Operation and Maintenance

W & Y Series Split-Shaft Form No. Section Issue Date Rev. Date
Chain Drive Transmission F-1031 2205.3 03/94 06/24/13

Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Description for Transmissions . . . . . . . . . . 2
General Description for Accessories . . . . . . . . . . . . 2
Shifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Pump Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electric or Pneumatic Pump Shift . . . . . . . . . . . . . . . . . . 4
Electric Shift Manual Override . . . . . . . . . . . . . . . . . . . . . 5
Pneumatic Shift Manual Override . . . . . . . . . . . . . . . . . . 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Indicating Lights Operation . . . . . . . . . . . . . . . . . . . . . . . 8
Tachometer Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump Shift Troubleshooting Guide . . . . . . . . . . . . . . . . 9
Pump Transmission Shift Component Inpection . . . . 12
Illustrations
1. Electric Shift Manual Override . . . . . . . . . . . . . . . . . 5
2. Pneumatic Shift Manual Override . . . . . . . . . . . . . . 6

W & Y Series Split−Shaft Transmission Operation & Maint.

Read through the safety information and

operating instructions carefully before
using your Waterous Fire Pump.

Visit us at www.waterousco.com
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000
Instructions subject to change without notice.
 Safety Information

Read through the safety information and operating instructions before using your Waterous Fire
Pump.

! WARNING ! WARNING

Death or serious personal injury might occur if proper Unexpected Truck Movement
operating procedures are not followed. The pump op­ May result in serious personal injury or death
erator, as well as individuals connecting supply or dis­ Failure to properly shift transmission in accordance to
charge hoses to the apparatus must be familiar with the transmission operating instructions may result in
these pump operating instructions as well as other unexpected truck movement which may result in
operating instructions and manuals for the apparatus, serious personal injury or death.
water hydraulics and component limitation.

! WARNING

If the truck attempts to move, reduce engine speed to

idle. Put truck transmission in NEUTRAL and repeat
shifting instructions.

F-1031, Section 2205.3 REV: 05/09/08 Page 1 of 13

 Introduction
Waterous Split Shaft Chain Drive Pump Transmissions This instruction is divided into four sections:
are used with mid-ship mounted fire pumps. They transmit · General Description for Transmissions
power from the truck's drive line to either the fire pump or
to the drive axle of the truck. · General Description for Accessories
· Shifting Instructions
· Maintenance Instructions

General Description for Transmissions

The W and Y Series pump transmissions are designed for The shift mechanism within the transmission consists of a
use with Waterous Models CM, CS, CG and CX mid-ship sliding internally-toothed collar which is always in engage­
mounted fire pumps and the RF-600 Self-Priming Pump. ment with an externally-toothed section of the drive shaft.
The transmissions used with the CM, CMU, CS and CSU A fork shifts the collar either to engage it with teeth on the
pumps have a separable splined connection to the pump drive sprocket hub (PUMP) or to engage it with the teeth
impeller shaft allowing for easy removal of the transmis­ on the coupling shaft (ROAD). When in PUMP position,
sion for major service. the shift collar transmits power from the drive shaft
through the drive sprocket and the chain to the driven
Primary lubrication is provided through a splash system. A sprocket. The coupling shaft remains stationary. When in
secondary chain lubrication system is also used, consist­ ROAD position, the shift collar transmits power directly
ing of the spray bar, pump, hoses and strainer. The com­ from the drive shaft through the coupling shaft to the truck
bined pressure and fluid splash system within the trans­ propeller shaft and drive axle(s). In this position, the pump
mission lubricates the sprockets, chain, bearings and drive and driven sprockets remain stationary while the
other parts. The shaft driven fluid pump draws fluid from drive shaft rotates.
the transmission sump through a strainer and then to a
spray tube between the drive and driven sprockets, where Three shift indicator lights are furnished. Two are
the fluid is sprayed on the inside face of the chain just be­ mounted in the cab and the other is mounted on the oper­
fore the chain meshes with the driven sprocket. The ators panel. These lights indicate to the operators that the
strainer mounted in the sump of the pump transmission shift has been completed into PUMP position and the
filters the fluid to the pump. This strainer is removable for truck transmission is in pumping gear.
cleaning.
An electronic tachometer sensor protrudes from the pump
drive shaft housing at a 45° angle. Shaft rotational speed
can be obtained with a frequency meter.
NOTE: W Series equipped with a mechanical tachom­
eter only. Y Series equipped with an electric tachome­
ter only.

General Description for Accessories

The electric or pneumatic shift assembly permits fast, pos­ Each accessory is equipped with a complete set of lights
itive shifting without leaving the cab. A two-position con­ that indicate when the shift has been fully completed to
trol, mounted on the instrument panel in the cab activates PUMP and the truck transmission is in pumping gear.
the shift unit. NOTE: W Series equipped with a mechanical tachom­
eter only. Y Series equipped with an electric tachome­
ter only.

F-1031, Section 2205.3 REV: 05/09/08 Page 2 of 13

 Shifting Instructions
Manual Pump Shift
Two series of Allison automatic transmissions are com­
monly used in fire trucks. Each series is available with the CAUTION
shift patterns controlled hydraulically or both electronically Shifting truck transmission into pumping gear
and hydraulically. This later type is commonly referred to (DRIVE) above engine idle speed may cause
as the ATEC transmission. damage to the equipment.
In each automatic transmission, either the non-ATEC or
the ATEC, certain sequences must occur in proper order 8. Green OK TO PUMP light should be on.
after the pump shift control is moved to either PUMP or 9. Increase engine speed above idle and hold for a few
ROAD position. seconds. Watch speedometer to make sure it shows
Split shaft pump transmissions, automatic transmissions some value of road speed.
and engines will vary in operation due to manufacturing NOTE: Some fire trucks have a speedometer that
tolerances, lubrication temperature, etc. This variance in will not show a value of road speed in a stationary
each may or may not affect the ease of completing a full position.
shift into either PUMP or ROAD. Operator training and
experience in shifting procedures is a requirement to be­ ! WARNING
coming skilled in a smooth, complete shift into either
PUMP or ROAD. If the truck attempts to move, reduce engine
When the pump shift is activated, the operator may speed to idle. Put truck transmission in NEU­
hear a noise associated with the movement of the TRAL and repeat shifting instructions.
shift unit. This does NOT mean that the shift has been
completed. 10. After leaving truck cab, block wheels using wheel
chocks.
After the shift to pump operation is completed, the green
11. To confirm that the pump is engaged:
PUMP ENGAGED and OK TO PUMP lights in the cab
must be on before leaving the cab to operate the pump S THROTTLE READY light on operator's panel is
from the operators panel. DO NOT LEAVE THE CAB IF illuminated.
THE GREEN PUMP ENGAGED AND OK TO PUMP S Pump discharge pressure registers on gages.
LIGHTS ARE NOT ON.
S Other safety interlocks are activated.
! WARNING
Shift to ROAD as follows:
Unexpected Truck Movement. 1. With engine speed at idle, put truck transmission in
May result in serious personal injury or NEUTRAL.
death. 2. When speedometer slows to zero, move pump shift
Failure to properly shift transmission in accor­ control to ROAD position.
dance to the transmission operating instructions 3. Lock pump shift control in ROAD position.
may result in unexpected truck movement which
may result in serious personal injury or death. 4. Engage truck transmission (DRIVE)

Shift to PUMP as follows: CAUTION

1. Bring truck to complete stop. If you hear a loud grinding noise when you at­
tempt to move the truck, the shift to ROAD has
2. Reduce engine to idle speed, put truck transmission
not been completed. Shift into NEUTRAL while
into NEUTRAL.
keeping pressure on pump shift lever.
3. Set truck parking brake.
4. Move pump shift control to PUMP position. If grinding is a common occurrence after Step 3 is
5. Green PUMP ENGAGED light should be on. performed, it may be prevented by shifting the truck trans­
mission into NEUTRAL, then to REVERSE, back to
CAUTION NEUTRAL and finally to DRIVE.
5. After shifting the truck transmission to DRIVE, release
If green PUMP ENGAGED light is not on, mo­ the parking brake and move the vehicle forward to
mentarily shift truck transmission into REVERSE confirm a shift to ROAD has been completed.
while keeping pressure on the manual shift rod.
Return to NEUTRAL. Green PUMP ENGAGED
light should be on.

6. Lock pump shift control in PUMP position.

7. Shift truck transmission into pumping gear (DRIVE).

F-1031, Section 2205.3 REV: 05/09/08 Page 3 of 13

 Electric or Pneumatic Pump Shift
Two series of Allison automatic transmissions are com­ 6. Green PUMP ENGAGED and OK TO PUMP lights
monly used in fire trucks. Each series is available with the should be on.
shift patterns controlled hydraulically or both electronically
and hydraulically. This later type is commonly referred to CAUTION
as the ATEC transmission.
If green PUMP ENGAGED and OK TO PUMP
In each automatic transmission, either the non-ATEC or light are not on, momentarily shift truck transmis­
the ATEC, certain sequences must occur in proper order sion from pumping gear (DRIVE) to NEUTRAL,
after the pump shift control is moved to either PUMP or then REVERSE, then NEUTRAL, then back into
ROAD position. pumping gear (DRIVE). Lights should be on. If
Split shaft pump transmissions, automatic transmissions lights are not on, repeat procedure.
and engines will vary in operation due to manufacturing
tolerances, lubrication temperature, etc. This variance in 7. Increase engine speed above idle and hold for a few
each may or may not affect the ease of completing a full seconds. Watch speedometer to make sure it shows
shift into either PUMP or ROAD. Operator training and some value of road speed.
experience in shifting procedures is a requirement to be­ NOTE: Some fire trucks have a speedometer that
coming skilled in a smooth, complete shift into either will not show a value of road speed in a stationary
PUMP or ROAD. position.
When the pump shift is activated, the operator may
hear a noise associated with the movement of the ! WARNING
shift unit. This does NOT mean that the shift has been
completed. If the truck attempts to move, reduce engine
After the shift to pump operation is completed, the green speed to idle. Put truck transmission in NEU­
PUMP ENGAGED and OK TO PUMP lights in the cab TRAL and repeat shifting instructions.
must be on before leaving the cab to operate the pump
8. After leaving truck cab, block wheels using wheel
from the operators panel. DO NOT LEAVE THE CAB IF
chocks.
THE GREEN PUMP ENGAGED AND OK TO PUMP
LIGHTS ARE NOT ON. 9. To confirm that the pump is engaged:
Some truck builders may install a manual override for the S THROTTLE READY light on operator's panel
electric or pneumatic pump shift. The controls are normal­ is illuminated.
ly installed from the pump transmission to the operators S Pump discharge pressure registers on gages.
panel.
S Other safety interlocks are activated.
! WARNING
Shift to ROAD as follows:
Unexpected Truck Movement. 1. With engine speed at idle, put truck transmission in
May result in serious personal injury or NEUTRAL.
death. 2. When speedometer slows to zero, move pump shift
Failure to properly shift transmission in accor­ control to ROAD position.
dance to the transmission operating instructions 3. Engage truck transmission (DRIVE).
may result in unexpected truck movement which
may result in serious personal injury or death. CAUTION
Shift to PUMP as follows: If you hear a loud grinding noise when you at­
tempt to move the truck, the shift to ROAD has
1. Bring truck to complete stop. not been completed. Shift into NEUTRAL, wait for
2. Reduce engine to idle speed, put truck transmission grinding noise to stop and re-engage truck trans­
into NEUTRAL. mission.
3. Set truck parking brake.
If grinding is a common occurrence after Step 3 is per­
4. Move pump shift control to PUMP position. formed, it may be prevented by shifting the truck transmis­
NOTE: Green PUMP ENGAGED light may not illumi­ sion into NEUTRAL, then to REVERSE, back to NEU­
nate. TRAL and finally to DRIVE.
5. Shift truck transmission into pumping gear (DRIVE). 4. After shifting the truck transmission to DRIVE, release
the parking brake and move the vehicle forward to
CAUTION confirm a shift to ROAD has been completed.
Shifting truck transmission into pumping gear
(DRIVE) above engine idle speed may cause
damage to the equipment.

F-1031, Section 2205.3 REV: 05/09/08 Page 4 of 13

 Electric Shift Manual Override
Two series of Allison automatic transmissions are com­ Shift to PUMP as follows:
monly used in fire trucks. Each series is available with the
shift patterns controlled hydraulically or both electronically 1. Bring truck to complete stop.
and hydraulically. This later type is commonly referred to 2. Reduce engine to idle speed, put truck transmission in
as the ATEC transmission. NEUTRAL.
In each automatic transmission, either the non-ATEC or 3. Set truck parking brake.
the ATEC, certain sequences must occur in proper order 4. Pull the shift override control rod out at the operators
after the pump shift control is moved to either PUMP or position to disengage the electric shift unit from the
ROAD position. pump transmission shift arm. See Figure 1.
Split shaft pump transmissions, automatic transmissions Figure 1. Electric Shift Manual Override
and engines will vary in operation due to manufacturing
tolerances, lubrication temperature, etc. This variance in
each may or may not affect the ease of completing a full
shift into either PUMP or ROAD. Operator training and
experience in shifting procedures is a requirement to be­
coming skilled in a smooth, complete shift into either
PUMP or ROAD.
When the pump shift is activated, the operator may
hear a noise associated with the movement of the
shift unit. This does NOT mean that the shift has been
completed.
After the shift to pump operation is completed, the green
PUMP ENGAGED and OK TO PUMP lights in the cab
must be on before leaving the cab to operate the pump
from the operators panel. DO NOT LEAVE THE CAB IF
THE GREEN PUMP ENGAGED AND OK TO PUMP
LIGHTS ARE NOT ON.
If the vehicle builder has provided a means to manually IL1676
override the electric pump shift, the override control will be 5. Push manual shift control rod in for PUMP position.
located at the operators panel or in the cab. The override
6. Move in-cab pump shift control into PUMP position.
control will consist of a rod to the panel or a cable or rod
mechanism to the inside of the cab. The rod or cable will 7. Green PUMP ENGAGED light should be on.
be attached to the shift arm on the pump transmission.
CAUTION
NOTE: This instruction is written based on an over­
ride control rod directed to the operators panel from If green PUMP ENGAGED light is not on, mo­
the short arm of the lever on the pump transmission. mentarily shift truck transmission into REVERSE
Other rod or cable arrangements may require reversal while keeping pressure on the manual shift rod.
of stated action to accomplish the desired shift. Return to NEUTRAL. Green PUMP ENGAGED
If the pump transmission is equipped with an override, light should be on.
shifting manually is done as follows:
8. Shift truck transmission into pumping gear (DRIVE).
It is recommended that this procedure be performed using
two people; one person in the cab and one at the override CAUTION
control position.
Shifting truck transmission into pumping gear
! WARNING (DRIVE) above engine idle speed may cause
damage to the equipment.
Unexpected Truck Movement.
May result in serious personal injury or 9. Green OK TO PUMP light should be on.
death. 10. Increase engine speed above idle and hold for a few
seconds. Watch speedometer to make sure it shows
Failure to properly shift transmission in accor­
some value of road speed.
dance to the transmission operating instructions
may result in unexpected truck movement which NOTE: Some fire trucks have a speedometer that
may result in serious personal injury or death. will not show a value of road speed in a stationary
position.

F-1031, Section 2205.3 REV: 05/09/08 Page 5 of 13

 2. When speedometer drops to zero, pull manual shift
! WARNING rod out for ROAD position. Push the override control
rod in to engage shift unit.
If the truck attempts to move, reduce engine
speed to idle. Put truck transmission in NEU­ 3. Move in-cab pump shift control into ROAD position.
TRAL and repeat shifting instructions. 4. Engage truck transmission (DRIVE).

11. After leaving truck cab, block wheels using wheel CAUTION
chocks.
If you hear a loud grinding noise when you at­
12. To confirm that the pump is engaged:
tempt to move the truck, the shift to ROAD has
S THROTTLE READY light on operator's panel not been completed. Shift into NEUTRAL, wait for
is illuminated. grinding noise to stop and re-engage truck trans­
S Pump discharge pressure registers on gages. mission, while keeping pressure on the manual
shift control rod.
S Other safety interlocks are activated.
5. After shifting the truck transmission to DRIVE, release
Shift to ROAD as follows: the parking brake and move the vehicle forward to
1. With engine at idle speed, put truck transmission in confirm a shift to ROAD has been completed.
NEUTRAL.

Pneumatic Shift Manual Override

Two series of Allison automatic transmissions are com­ Figure 2. Pneumatic Shift Manual Override
monly used in fire trucks. Each series is available with the Rod or cable to cab
shift patterns controlled hydraulically or both electronically
and hydraulically. This later type is commonly referred to
as the ATEC transmission.
In each automatic transmission, either the non-ATEC or
the ATEC, certain sequences must occur in proper order
after the pump shift control is moved to either PUMP or
ROAD position.
Split shaft pump transmissions, automatic transmissions
and engines will vary in operation due to manufacturing
tolerances, lubrication temperature, etc. This variance in
each may or may not affect the ease of completing a full
shift into either PUMP or ROAD. Operator training and
experience in shifting procedures is a requirement to be­
coming skilled in a smooth, complete shift into either
PUMP or ROAD.
When the pump shift is activated, the operator may IL1011
hear a noise associated with the movement of the
shift unit. This does NOT mean that the shift has been Rod to side of truck
completed.
If the pump transmission is equipped with an override,
After the shift to pump operation is completed, the green shifting manually is done as follows:
PUMP ENGAGED and OK TO PUMP lights in the cab
must be on before leaving the cab to operate the pump It is recommended that this procedure be performed using
from the operators panel. DO NOT LEAVE THE CAB IF two people; one person in the cab and one at the override
THE GREEN PUMP ENGAGED AND OK TO PUMP control position.
LIGHTS ARE NOT ON.
! WARNING
If the vehicle builder has provided a means to manually
override the pneumatic pump shift, the override control Unexpected Truck Movement.
will be located at the operators panel or in the cab. The
May result in serious personal injury or
override control will consist of a rod to the panel or a
death.
cable or rod mechanism to the inside of the cab. The rod
or cable will be attached to the shift arm on the pump Failure to properly shift transmission in accor­
transmission. dance to the transmission operating instructions
may result in unexpected truck movement which
NOTE: This instruction is written based on an over­
may result in serious personal injury or death.
ride control rod directed to the operators panel from
the short arm of the lever on the pump transmission.
Other rod or cable arrangements may require reversal
of stated action to accomplish the desired shift.

F-1031, Section 2205.3 REV: 05/09/08 Page 6 of 13

Shift to PUMP as follows: Shift to ROAD as follows:
1. Bring truck to complete stop. 1. With engine at idle speed, put truck transmission in
NEUTRAL.
2. Reduce engine to idle speed, put truck transmission in
NEUTRAL. 2. When speedometer drops to zero, move in-cab pump
shift control into the CENTER position.
3. Set truck parking brake.
3. Pull manual shift rod out for ROAD position.
4. Move in-cab pump shift control into the CENTER posi­
tion. 4. Move the in-cab pump shift control into the ROAD
position.
5. Push manual shift control rod in for PUMP position.
5. Engage truck transmission (DRIVE).
6. Move the in-cab pump shift control into the PUMP
position. CAUTION
7. Green PUMP ENGAGED light should be on.
If you hear a loud grinding noise when you at­
CAUTION tempt to move the truck, the shift to ROAD has
not been completed. Shift into NEUTRAL, wait for
If green PUMP ENGAGED light is not on, mo­ grinding noise to stop and re-engage truck trans­
mentarily shift truck transmission into REVERSE mission, while keeping pressure on the manual
while keeping pressure on the manual shift rod. shift control rod.
Return to NEUTRAL. Green PUMP ENGAGED
light should be on. 6. After shifting the truck transmission to DRIVE, release
the parking brake and move the vehicle forward to
8. Shift truck transmission into pumping gear (DRIVE). confirm a shift to ROAD has been completed.

CAUTION
Shifting truck transmission into pumping gear
(DRIVE) above engine idle speed may cause
damage to the equipment.

9. Green OK TO PUMP light should be on.

10. Increase engine speed above idle and hold for a few
seconds. Watch speedometer to make sure it shows
some value of road speed.
NOTE: Some fire trucks have a speedometer that will
not show a value of road speed in a stationary posi­
tion.

! WARNING

If the truck attempts to move, reduce engine

speed to idle. Put truck transmission in NEU­
TRAL and repeat shifting instructions.

11. After leaving truck cab, block wheels using wheel

chocks.
12. To confirm that the pump is engaged:
S THROTTLE READY light on operator's panel
is illuminated.
S Pump discharge pressure registers on gages.
S Other safety interlocks are activated.

F-1031, Section 2205.3 REV: 05/09/08 Page 7 of 13

 Maintenance
Indicating Lights Operation Fluid Levels
Check the operation of the pump shift indicating lights at 1. Check fluid level monthly by removing fluid level plug
least weekly as follows: at rear of case. The fluid should be level with bottom
of hole.
NOTE: Block wheels with wheel chocks before begin­
ning. A sight plug is also provided for this purpose, and the fluid
level should be visible thru this plug.
1. With the pump in the ROAD position, truck transmis­
sion in NEUTRAL and the parking brake engaged,
ensure that the PUMP ENGAGED and OK TO PUMP CAUTION
lights in the cab are off. If fluid level is low, locate source of leak and
2. Shift to PUMP following the shifting instructions repair. If fluid level is high, loosen drain plug until
section of this document. fluid drops to proper level. If excessive water
a. Ensure that the green PUMP ENGAGED and OK drains out, change fluid and determine source of
TO PUMP lights in the cab are on. water leakage and repair.

b. Ensure that the green THROTTLE READY light NOTE: Fluid temperature should not exceed 250° for
on the operator's panel is on. an extended period of time or premature seal wear
and damage may occur.
3. Apply the service (foot) brake and release the parking
brake. Fluid can be added thru the fluid level hole or by removing
the breather and adding fluid thru this opening. Any type
a. Ensure that the green OK TO PUMP light in the of automatic transmission fluid (ATF) can be used.
cab is off.
2. Transmission fluid pump operation should be checked
b. Ensure that the green THROTTLE READY light monthly. If a transmission fluid pump pressure gauge
on the operator's panel is off. has been installed in the system, it should show a
4. Engage the parking brake and shift truck transmission positive pressure while in the PUMP position.
to NEUTRAL. NOTE: Fluid pressure will vary depending on en­
a. Ensure that the green OK TO PUMP light in the gine speed and lubricant temperature.
cab is off (automatic truck transmission only). 3. Change fluid twice per year or after each 100 hours of
5. Shift to ROAD following the shifting instructions operation, whichever comes first. Clean the fluid sump
section of this document. strainer, breather and magnetic drain plug thoroughly
whenever the transmission fluid is changed. The
a. Ensure that the green PUMP ENGAGED and OK strainer can easily be removed by disconnecting the
TO PUMP lights in the cab are off. hose at the strainer and unscrewing the strainer from
b. Ensure that the green THROTTLE READY light the case. Replace the strainer if it cannot be cleaned
on the operator's panel is off. or is damaged.

Tachometer Readings Amount required if system is drained and refilled

Mechanical Tachometer: Y Series 13 qts. (approx.)
Speed of drive tachometer gear is 1/2 of input shaft W Series 6 qts. (approx.)
speed.
Electric Tachometer: Shift Linkage
To verify input shaft speed, take a frequency reading from Periodically check all shift linkage for freedom of move­
the tachometer sensor. Multiply frequency reading (Hz) by ment and clean as necessary.
1.5 for shaft speed. The impeller shaft speed can be cal­
culated by multiplying the input shaft speed by the ratio of
the pump transmission.

F-1031, Section 2205.3 REV: 05/09/08 Page 8 of 13

Pump Shift Troubleshooting Guide
It is important to know what to do if you experience shifting problems with your pump. This troubleshooting guide will help
you diagnose, isolate and correct problems as they are encountered.
For problems not covered in this guide, or for additional technical assistance, please contact the Waterous Service
Department.

Is the chassis
transmission Possible Cause
in DRIVE
Problem Recommended Action
(automatic) or
in its pump Pneumatic Shift Electric Shift
gear (Manual)?
Place the chassis
transmission in Drive
No Butt-tooth condition Butt-tooth condition
(automatic) or in its
pumping gear (manual).
Malfunctioning shift Malfunctioning shift
Replace or adjust the
indicating switch or indicating switch or
shift indicating switch or
switch out of switch out of
bracket.
adjustment adjustment
Manual override Manual override Repair or replace to
linkage binding linkage binding eliminate binding.
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
Pump won't engage DRIVE.
----------
Pump shift control is in the Excessive driveline Excessive driveline Consider reducing
PUMP position and: torque torque engine idle speed.
----------
1. No lights or Red light It may be necessary to
stays on or flashed (units contact the chassis
built prior to 1991). transmission
manufacturer for
or assistance.
Yes Allow air pressure to
2. PUMP ENGAGED light Low air pressure to
build in the system,
does not come on (units pneumatic shift unit --
repair any leaks in the
built 1991 or newer). (80 psi min.)
system.
Leaking pneumatic Repair or replace
--
shift unit. pneumatic shift unit.
Malfunctioning air Repair or replace air
--
control valve control valve.
Repair as needed to
-- No power to shift unit.
restore power supply.
Failed shift motor -
check current draw,
-- should be 20A at Replace the shift motor.
startup and 10A
through the cycle.
Failed shift unit - unit
has power and draws Repair or replace the
--
correct amperage but electric shift unit.
will not activate.

F-1031, Section 2205.3 REV: 05/09/08 Page 9 of 13

 Is the PUMP Possible Cause
Problem ENGAGED Recommended Action
light on? Pneumatic Shift Electric Shift
Manual override Manual override Repair or replace to
linkage binding. linkage binding. eliminate binding.
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
DRIVE.
----------
Excessive driveline Excessive driveline Consider reducing
Pump will not engage torque. torque. engine idle speed.
and there is a grinding ----------
noise emanating from It may be necessary to
the pump transmission. contact the chassis
No transmission
Pump shift control is in the manufacturer for
PUMP position and: assistance.
1. The chassis Allow air pressure to
Low or no air pressure
transmission is in DRIVE build in the system,
to pneumatic shift unit --
(automatic) or in its repair any leaks in the
(80 psi min.)
pumping gear (manual). system.
Weak shift unit or Replace shift unit with a
or -- non-Waterous high-torque shift unit
supplied shift unit. provided by Waterous.
2. The chassis
transmission is in Damage to internal Damage to internal
See pump transmission
NEUTRAL. pump transmission pump transmission
inspection instructions.
shifting components. shifting components.
Shift indicating switch Malfunctioning shift
Adjust the shift
is out of adjustment or indicating switch or
indicating switch or
its bracket is switch out of
replace the bracket.
Yes damaged. adjustment.
Damage to internal Damage to internal
See pump transmission
pump transmission pump transmission
inspection instructions.
shifting components. shifting components.
Shift the chassis
transmission into
REVERSE momentarily,
then NEUTRAL, then
DRIVE.
Pump transmission Pump transmission
----------
has not shifted out of has not shifted out of
Consider reducing
Chassis engine stalls ROAD due to ROAD due to
engine idle speed.
after placing the pump excessive driveline excessive driveline
No ----------
shift control in PUMP torque. torque.
It may be necessary to
and placing the chassis contact the chassis
transmission in DRIVE transmission
(automatic) or in its manufacturer for
pumping gear (manual). assistance.
Damage to internal Damage to internal
See pump transmission
pump transmission pump transmission
inspection instructions.
shifting components. shifting components.
Repair fire pump as
Yes Seized fire pump. Seized fire pump.
necessary.

F-1031, Section 2205.3 REV: 05/09/08 Page 10 of 13

 Is the chassis
transmission Possible Cause
in DRIVE
Problem Recommended Action
(automatic) or
in its pump Pneumatic Shift Electric Shift
gear (Manual)?
Place the chassis
Chassis transmission Chassis transmission transmission in DRIVE
No
not in the proper gear. not in the proper gear. (automatic) or in its
pumping gear (manual).
Parking brake is not Parking brake is not
PUMP ENGAGED light is Apply the parking brake.
applied. applied.
on but OK TO PUMP
light will not illuminate. Contact the apparatus
Problem with high Problem with high manufacturer or
(Units built 1991 and range lockup or safety range lockup or safety consider
later) Yes interlock systems. interlock systems. alternative wiring for
high range lockup.
Problem with chassis Problem with chassis Contact the chassis
transmission or transmission or transmission
transmission transmission manufacturer for
electronic control unit. electronic control unit. assistance.

Is the Pump
transmission Possible Cause
shift arm in
Problem contact with Recommended Action
the shift
indicating Pneumatic Shift Electric Shift
switch?

Pump shift control is in

Shift indicating switch Shift indicating switch Replace the shift
the ROAD position, but No
stuck closed. stuck closed. indicating switch.
the PUMP ENGAGED
and/or OK TO PUMP
lights stay on. Locking arm assembly Locking arm assembly
is installed backwards is installed backwards
Note: Chassis engine may inside pump inside pump
stall if the chassis Remove locking arm
transmission (the shift transmission (the shift
transmission is placed in Yes assembly and re-install
arm should move arm should move
DRIVE (automatic) or in correctly.
away from the shift away from the shift
its pumping gear indicating switch when indicating switch when
(manual). shifting to pump). shifting to pump).

F-1031, Section 2205.3 REV: 05/09/08 Page 11 of 13

 Possible Cause
Problem Recommended Action
Pneumatic Shift Electric Shift
Place the chassis
Chassis transmission is in Chassis transmission is in transmission in NEUTRAL
gear when shifting pump. gear when shifting pump. before shifting pump
transmission.
Place the chassis
Butt-tooth condition - Butt-tooth condition -
transmission in DRIVE after
chassis transmission is in chassis transmission is in
shifting pump transmission
REVERSE. REVERSE.
to ROAD.

Pump shift control is in Ensure the driveline is not

the ROAD position and rotating before shifting to
grinding sounds are ROAD.
heard emanating from the ----------
pump transmission. Consider reducing engine
Excessive driveline torque Excessive driveline torque
idle speed.
and/or rotation. and/or rotation.
----------
It may be necessary to
contact the chassis
transmission manufacturer
for assistance.
Damage to pump Damage to pump
See pump transmission
transmission shifting transmission shifting
inspection instructions.
components. components.
Place the shift air control
valve in the center position.
Air pressure present on
-- (Note: There is no center
Manual pump shift pneumatic shift piston.
position on units built prior
override control cannot to 1994).
be moved by hand
(electric or pneumatic Electric shift still engaged Operate the electric shift to
--
shift functions properly). with shift arm. disengage control.
Binding or malfunctioning Binding or malfunctioning Repair or replace to
manual shift linkage. manual shift linkage. eliminate linkage binding.

The chassis engine stalls Shift indicating switch stuck Shift indicating switch stuck Replace the shift indicating
when the chassis closed. closed. switch.
transmission is placed in
DRIVE (automatic) Problem with chassis Problem with chassis
Contact chassis
after moving the pump transmission or transmission or
transmission manufacturer
shift control to the ROAD transmission electronic transmission electronic
for assistance.
position. control unit. control unit.

Pump Transmission Shift Component d. Remove the pneumatic or electric shift unit (if so
Inspection equipped) from the pump transmission.

The following procedures should be followed when a e. Manually align the shift teeth by actuating the
problem with the pump transmission shift components is pump transmission shift arm and rotating the drive
suspected: shaft until the shift collar is engaged in the PUMP
position.
1. Perform a shift force test on the pump transmission.
f. Pull on the long side of the shift arm to shift the
a. Place the chassis transmission in NEUTRAL and
pump transmission between ROAD and PUMP
shut off the engine.
using a pull scale to measure the force required in
b. Set the apparatus parking brake. pounds. The force required to shift the pump
transmission should not exceed 18 pounds.
c. Remove any manual override linkage from the
pump transmission shift arm.

F-1031, Section 2205.3 REV: 05/09/08 Page 12 of 13

2. Drain the lubricant from the pump transmission and 4. Inspect the pump transmission shift components, in­
examine it for metal particles appearing in quantity cluding:
and/or size which may indicate excessive wear to in­ a. Check for damage to the shift fork and the shift
ternal components. Also check the magnetic drain shoes.
plug and the sump screen on the lube pump intake
line (if so equipped) for debris. If there is little or no b. Check for damage to the shift shaft, locking arm
debris refill with clean lubricant and retest. If the prob­ assembly and sector gear.
lem persists or if large quantities or sizes of debris are
found proceed to step 3. c. Check for damage to the engaging teeth on the
drive sprocket, coupling shaft and shift collar.
3. Remove the lower section of the pump transmission Note: it will be necessary to manually actuate the
according to the pump transmission overhaul instruc­
shift arm to inspect all of the teeth. Some binding
tions.
may normally occur when actuating the shift arm
with the lower case section removed). Minor burrs
found on the teeth of the shift collar, drive sprock­
et, or coupling shaft may be filed clean. If exces­
sive damage is found the component(s) should be
replaced.
d. Check to make sure that all bearings turn freely.
5. Contact Waterous to order any replacement parts or
for further assistance.

F-1031, Section 2205.3 REV: 05/09/08 Page 13 of 13