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DARLEY ZSP Nstallation, Operation, Maintenance, Repair And Troubleshooting Instructions

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INSTALLATION, OPERATION,
MAINTENANCE, REPAIR AND
TROUBLESHOOTING INSTRUCTIONS FOR
Corporate Office:
325 Spring Lake Drive
Itasca, Illinois 60143-2072
800-323-0244, fax (708) 345-8993
Prepared by: RJG
Approved by: WAH
Revised by: WAH Via ECO 11337
THE ZSP Fire Pump
Pump Manufacturing:
1051 Palmer St.
Chippewa Falls, WI 54729
800-634-7812, Fax (715) 726-2656
WWW.DARLEY.COM
This manual is for DARLEY FIRE PUMP:
Model: ZSP
Pump Serial Number: ________
Apparatus Division:
920 Kurth Rd.
Chippewa Falls, WI 54729
800-527-0068, Fax 726-2648
Rev. A
Date: 03/16/12
Rev. Date: 02/19/2016
1200643.doc

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Summary of Contents for DARLEY ZSP

  • Page 1 Chippewa Falls, WI 54729 Chippewa Falls, WI 54729 800-323-0244, fax (708) 345-8993 800-634-7812, Fax (715) 726-2656 800-527-0068, Fax 726-2648 WWW.DARLEY.COM This manual is for DARLEY FIRE PUMP: Model: ZSP Pump Serial Number: ________ Prepared by: RJG Rev. A Approved by: WAH...
  • Page 2 Introduction This manual provides information for the correct safety, installation, operation, maintenance, repair, and troubleshooting of the Darley ZSP pump system. Please read and follow these instructions thoroughly before putting the system in service. Doing so will ensure optimal performance and long life of your equipped apparatus.
  • Page 3 Mounting Isolator Snubbing Washer – 3603931 Pump Heater Core Plumbing Detail – DGS0400 PTO Pump Engagement Electrical Schematic – DGS1100 ZSP Installation Manual Appendix SPICER DRIVELINE GUIDE J3311-1-DSSP – 1201026 SECTION 4 – Pump Detail Description, Operation & Maintenance, & Lubrication --------------------------------------- 1200643 Related Drawings --------------------------- Pump Cross Section &...
  • Page 4 Electrically Clutched Belt Driven Primer --------------------------------------------------------- 1200644 Primer - DVC0317-DVC0320 SECTION 5 – Optional Equipment Multiple Drain Valve ------------------------------------------------------------------------------------DGC0904 Ball Valve --------------------------------------------------------------------------------------------------- 1200000 Valve Cross Section - DGC0100 Relief Valve “Discharge Valve” ---------------------------------------------------------------------- 1200503 RV and Remote Head Schematic and Cross Section- DGC0141 RV and Remote Head Dimensional - DGD0800 RV Alarm Installation –...
  • Page 5 Section 1 Definition of Symbols and Immediate Safety Information Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 6 - Signifies a potentially hazardous situation that might result in property damage. Ignoring any of these identified hazards is not recommended. W.S. Darley does not advise such actions or take responsibility for the actions of any operator of this unit. Prepared by: RJG Rev.
  • Page 7 Installation of said drivelines should not occur until a proper analysis is performed by either said drafter or W.S. Darley. Darley utilizes and can distribute the Allison Driveline Analysis program which they use for said analysis, along with an instruction for use.
  • Page 8 Exposed rotating drive-shafts should be guarded. It is highly recommended by Darley to use safety rings around drive tubes. Especially near connecting u-joint crosses. Such safety rings would be sufficiently attached to the chassis frame and sufficiently strong enough to prevent a broken u-joint assembly from allowing a driveline to slide out from underneath the truck at high speeds while still rotating, causing severe personnel injury.
  • Page 9 Darley. W.S. Darley utilizes, can distribute and can train qualified individuals to use the Allison Multiple Joint Driveline Analysis program. W.S. Darley requires that Power Take Off (PTO) driven pumps have at most 500 radians per second torsional vibration and at most 1000 radians per second...
  • Page 10 Section 2 General Information and Operations Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 11 THINGS TO REMEMBER Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 12 20. If pump is equipped with a Darley plastallic (injection) packing shaft seal, check the drip rate frequently, and adjust according to the packing adjustment instruction, as required. The drip rate may vary between 5 and 60 drops per minute.
  • Page 13 PTO SAFETY SHIFTING INFORMATION Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 14 PTO Safety Information These instructions are for your safety and the safety of the end user. Read them carefully until you understand them. General Safety Information To prevent injury to yourself and/or damage to the equipment:  Read carefully all owner’s manuals, service manuals, and/or other instructions. ...
  • Page 15 Rotating Auxiliary Driveshafts WARNING:  Rotating auxiliary driveshafts are dangerous. You can snag clothes, skin, hair, hands, etc. This can cause serious injury or death.  Do not go under the vehicle when the engine is running.  Do not work on or near an exposed shaft when the engine is running. ...
  • Page 16 PTO PUMP SHIFTING PROCEDURE This pump is driven by a transmission mounted (SAE) PTO, a front-of-engine crank shaft PTO, or engine flywheel Depending on the PTO and PTO. transmission configuration, the PTO may be either a sliding gear type or “hot shift” clutch type.
  • Page 17 PTO PUMP SHIFTING PROCEDURE drive system components are engaged in the pumping mode of operation so that the apparatus can be operated in either stationary or pump-and-roll pumping modes. 16.10.6.1 A “Pump Engaged” indicator shall be provided both in the driving compartment and on the pump operator’s panel to indicate that the pump shift has been successfully completed 16.10.6.2 An “OK to Pump”...
  • Page 18 PTO PUMP SHIFTING PROCEDURE required when the chassis transmission is in neutral and the parking brake is engaged, and “Throttle Ready” indication for this condition is not required. 16.10.10.4 An interlock system shall be provided to prevent advancement of the engine speed at the pump operator’s panel unless the apparatus has “Throttle Ready”...
  • Page 19 PTO PUMP SHIFTING PROCEDURE For STATIONARY pumping, proceed as follows for pump engagement: 1. Set parking brake. 2. Shift chassis transmission to neutral. 3. Reduce engine speed to idle or below 1000 rpm. 4. Following the PTO manufacturer’s shifting instructions, engage chassis PTO. The “Pump Engaged”...
  • Page 20 PTO PUMP SHIFTING PROCEDURE For PUMP and ROLL pumping, proceed as follows for pump engagement: 1. Set parking brake. 2. Shift chassis transmission to neutral. 3. Reduce engine speed to idle or below 1000 rpm. 4. Following the PTO manufacturer’s shifting instructions, engage chassis PTO. The “Pump Engaged”...
  • Page 21 GENERAL OPERATIONS INFO Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 22 WARNING: DO NOT USE THIS PUMP FOR HOSE TESTING OPERATING THE ENGINE After the pump has been primed, the engine speed should be increased gradually -- never jerk throttle wide open. Likewise, the engine speed should be decreased gradually when shutting down.
  • Page 23 Air leakage into pump while operating is usually indicated by a rattling sound in pump casing, miniature explosions in stream issuing from the nozzle, or by losing of prime when operating at very low capacities. The usual cause of leaky suction lines is carelessness in handling of suction hose. Bruising of hose threads by bumping against hard surfaces or sand in the coupling often prevents tightening of the joints up against the gaskets.
  • Page 24 capacity further, and usually sets up a vibratory motion and “water hammer” as the water surges in and out of the void spaces. When operating with a long suction line, the driving engine should be accelerated gradually, the discharge gates opened gradually, and the capacities of the pump should be held down to within the range of smooth performance.
  • Page 25 TESTING FOR AIR LEAKS Tests for leakage should be made with the suction hose attached and capped, discharge gate open, and all other openings closed tightly. Run electric priming pump with primer shut-off valve open, until 22” of Hg is shown on the gage. The vacuum should hold for no more than 10”...
  • Page 26 If pump is equipped with a heat exchanger, drain heat exchanger using gravity and vacuum drain on all trucks as follows: Close all open lines and drain cocks. Open cooler valve and open air vent at top or drain cock at bottom of heat exchanger depending on model. With the pump air-tight, open primer with engine running for about a minute and then close primer.
  • Page 27 Capacity of fire pump is measured in gallons per minute. The usual method of measurement is to determine the pressure of the jet of water leaving a given size of nozzle by means of a “Pitot Gage” from which the capacity is computed mathematically. A Pitot Gage consists of a small tube adapted to a point directly into the hose nozzle from the center of the issuing stream, the other end of the tube being connected to an accurate pressure gage.
  • Page 28 F will reduce the lift at least 1 1/2 feet. Temperature is an important consideration when pumping from a test pit where the water is heated by recirculation. IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. AT CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650 Prepared by: EAP Rev.
  • Page 29 DEFINITIONS, OPERATING CHARACTERISTICS OF PUMPS, AND CONVERSION FACTORS Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 30 DEFINITIONS HEAD OF WATER -- vertical depth of water measured in feet or in pressure per unit or area. In hydraulics, head always represents pressure and it is expressed interchangeably in feet of water or pounds per square inch and sometimes in inches of depth of mercury. STATIC HEAD -- the pressure that is exerted by a stationary column of water of a given height or depth.
  • Page 31 Slip is the greatest factor affecting efficiency of a displacement pump, and this factor is greatly influenced by the condition of and wears on the working parts. IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. AT CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650 Prepared by: EAP Rev.
  • Page 32 CONVERSION FACTORS One pound per square inch 2.31 feet of water 2.04 inches of mercury 27.7 inches of water One foot of water 0.43 pounds per square inch One inch of mercury 1.13 feet of water 0.49 pounds per square inch One cubic foot of water 62.4 pounds 7.5 gallons...
  • Page 33 NFPA 1901 TABLES Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 34 TABLE NO. 1 NFPA 1901 TEST Class A TEST Recom- Min. Min. Min. Net Disch. Suction mended Nozzle Disch. Pump Lines Hose Nozzles Press. PSI Press. PSI Press. PSI 250 GPM Fire Pump (1), 1” (1), 7/8” 20’ of 3” (1), 50' (1), 3/4”...
  • Page 35 TABLE NO. 1 NFPA 1901 TEST Class A TEST Recom- Min. Min. Min. Net Disch. Suction mended Nozzle Disch. Pump Lines Hose Nozzles Press. PSI Press. PSI Press. PSI 1250 GPM Fire Pump (1), 2-1/4" 1250 (3), 50' (2), 1-1/2" (1), 2"...
  • Page 36 TABLE NO. 1 NFPA 1901 TEST Class A TEST Recom- Min. Min. Min. Net Disch. Suction mended Nozzle Disch. Pump Lines Hose Nozzles Press. PSI Press. PSI Press. PSI 1750 GPM Fire Pump (2), 2” (4), 50’ 1750 (3), 1-1/2” (2), 1-5/8”...
  • Page 37 Min. discharge pressures listed above are for pumps operating with full 10’ static suction lift. These pressures must be increased by 1 PSI for each 2.3 ft. less than 10’ of lift. IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. AT CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650 Prepared by: CJC Rev.
  • Page 38 DISCHARGE TABLES Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 39 TABLE NO. 2 DISCHARGE FROM SMOOTH BORE NOZZLE Pressures measured by Pitot gage. Nozzle Pressure 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 2 1/4 2 1/2 GALLONS PER MINUTE DELIVERED 1017 1050 1082 1114 1144 1174 1203 1000...
  • Page 40 TABLE NO. 2 DISCHARGE FROM SMOOTH BORE NOZZLE Pressures measured by Pitot gage. Nozzle Pressur 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 2 1/4 2 1/2 GALLONS PER MINUTE DELIVERED 1063 1347 1660 1076 1364 1681 1089 1380...
  • Page 41 TABLE NO. 3 Approximate Discharge Flow From Different Nozzles At the end of Fifty Feet of Average, 2 1/2” Rubber Lined Fire Hose, for Various Pump Pressures with Discharge Valve Wide Open PUMP SIZE NOZZLE & GALLONS MINUTE PRESSURE 1 1/8 1 1/4 1 3/8 1 1/2...
  • Page 42 TABLE NO. 4 Pump or Hydrant Pressure required to give Effective Nozzle Pressure through various Lengths of Rubber Lined Hose. Size of Hose 1 1/2 2 1/2 Size of Nozzle 1 1/4 1 1/2 1 1/4 1 1/2 Nozzle Length of Press Hose PUMP OR HYDRANT PRESSURE - PSI...
  • Page 43 REACH AND FRICTION LOSS TABLES Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 44 TABLE NO. 5 REACH OF FIRE STREAMS Size of Nozzle 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" NOZZLE PRESSURE EFFECTIVE VERTICAL REACH - Feet NOZZLE PRESSURE MAXIMUM VERTICAL REACH - Feet 105 106 108 117 125 132 88 100 122 135 145 NOZZLE PRESSURE EFFECTIVE HORIZONTAL REACH - Feet...
  • Page 45 TABLE NO. 6 Friction Loss in Fire Hose Loss in PSI per 100 Feet of Hose SIZE HOSE LINEN HOSE BEST RUBER LINED HOSE G.P.M. 1 1/2 2 1/2 1 1/2 2 1/2 3 1/2 (2)-2 1/2 13.5 0.5 .1 29.0 50.0 12.3...
  • Page 46 Losses in rough walled, rubber hose may be 50% higher than values given above. TABLE NO. 7 Friction Loss in 15-year-old Steel Pipe Loss in PSI per 100 Feet of Pipe 1 1/4 1 1/2 2 1/2 PIPE SIZE G.P.M. 52.0 12.0 45.0 10.0...
  • Page 47 7.025 9.05 Ref. NFPA 1963 Underwriters Nozzle Tip Thread: 2.1875 O.D. - 12 threads per inch. IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. AT CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650 Prepared by: EAP Revised by: JAF Rev.
  • Page 48 Section 3 Installation Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 49 INSTALLATION OF TYPE ZSP PTO DRIVEN Fire Pump Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 50 Allison Multiple Joint Driveline Analysis program. W.S. Darley requires that Power Take Off (PTO) driven pumps have at most 500 radians per second torsional vibration and at most 1000 radians per second...
  • Page 51 U-Joints: Universal joints must always be installed in pairs to transmit uniform rotary motion. The operating angles of each universal joint in the pair should be as close to equal as possible. The input and output shafts of each universal joint pair may be either parallel, or so located that the centerline of each shaft intersects the midpoint of the shaft connecting each universal joint (intersecting angles).
  • Page 52 Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 53 Driveline and Mounting: Determine the best location for the pump in your chassis. Allow adequate room for pump maintenance. Place the pump/cross-member assembly on the chassis frame at the desired location. Be sure to set the suction manifold and transmission support brackets at a position allowing the best possible operating angle and driveline performance.
  • Page 54 Place suction manifold mounting brackets into position as shown on detail drawing DGM2902 and securely clamp against side of frames. Attach brackets to the suction extensions with pipe U-bolts. One of the two suction manifold brackets must be free to pivot as seen in drawing DGM1302. Choose one side of the frame or the other for the location of the pivot, the opposite must be rigidly secured with (2) 5/8”...
  • Page 55 Reference drawing DGM2908 for the KM02102 and KM02103 bracket assembly locations on the ZSP. Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 56 Assembly KM02102, depicted by drawing DGM2905, is the vibration isolating mounting bracket that attaches to the pump’s suction head. Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 57 Assembly KM02103, depicted by drawing DGM2906, is the vibration isolating mounting bracket that attaches to the pump’s gearbox. Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 58 ZSP back to the apparatus frame rails. If need be, customers can fabricate their own bracket to replace the 4042200 bracket from within the KM02103 or KM02103 assemblies.
  • Page 59 Reference drawing 4421804 and 3603931 for vibration isolating mounts and washers for adapting the mounting brackets to attach to the customer’s supplied cross member or bracketing. Snubbing Washer Side IMPORTANT: These rubber isolators are a two piece design. The loading on these isolation mounts is cantilevered in this application (i.e.
  • Page 60 Core/Bushing of Rubber Isolator Ring Portion Rubber Isolator Core/Bushing of Rubber Isolator Prepared by: RJG Revision: A Approved by: WAH Original release date: 03/16/12 Revised by: WAH VIA ECO 11337 Revision release date: 02/19/2016 1201050.doc...
  • Page 61 Drill holes through the apparatus frame rails and attach necessary mounting brackets and cross members. Note, the KM02102 and KM02103 mounting bracket assemblies are designed to permit truck frame flexing without imposing stress on the pump. The installed brackets must be free to pivot as shown in drawing DGM1302.
  • Page 62 Torque the universal joint bearing cap retaining bolts to the following Dana Spicer Recommendations: U-BOLT CAP & BOLT SERIES RECOMMENDED NUT TORQUE SERIES RECOMMENDED BOLT TORQUE 1280 14-17 LB. FT 1650 77-103 LB. FT 1310 14-17 LB. FT 1850 110-147 LB. FT 1330 14-17 LB.
  • Page 63 (Consult your local lubricant source for greases that meet this specification. PRIMER CONNECTION: For 12/24-volt electrically-clutched belt-driven priming pump installation, see drawings DVC0306 through DVC0309 found in “Section 4 - Pump Detail” of the “ZSP Installation, Operation, Maintenance, Repair and Troubleshooting Manual”.
  • Page 67 DRIVELINE INSTALLATION J3311-1-DSSP AUGUST 2008 Supersedes J3311-1-HVTSS, Dated February 2005...
  • Page 68 Safety Precautions General Safety Information WARNING: GUARDING AUXILIARY DRIVESHAFTS To prevent injury to yourself and /or damage to the equipment: • Read carefully all owners manuals, service manuals, We strongly recommend that a power take-off and a directly and/or other instructions. mounted pump be used to eliminate the auxiliary driveshaft •...

  • Page 69: Table Of Contents

    Table of Contents Introduction ................................1 Driveshaft Torque ..............................2 Common Causes of Vibrations ..........................3 Universal Joint Operating Angles ..........................5 Eliminating Compound Angle Induced Vibrations ..................... 11 Multiple Shaft Installations ............................13 Mounting a Midship-Mounted PTO, Pump, or Auxiliary Transmission ..............16 Maximum Safe Operating Speed ..........................

  • Page 70: Introduction

    General Information Introduction This brochure is intended for: • Installers who install Spicer driveshafts into an application where the transmission and axle are not in direct line with each other, causing the driveshaft universal joints to operate at an angle. •...

  • Page 71: Driveshaft Torque

    Installation Techniques Driveshaft Torque The following problems are usually a result of torque overloads: Twisted driveshaft tube Broken yoke shaft, slip yoke, tube yoke, flange yoke, end yoke Broken journal cross How much torque can be generated in your application? Engine Trans.

  • Page 72: Common Causes Of Vibrations

    Installation Techniques Common Causes of Vibrations The three most common causes of driveshaft vibration are: Driveshaft Imbalance, Critical Speed, and Universal Joint Operating Angles. Driveshaft Imbalance Eliminate the potential for balance problems before you undertake any other measures. A driveshaft on a vehicle usually rotates at a higher rate of speed than the tire. For that reason, like tires, driveshafts should be balanced.
  • Page 73 Installation Techniques Maximum Possible Driveshaft RPM To calculate the maximum possible driveshaft RPM in vehicles having an overdrive transmission, divide the maximum possible engine RPM by the overdrive ratio. (See examples below.) Example 1: Max. engine RPM: 2100 Overdrive ratio: .79 2100/.79 = 2658 maximum possible driveshaft RPM Example 2: Max.

  • Page 74: Universal Joint Operating Angles

    Installation Techniques Universal Joint Operating Angles Every Universal Joint that Operates at an Angle Creates a Vibration Universal joint operating angles are probably the most common causes of driveline vibration in vehicles that have been reworked, or in vehicles that have had auxiliary equipment installed. Universal joint operating angles are a primary source of problems contributing to: •...
  • Page 75 Installation Techniques Reducing and Canceling Vibration A key point to remember about universal joint operating angles: To reduce the amount of vibration, the angles on each end of a driveshaft should always be SMALL. To cancel an angle vibration, the universal joint operating angles need to be EQUAL within 1 degree at each end of a driveshaft. On motor home applications and auxiliary transmission installations, the tolerance is 1/2 degree.
  • Page 76 Installation Techniques Single Plane and Compound Universal Joint Operating Angles There are two types of universal joint operating angles: Single Plane and Compound. Single Plane Single Plane angles occur when the transmission and axle components are in line when viewed from either the top or side, but not both.
  • Page 77 Installation Techniques Determining the universal joint operating angles on a driveshaft that is straight when viewed from the side and offset when viewed from the top requires the use of a special chart (See Angle Chart). In this type of application, the centerlines of the connected components must be parallel when viewed from the top as shown.
  • Page 78 Installation Techniques Compound Angles Compound universal joint operating angles occur when the transmission and axle are not in line when viewed from BOTH the top and side. Their centerlines, however, are parallel in both views. (See Fig. 5) Engine Trans. Axle Top View Parallel Centerlines...
  • Page 79 Installation Techniques True Universal Joint Operating Angle The True Universal Joint Operating Angle, which must be calculated for each end of the shaft with compound angles, is a combi- nation of the universal joint operating angle in the top view, as determined from the chart, and the measured universal joint oper- ating angle in the side view.

  • Page 80: Eliminating Compound Angle Induced Vibrations

    Installation Techniques Eliminating Compound Angle Induced Vibrations Compound universal joint operating angles are one of the most common causes of driveline vibration. To avoid theses problems, remember these important points: • When setting up an application that requires compound universal joint operating angles, always keep the centerlines of the transmission and axle parallel in both views.
  • Page 81 Installation Techniques Angle Size The magnitude of a vibration created by a universal joint operating angle is proportional to the size of the universal joint operating angle. Spicer Engineers recommend true universal joint operating angles of 3 degrees or less. Obtain the true universal joint operating angle, as explained above, and if it is greater than 3 degrees, compare it to this chart.

  • Page 82: Multiple Shaft Installations

    Installation Techniques Multiple Shaft Installations Multiple Shaft Set Up Recommendations In general, multiple shaft installations follow the same guidelines, except there are different recommendations for setting up the driveline: • For a 2-shaft application, set up the first coupling shaft (sometimes called a jackshaft) so that the universal joint operating angle that occurs at the transmission end is 1 to 1-1/2 degrees.
  • Page 83 Installation Techniques True angle Adjust the axle to be 1 to 1-1/2 on the same angle as the first shaft Center Bearing These angles will automatically be equal Figure 9 If there is an offset in the installation of the axle, make sure it does not create too large of a compound universal joint operating angle.
  • Page 84 Installation Techniques On applications having more than two shafts, mount the first coupling shaft as outlined in the preceding example, and each addi- tional coupling shaft at a 1 to 1-1/2 degree universal joint operating angle to the previous coupling shaft. Install or tilt the axle to the same angle as the last fixed coupling shaft so the centerline of the axle and the last fixed coupling shaft are parallel.

  • Page 85: Mounting A Midship-Mounted Pto, Pump, Or Auxiliary Transmission

    Installation Techniques Mounting a Midship-Mounted PTO, Pump, or Auxiliary Transmission When installing a midship-mounted PTO, auxiliary transmission, or midship-mounted pump into the main driveline of a vehicle, install it at the same angle as the transmission. Keep the offset to a minimum to reduce universal joint operating angles. Note: Do not make the universal joint operating angle less than 1/2 degree.
  • Page 86 Installation Techniques If there is more than one driveshaft between the device and the rear axle, install the driveshaft as outlined earlier with a 1 to 1-1/2 degree universal joint operating angle on the input end of each shaft. Then rotate the axle so it is on the same angle as the last fixed shaft.

  • Page 87: Maximum Safe Operating Speed

    Installation Techniques Maximum Safe Operating Speed MAXIMUM OPERATING SPEED* BY TUBE SIZE, SOLID SHAFT SIZE, AND LENGTH *(For speeds over 6000 RPM, contact Spicer Universal Joint Division Engineering) TUBING MAXIMUM INSTALLED LENGTH (IN INCHES) FOR GIVEN RPM Diameter Centerline to Centerline of Joints for a Two Joint Assembly &...
  • Page 88 Installation Techniques Special Notes Regarding Auxiliary Driveshafts WARNING: Working on or near an auxiliary driveshaft when the engine is running is extremely dangerous and should be avoided. You can snag clothes, skin, hair, hands, etc. This can cause serious injury or death. •...
  • Page 90 Dana Holding Corporation Dana Holding Corporation Dana Holding Corporation Spicer Service Parts Spicer Service Parts - Canada Spicer Service Parts - International PO Box 321 5095 South Service Road (419) 861-6325 Toledo, Ohio 43697-0321 Beamsville, Ontario LOR 1BO 1-800-SAY-DANA (729-3262) www.spicerparts.com J3311-1-DSSP ©...
  • Page 91 Section 4 Pump Detail Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 92 Operating/Troubleshooting Instructions for Darley Electrically-Clutched Belt-Driven Priming Pump The Darley electrically-clutched belt-driven primer will develop up to 25 in. Hg. in an air tight pumping system. The Primer is activated by a push-button momentary electric switch. Pushing and holding this switch in opens the 12/24 VDC electric ¼...
  • Page 93 To prime the pump a certain amount of dry running of the pump along with a recommended engine speed are given. Significant testing has proven these figures at W.S. Darley and should never be exceeded without W.S Darley Customer Service approval.
  • Page 94  Loose clutch body mounting bolt (through clutch bore into primer rotor/shaft assembly)  Loose bolts holding belt tension  Revisit the primer assembly drawing and contact W.S. Darley Customer Service if necessary. Proper belt tension is a must.  Belt tension can be inspected and validated by: o Placing a 6 lb–...
  • Page 95 - Other challenges may occur that have not been listed here, we kindly ask that you document these challenges as best you can and contact W.S. Darley Customer Service to identify the root cause and evaluate any necessary changes in the design.
  • Page 96 ANGLES ±1° SURFACES TO ENHANCE THE VANE SEAL DR'N DATE 21-May-10 DVC0300 THIS DESIGN IS THE PROPERTY OF ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 97 SURFACES TO ENHANCE THE VANE SEAL SCALE GREASE PRIOR TO ASSEMBLY DR'N DATE 21-May-10 DVC0301 THIS DESIGN IS THE PROPERTY OF ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 98 DATE 22-Feb-12 DVC0306 AND HOUSING END SURFACES TO ENHANCE VANE SEAL THIS DESIGN IS THE PROPERTY OF SCALE ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 99 GREASE PRIOR TO ASSEMBLY SCALE DVC0307 AND HOUSING END SURFACES TO ENHANCE VANE SEAL THIS DESIGN IS THE PROPERTY OF ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 100 GREASE PRIOR TO ASSEMBLY DVC0308 THIS DESIGN IS THE PROPERTY OF SCALE AND HOUSING END SURFACES TO ENHANCE VANE SEAL ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 101 AND HOUSING END SURFACES TO ENHANCE VANE SEAL THIS DESIGN IS THE PROPERTY OF GREASE PRIOR TO ASSEMBLY ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 102 AS LISTED CROSS SECTION, ZSP, DARLEY ANGLES ±1° DR'N DATE 21JAN2013 DVC0310 THIS DESIGN IS THE PROPERTY OF ALL DIMENSIONS IN CHKD W.S. DARLEY AND CO. - UNAUTHORIZED DO NOT SCALE PRINT INCHES UNLESS NOTED TRCD SCALE REPRODUCTION IS PROHIBITED...
  • Page 103 PUMP DRAWINGS Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 104 ZSM, PUMP REAR, 2908700 RH IMPELLER. ZSE OR ZSP 2 GR, ENG ROT, 2908600 LH IMPELLER ZSE OR ZSP 2 GR, OPP ENG ROT, 2908700 RH IMPELLER ZSP 3 GR, PUMP REAR, ENG ROT, 2908700 RH IMPELLER ZSP 3 GR, PUMP REAR, OPP ENG ROT, 2908600 LH IMPELLER...
  • Page 105 PLUG - PIPE, 0.125, W/.125 THRU 1080553 PRIMER - BELT DRV, 24V, ENG AP02400 PUMP - HYD, INTERNAL GEAR, LUBE 4821020 SHAFT - INPUT, 2 GR ZSP 5023700 SLEEVE - MEGATRANS, OIL PUMP 1887400 SPACER - 2.17 X 2.62 X .513 3309301 SPACER - 2.17 x 2.63 x .611...
  • Page 106 1080553 150 LB-FT PRIMER - BELT DRV, 24V, ENG AP02400 PUMP - HYD, INTERNAL GEAR, LUBE 4821020 SHAFT - INPUT, 2 GR ZSP 5023700 SLEEVE - MEGATRANS, OIL PUMP 1887400 SPACER - 2.17 X 2.62 X .513 3309301 SPACER - 2.17 x 2.63 x .611...
  • Page 107 PLUG - PIPE, 0.125, W/.125 THRU 1080553 PRIMER - BELT DRV, 24V, ENG AP02400_STANDARD 1 PUMP - HYD, INTERNAL GEAR, LUBE 4821020 SHAFT - INPUT, 2 GR ZSP 5023700 SLEEVE - MEGATRANS, OIL PUMP 1887400 SPACER - 2.17 X 2.62 X .513 3309301 SPACER - 2.17 x 2.63 x .611...
  • Page 108 PLUG - PIPE, 0.125, W/.125 THRU 1080553 PRIMER - BELT DRV, 24V, ENG AP02400_STANDARD 1 PUMP - HYD, INTERNAL GEAR, LUBE 4821020 SHAFT - INPUT, 2 GR ZSP 5023700 SLEEVE - MEGATRANS, OIL PUMP 1887400 SPACER - 2.17 X 2.62 X .513 3309301 SPACER - 2.17 x 2.63 x .611...
  • Page 109 TOLERANCE THIRD ANGLE PROJECTION OLD PART NO. REMOVE SHARP EDGES [MILLIMETER] EXCEPT ITASCA, IL - CHIPPEWA FALLS, WI AS NOTED DWG - ZSP, INPUT ABOVE MATERIAL DESCRIPTION: MATERIAL NO. PATTERN NO. .000 .010 APPROXIMATE WEIGHT 690 LBS [312] AS LISTED...
  • Page 110 THIRD ANGLE PROJECTION OLD PART NO. REMOVE SHARP EDGES [MILLIMETER] EXCEPT ITASCA, IL - CHIPPEWA FALLS, WI AS NOTED DWG - ZSP, INPUT LEFT APPROXIMATE WEIGHT 690 LBS [312 KG] MATERIAL DESCRIPTION: MATERIAL NO. PATTERN NO. .000 .010 AS LISTED...
  • Page 111 THIRD ANGLE PROJECTION OLD PART NO. REMOVE SHARP EDGES APPROXIMATE WEIGHT 690 LBS [312 KG] [MILLIMETER] EXCEPT ITASCA, IL - CHIPPEWA FALLS, WI AS NOTED DWG - ZSP, INPUT RIGHT MATERIAL DESCRIPTION: MATERIAL NO. PATTERN NO. .000 .010 AS LISTED CROSS SECTION...
  • Page 112 THIRD ANGLE PROJECTION OLD PART NO. [298,5] REMOVE SHARP EDGES [620,4] [MILLIMETER] EXCEPT ITASCA, IL - CHIPPEWA FALLS, WI AS NOTED DWG - ZSP, INPUT STANDARD MATERIAL DESCRIPTION: MATERIAL NO. PATTERN NO. .000 .010 AS LISTED CROSS SECTION ANGLES APPROXIMATE WEIGHT 690 LBS [312 KG]...
  • Page 113 MECHANICAL SEAL Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 114 • Seal face contact pressure is controlled by a single, non-clogging coil spring. This coil spring has been custom welded per Darley specifications to eliminate high-speed spring distortion. The seal housing is designed and ported to provide optimal water flow and pressure assuring proper cooling and flushing of the seal components.
  • Page 115 Operation and Maintenance When operated within rated operating conditions of this pump, these seals will provide trouble free service for extended periods. Properly selected and applied mechanical shaft seals are leak free and require no adjustment. Should the seal area develop a leak, investigate the cause as soon as possible. Seal failure, leakage, may be the result of;...
  • Page 116 DARLEY INSTALLATION OF MECHANICAL FACE SEAL WITH O’RING SPECIAL HANDLING Study the engineering layout before installing the seal. This shaft seal is a precision product and should be handled and treated with care. Take special care to prevent scratches on the lapped faces of the primary and mating ring.
  • Page 117 4. Clean the mating ring surface with isopropyl alcohol to remove any fingerprints and any other contaminants left on mating ring. Note: Steps 5 – 9 need to all be completed with in 15 minutes or less. The approximate 5. Apply a small drop of P-80 rubber lubricant or water-soluble lubricant (not soapy size of a drop water) evenly distributed to the inside diameter of the bellows assembly allowing it to should be between...
  • Page 118 50-60 psi to rinse out excess lubricant and other contaminants. Once a mechanical seal has been installed, it is recommended that it not be reused. DARLEY If further information is needed, call Chippewa Falls, WI. at 800-634-7812 or 715-726-2650 Prepared by: AAN Rev.: C...
  • Page 119 ELECTRICALLY-CLUTCHED BELT-DRIVEN ROTARY VANE PRIMER Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 120 Operating/Troubleshooting Instructions for Darley Electrically-Clutched Belt-Driven Priming Pump The Darley electrically-clutched belt-driven primer will develop up to 25 in. Hg. in an air tight pumping system. The Primer is activated by a push-button momentary electric switch. Pushing and holding this switch in opens the 12/24 VDC electric ¼...
  • Page 121 To prime the pump a certain amount of dry running of the pump along with a recommended engine speed are given. Significant testing has proven these figures at W.S. Darley and should never be exceeded without W.S Darley Customer Service approval.
  • Page 122  Loose clutch body mounting bolt (through clutch bore into primer rotor/shaft assembly)  Loose bolts holding belt tension  Revisit the primer assembly drawing and contact W.S. Darley Customer Service if necessary. Proper belt tension is a must.  Belt tension can be inspected and validated by: o Placing a 6 lb–...
  • Page 123 - Other challenges may occur that have not been listed here, we kindly ask that you document these challenges as best you can and contact W.S. Darley Customer Service to identify the root cause and evaluate any necessary changes in the design.
  • Page 128 Section 5 Optional Equipment Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 129 MULTIPLE DRAIN VALVE Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 131 BALL VALVE Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 132 BALL VALVE QUARTER TURN - SELF LOCKING The Darley Ball Valve is a quarter turn, all bronze valve designed for the fire service. The ball is cast bronze, precision machined stainless steel ball for long trouble free service. It is easily serviced in the field.
  • Page 134 PRESSURE RELIEF VALVE Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 135 7.31 1200503...
  • Page 136 7.32 1200503...
  • Page 139 7.35 1200503...
  • Page 140 7.36 1201002...
  • Page 141 BUTTERFLY VALVE Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 145 PUMP OVERHEAT PROTECTION Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 152 Appendix Prepared by: RJG Rev. A Approved by: WAH Date: 03/16/12 Revised by: WAH Via ECO 11337 Rev. Date: 02/19/2016 1200643.doc...
  • Page 153 Detailed Specification Darley ZSP 2500-3000 A Darley model ZSP 2500-3000 GPM single stage shaft driven fire pump shall be provided and installed. The pump shall be midship or rear mounted and designed to operate through an integral transmission. The pump shall be driven by a driveline from the chassis transmission. The engine, transmission and driveline components shall provide sufficient horsepower and RPM to enable the pump to meet and exceed its rated performance.
  • Page 154 equipped with a removable access plate for quick inspection of gears, shafts, and bearings inside the transmission. The pump drive shaft shall be precision ground, heat treated alloy steel, with a minimum 2"-10 spline. Gears shall be helical design and shall be precision ground for quiet operation and extended life.
  • Page 155 Corporate Darley Office 325 Spring Lake Drive Itasca, Illinois 60143-2072 Toll Free Phone: 800-323-0244 Phone: 630-735-3500 Fax: (708) 345-8993 Apparatus Division 920 Kurth Rd. Chippewa Falls, WI 54729 Toll Free Phone: 800-527-0068 Phone: 715-726-2645 Fax: (715) 726-2648 Pump Manufacturing 1051 Palmer St.