger ...... 1 140 Shift Collar ..1 r93 Shift Bar Oil Seal 1 t42 Idler Gear Spacer ..1 194 StuffingBox Gasket ...... 1 t43 Pump Shaft . ..1 195 ReainingRing...... 2 nrc0'7I 06-ll 98-X -----'l-----'l g 0 I i lF (,|@ { lan p I I l' l'1 € - B I (' I lrf ! m 0 ln an m ft u I t o 0o a d I rn o (,N I o t- I I o rl ! t0 c o o ! o U) I I t o ! a o { I a : - BocD'l1 W.S. DARLEY & CO. REPAIR SERVICE INSTRUCTIONS THIRD STAGE HIGH PRESSTJREPIJMP TO REIVTOVETHIRD STAGE FROM MAIN TRANSMISSION Refer to Drawing S107l l. Disconnectshift bar linkage.Do not removeadjustable yoke from bearingcap (146). 2. Removefour 3/8"NC cap screwsholding inlet flange(A, b pump casing(nD. 3. Removetwelve l/4"NC cap screwsholding pump head (145) to main pumptransmission case. Use gearcase cap screwsin tappedpuller holeson top and bonom of gear caseto sepamteflanges. 4. If third stagepump is to be returnedto factory for repairs,disconnect suction tube, plug opening in mainpump discharge elbow, and cover transmission case opening with the blankcover provided. CAUTION: If the pumpis returnedto servicewithout the third stagepump, refill transmissioncase with SAEI0W40 SF grademotor oil to the level of the l/8" NPT gageplug. DISASSEIVTBLYOF THIRD STAGEPUMP FOR OVERHAUL . l. Makealignment marks on the pumpcasing (A2) andthe pumphead (145). A centerpunch or cold chisel works well for this. 2. Removesixteen 3/8"NC nutsholding pump casing (D2) to pumphead (145) and separateflanges. 3. Removecotter key (106),impeller nut (128)and impeller washer (129) from pumpshaft (143). Place a hardwoodblock againstidler gear(144) engaged with pinion gear(147) to keepshaft from rotating. 4. Pry impeller (132)off of pumpshaft (143), using a pair of flat barsbetween back of impellerand stuffingbox at oppositesides. Bear against impeller where vanes prwide support.Remove spacer (188). 5. Make alignmentmarks on stuffingbox (135)and pump head(145) with indeliblemarkeT. 6. Removetwo 5/l6"NC cap screwsand removepacking plunger guide (84) from stuffingbox 035). 7. Removesix l/4" flat headbrass machine screws holding stuffing box (135)to pumphead (145) and separate. 8. Slide waterslinger (192)off of pump shaft (143). 9. Removefour reaining ringsfrom shift bar (61) andslide shift bar out of shift collar (140)and pump head(145). 10. Removeshift bar o-ring (104)and shift bar oil seal (193)from pump head(145). ll. Removesix 5/l6"NC cap screwsand removebearing cap (146)from pump head(145). 12. Usea heavyflat puller bar with two tappedholes 3-ll4" apartwith a 13132"clearance hole centered in betweento pull idler gearshaft (154) and bearing(155) out of idler gear (144)and pumphead (145)using the 3/8"NC tappedpuller hole in end of shaft. 13. Pressbearing (155) off of idler gearshaft (154). t4. Removebearing (155) at pump end with a hookedpry bar. 15. Pushpump shaft (143)assembly through gear casetoward bearing cap end. 16. Pressbearing (149), spacer (148), and pinion gear(147) off of pump shaft (143)rogerher. 17. Pressbearing (139) off of pump shaft (143). 18. Pull or tap oil seal(138) out of pumphead (145). l?tgett PTJMP PARTS INSPECTION AND MEASI,JREIVIEr\iI l. Cleanall parts and inspectcarefully for wear or deterioration.Replace all questionableparts. 2. Measurethe impeller sealrings and the impellerfor wear.Use the follorvingtable for comparison. Impeller SealRing O.D. 1.868- 1.870" Impeller SealRing I.D. t.625- r.626" SealRing O.D. 1.878- r.879" SealRing I.D. 1.618- r.620" Stuffing Box SealRing O.D. 1.878- 1.879" StuffingBox SealRing I.D. 1.618- 1.620" ClearanceO.D. - original 0.008- 0.013" ClearanceI.D. - original 0.005- 0.008" 3. If clearanceexceeds 0.025 inch on diameterimpeller seal rings can be restoredto original sizeby solderinga ring over trued surfacewhich retainsat least0.(80" wall thickness.Stationary seal ring (125)and stuffing box (35) shouldalso be replaced. 4. Measurethe impeller shaft and stuffing box for wear.Use the following able for comparison. Impeller shaft diameter at packingarea 0.870- 0.971" Stuffing box bore - original 0.875- 0.877" Stuffing box bore - maximum 0.882" Clearance- original 0.004- 0.007" Clearance- maximumallowable 0.012" 5. Measurebearing housing bores for propersize. Use the followingtable for comparison.If anybore exceedsthe high limit by 0.0(n5", the part shouldbe replaced . PART REP. NO. ORIGINAL BORE DIA. Pumphead 145 all 2.4410- 2.U16" 6. Measureshaft bearing journals for proper size.Use the following table for comparison.The low limit underbearing is requiredto insurea pressfit with inner ball bearingrace. ORIGINAL JOURNAL PART REP. NO. DIAMETER Pumpshaft 143 pump side 0.9849- 0.9846" 0.6692- 0.6695" Idler gear shaft 154 1.1808- 1.1812" 7. Theoriginal idler gearshaft diameter under the idler gearis 1.3775to 1.3780inches. The original idler gearbore is 1.3785to 1.3790inches providing a 0.0005to 0.0015inch clearance.The parts are still serviceableup to 0.0020 inch clearance. ASSEMBLY OF THIRD STAGE HIGH PRESSI.JREPUMP Refer to Drawing 51071 l. Apply'greaseto shift bar oil seal(193) and insertinto groovein pumphead (145) with insidelip facinggear case, 2. Apply greaseto shift bar o-ring (104)and insertinto groovein pump head(145). 3. Pressoil seal(138) into pumphead (145) flush with face,with lip springof sealfacing bearing. Fill greasecavity with greaseand lubricateoil seallips. le&o7l 3il9t91 I 4. Pressbearing (139) onto pump shaft (143)tight againstshoulder. 5. Apply oil to splinesof pump shaft (143).Slide pinion gear (147)onto pump shaft with shift groove end touards pump side. Slide pinion spacer(148) onto pump shaft. 6. Apply a light coatingof greaseto bore of bearing(149). Press bearing onto pump shaft(143) until inner raceof bearingis tight againstspacer (148). 7. Wrapsplined end of pumpshaft (143) in shimstock to preventdamage to oil sealas shaft is inserted. 8. Presspump shaft (143) assembly into pumphead 045) from bearingcap end until bearing(li]9) con- tactsthe shoulderof its bearingpocket. 9. Thp idler shaft bearing(155) into bearingpocket on pump side of pump head(145) until bearing contactsthe shoulder. 10. Positionidler gear (144)and spacer(142) in gearcase and pushidler shaft (154)in by handuntil resistanceis felt. Rotategear on shaft to line up keyways. ll. Insertidler gearkey (63) to hold keywaysin line andpress idler shaft(154) all the wayinto bearing (155).thp key all the way into keyway. 12. Thpremaining idler shaftbearing (65) onto idler gearshaft (154)and into bearingbore of pump head(145). 13. Trim bearingcap gasket(l8l) so that it doesnot interferewith bearings(155) and (149). 14. Apply a thin layerof No. 2 Permatexto gasketflange surface of bearingcap (146).Place bearing cap gasket(181) on bearingcap againstPermatexed surface. 15. Attachbearing cap (146) to pumphead (145) with six 5/l6"NC x314" cap screwsand lock washers. 16. Apply oil to shift bar (l5l) and slide shift bar half-wayinto pump head(145). 17. Engagelarge side of shift collar (140)in grooveof pinion gear(147) and slide shift bar (151)into shift collar and all the way into pump head. 18. Placefour retainingrings (182),(195) on shift bar (151).Make sureshift collar (1,10)is betweentwo closelyspaced grooves near center of bar. SeeDrawing X3494, which showssharp corner side of retainingring in properposition to takethrust load. All retainingrings shouldbe tight in groove. Replaceany looserings. 19. Slide waterslinger (192)onto pump shaft (143). 20. Apply a thin layerof No. 2 Permatexto gasketflange surface of stuffing box (135).Place stuffing box gasket(194) in positionagainst Permatexed surface. 21. Slidestuffing box (135)over pump shaft (143). Line up alignmentmarks on stuffingbox (135)and pumphead (145). Apply threadtape and Permatexto the threadsof six Il4" x l" flat headbrass machinescrews. Attach stuffing box to pump headwith thesescrews. 22. Trim gasketaround stuffing box and cleanoff Permatex. 23. Slide impeller spacer088), impeller (132),and impeller washer(129) onto pump shaft(143). 24. Cleanand dry shaftthread and impeller nut (128),removing dirt, grease,and oil. (LoctiteKlean N' Prime, Fart No. 2556,can be usedto cleanparts and shortencure time.) 25. Apply Loctite 242 Threadlockerto shaftthread and nut thread. 26. Tightenimpeller nut (128)until it contactsimpeller washer (L29), then turn to nextcotter key hole. (DO NC}TOVER TIGHTEN.) 27. Install a 3132" x l-114"STAINLESS STEEL cotter key (106)in pump shaft cotter key hole. 28. Placepump casinggasket (136) on studsof pump casing(122\. 29. Line up alignmentmarks and push pump casing (122) onto pump head (145). Attach with sixteen 3/8"NC nutson studs. 30. Attachpacking plunger guide (184) to stuffingbox (135)with two 5/l6"NC x 314"cap screwsand lock washers. 31. Apply a thin layerof No. 2 Permatexto gasketflange surface of stuffingbox (135)and place gasket in positionagainst Permatexed surface. 3 leoi'xt7!' T]ILLING TIIE STUFFING BOX WITH PACKING U_seonly plastallicpacking supplied by W.S. Darley & Co. It is importantthat the stuffingbox be completelyfilled solid with packing.If voidsare present, pump pressuremay force packing out betweenshaft and box opening,enlarging the void until no packingre- mains.This will not occur when packingis solid. To packthe stuffingbox whenempty and assembled in the pump,it is convenientto usepellet packing and feed with packing screwusing a speedwrench. At the sametime the pump shaft shouldbe turned' by handuntil resistanceto turningis felt whenalmost full. Continueturning packing screw by handusing a standard9/16" end wrenchuntil about2 n 4lb. force is felt at the end of wrench.Continue turning until a few flakes of packing are extrudedout of shaft opening.Rotate pump shaft by handuntil it turns freely. The gland is now readyfor further adjustmentwhile pumping. INSIALLING PT]MP IN TRUCK CHASSIS Reversethe proceduresoutlined under removalinstructions. PACKING ADJUSTMENT While pumping a 50 psi dischargepressure, observe that 10 to 20 drops per minute of water comes out of stuffing box. Increasepump dischargepressure to normal operatinglevel and checkthat drip rate remainswithin samelimig. A slight additionaltightening of packing screwmay be necessaryto achieve a stabledrip rate. For pumpsthat havebeen in service,it is imporant to periodically checkthat drip rate remainscons- tant at normal operatingpressures and at 50 psi. To insurethat packingactually is solid, we recommend that the packing screw be turned while pumping at 50 psi until the normal 2 n 4lb. resistanceis felt at end of standard9116" end wrench. Alternatepumping at both normal pressureand 50 psi level and observethat drip rateremains constant betweenl0 to 20 dropsper minute. It maybe necessaryto repeatthis procedureseveral times to achieve a stabledrip rate if the packing has not been attendedto over a long period of time. SOME CARE AND HANDLING INSTRUCTIONS l. Avoid unnecessaryforce and rough handlingof parts in disassemblingand reassembling. 2. Clean partsthoroughly and maintainfree from abrasiveforeign matter. 3. Keep bearingin original containersuntil readyto install. 4. Work with cleantools, in cleansurroundings during reassembly. 5. Do not bump or abrademachine finished surfaces, giving specialcare to wearingsurfaces, shaft shoulders,gear and impeller hub faces,gear teeth,etc. Use an arbor pressfor forcingpress fits wheneverpossible. If necessaryto usea hammer,use one havingsoft plasticheads. 7. Use suitablemachined and fitted sleevesor barsfor forcingor driving ball bearingsand other parts havingpress fits. Do not pressa ball bearingonto a shaftby forcingagainst the outerrace. Heavy pressure or impact againstbearing balls will damagethe bearingand causepremature failure. 4 iSwtt g. If necessaryto removea ball bearingfrom a shaftby forcing againstthe outer race,the bearing shouldbe discardedand rePlaced. 10. Whenpressing or driving a bearingor other part onto a tight fining shaftthe Part mustbe started dead squarewittr ttre shaft and forced on squarelyall the way. 11. Cleanand oil bearingseats and other partshaving press fits to Preventgalling. 12. Keeploose parts marked or otherwiseidentified to avoiderrors in assembly. IF FuRITIER INFORMAIION IS NEEDED,CA,LL W.S. DARLEY CO. AT CIIIPPEWA FALI^S,WIS. at 8fi){34'78n or T15'723'0216 la0oo'7t