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HALE DSD Operating And Maintenance Manual

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A Hale pump is a quality product; ruggedly designed, accurately ma-
chined, carefully assembled and thoroughly tested. In order to maintain
the high quality of your pump and to keep it in a ready condition, it is im-
portant to follow the instructions on care and operation. Proper use and
good preventive maintenance will lengthen the life of your pump.
ALWAYS INCLUDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE
OPERATING AND
MAINTENANCE MANUAL
MODEL: DSD
SERIAL NO._______________
Failure to follow the operating, lubrication,
and maintenance requirements set forth in
the operating and instruction manual may
result in serious personal injury and/or dam-
age to equipment.
HALE PRODUCTS INC.
A Unit of IDEX Corporation
700 Spring Mill Avenue
610/825-6300
Fax: 610/825-6440
n
www.haleproducts.com
Fire Suppression Division
n
Conshohocken, PA 19428
n

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  • Page 1 A Hale pump is a quality product; ruggedly designed, accurately ma- chined, carefully assembled and thoroughly tested. In order to maintain the high quality of your pump and to keep it in a ready condition, it is im- portant to follow the instructions on care and operation.
  • Page 3 Hale Products Inc., prior to returning any merchandise. • Replacement parts, complete items or accessories must be in new condition or are able to be resold, properly identified with Hale part numbers. • Any material that is returned that does not reflect the original purchase will be accepted upon Hale’s discretion and evaluation fee.
  • Page 4 Hale single-stage and two-stage midship pumps are favorites of firefighters throughout the world. Covering a range of capacities from 750 Gallons Per Minute (GPM) to 2000 GPM, Hale pumps offer the versatility, dependability, reliability, and ease of operation so necessary to effective fire fighting.
  • Page 5 BASIC PARTS OF A HALE Midship CENTRIFUGAL PUMP Figure. 1-2 shows the basic parts of a Hale midship centrifugal pump. These parts are briefly described in the following text IMPELLERS (TWO STAGE) BALL BEARINGS BALL BEARINGS SLEEVE BEARING AUTO-LUBE SLINGER RING...

  • Page 6: Pump Body

    Bearings Bearings support and align the impeller shaft for smooth operation. See Figure 1-2. Pump Body The standard pump body (Figure 1-2) and related parts are constructed from fine grain alloy cast iron, with a minimum tensile strength of 30,000 PSI. All moving parts subject to water contact are of high quality bronze with stainless steel shafts.
  • Page 7 MECHANICAL SEAL Auto-Lube A miniature centrifugal pump (A) is built into the shaft of Hale midship pumps (see Figure 1-6). This miniature pump continuously forces oil from the reservoir (B), through the bearing (C), and back again.
  • Page 8 CENTRIFUGAL PUMP DRIVE There are four common types of centrifugal pump drives used with fire fighting apparatus: • Operation from the truck chassis drive shaft (split-shaft PTO). • Operation from a separate engine. • Operation from the front of the truck chassis engine (front engine PTO) crankshaft •...
  • Page 9 GEARBOX Hale offers a variety of pump gear ratios to accommodate a wide range of apparatus manufacturer requirements. The gearbox (Figure 1-8) consists of a gearbox, gear set, and input and output drive shafts that are both made of heat treated nickel steel. This unit can withstand the full torque of the engine in road operating conditions up to 16,000 pounds-feet.
  • Page 10 • 1000 GPM to 2000 GPM Hale single-stage pumps are of a size and design to attach to the chassis rails of commercial and custom chassis. The pump is driven from the truck main drive line. Generally, it consists of the following major components: •...
  • Page 11 • 1000 to 2000 GPM Hale two-stage pumps are of a size and design to mount on the chassis rails of commercial and custom trucks The pump is driven from the truck main drive line. Generally, the pump consists of the following major components: •...
  • Page 12 Pressure (Series) Operation Pressure operation, Figure 1-11, finds the impellers connected in series. That is, the output of the impeller supplied from the pump intake is supplied to the input of the next impeller. The pressure at the pump discharge is the sum of the pressures of the two impellers plus the pressure at the intake.
  • Page 13 If your fire department does not have a policy to follow, here are general guidelines: 1. Hale pumps are designed to pump up to 200 PSI net pressure in volume operation at reasonable engine speeds. 2 Generally, volume operation should be used at any net pump pressure under 150 PSI, especially when pumping from a hydrant 3.
  • Page 14 BOOSTER PUMPS Hale booster pumps offer the added dimension of low volume and high pressure for use with the midship pumps. The booster is ideal for high pressure, hose reel operation. As shown in Figure 1-12, the booster pump is designed for direct mounting at the accessory port of the Hale gearbox.
  • Page 15 The pump should not be operated unless the lubricant tank is filled A Hale priming pump has a single control that both opens the priming valve between the midship pump and the priming pump and starts the priming motor. The primer is automatically lubricated during operation.
  • Page 16 PRESSURE CONTROL DEVICES Three basic types of pressure control devices are used with Hale Midship pumps: • Engine speed governor system (optional). • Relief valve system (standard). • Hale Total Pressure Master Relief Valve System (optional). Relief Valve System As shown in Figure 1-14, the Relief Valve System is a single bronze, variable press= setting relief valve of sufficient capacity to prevent an undue pressure rise (NFPA Pamphlet No.
  • Page 17 PUMP DISCHARGE PRESSURE PUMP SUCTION WATER TANK WATER TANK VACUUM ATMOSPHERE SINGLE PORT DRAIN VALVES Figure 1-15. Hale Total Pressure Master Relief Valve System...
  • Page 18 The Hale drain valve is a sliding plug type valve used to relieve pressure from hose lines after pumping. To open, pull the knob out; to close, push the knob in. The valve must be seated completely to prevent leakage while priming and pumping.
  • Page 19 3. Apply the truck parking brake. This section supplies information and procedures 4. Shift the truck transmission to the NEUTRAL for the operation of Hale single -stage and two- position. stage pumps. Included in this section are procedures for pumping from a hydrant, pumping 5.
  • Page 20 15. Open the discharge valves. SWITCH THE TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS “0” BEFORE 16. If the pump overheats and is not equipped with MAKING PUMP TRANSMISSION SHIFT. the Hale TRV valve, open the valve to access...
  • Page 21 2. Bring the truck to a complete stop before you 9. Activate the priming pump by pulling the attempt to connect suction hoses or shift from control handle located on the pump panel or road to pump. depressing the push button. 3.
  • Page 22 5 to 15 MPH after 16. If the pump overheats and is not equipped with shifting to the pump position. See the chassis the Hale TRV valve, open the valve to access manual for details. the pump auxiliary cooling system, or slightly...
  • Page 23 15. If the pump overheats and is not equipped with priming pump by pulling the control handle the Hale TRV valve, open the valve to access located on the pump panel or depressing the the pump auxiliary cooling system, or slightly prime push button or just crack the tank fill open the tank fill line.
  • Page 24 TPM (if available) very low in order to limit the 7. Adjust the discharge pressure or flow at the incoming pump pressure by dumping water on the fire scene to supply the lines being used. ground before you have discharge hose lines 8.
  • Page 25 Pump To Road Shift Procedures TPM Relief Valve Procedures 1. Verify that the operator’s hand throttle or These procedures cover the Hale TPM Relief governor control has returned to idle speed. Valve System. Be sure to select the correct procedure, according to relief valve.
  • Page 26 5. Turn the hand wheel slowly clockwise, until Decreasing Pressure the amber light just goes out. Then turn the hand wheel one additional full turn clockwise Put the governor control in the RPM for proper operation. mode, and reduce the speed to the new pressure.
  • Page 27 Open discharge valves, remove suction tube caps, and discharge valve caps. DO NOT ATTEMPT EMERGENCY SHIFT Open the pump body drain cocks or Hale PROCEDURES WHILE THE ENGINE IS multiple drain valve. If a multiple drain RUNNING. valve is used, all pump drain lines should be connected to this valve.
  • Page 28 Hale Midship Pumps require very little care and material that will be harmful to the pump if not maintenance. However, the little required is purged.
  • Page 29 Verify that the discharge pressure gauge Relief Valve and TPM Test readings have approximately doubled. When the relief valve is not in operation, maintain a setting above the normal operating pressure. 2. For power transfer valves: 1. Set up to pump from the onboard water tank With the apparatus engine turned off, use with the discharge valve back to the water tank either a 3/8-inch socket on the indicator...
  • Page 30 2. Remove the gearbox oil fill plug (refer to the To loosen the nut, turn it in the direction Hale Service Chart), and check the level of the of engine rotation. oil in the gearbox. The level should be up to the plug hole.
  • Page 31 Attach the suction hose to the pump. Drive Line and Flange Bolts Check all drive line and flange bolts to ensure: Place the suction tube cap on the end of the hose in place of a strainer. 1. No bolts are missing. Close all valves and drains.
  • Page 32 Test apparatus and check for leaks around testing criteria refer to the latest version of NFPA strainer fittings 1911 pamphlet. Pumpers are rated at capacities of 500, 750, 1000, 1250, 1500, 1750, 2000, or 2250 3. Place apparatus back in service. GPM (1892, 2839, 3785, 4731, 5678, 6624, 7570, or 8516 LPM).
  • Page 33 TABLE 3-1. PUMP RATING GPM (LPM) PRESSURE CAPACITY 1000 1250 1500 1750 2000 2250 PSI (BAR) 1000 1250 1500 1750 2000 2250 FULL 150 (10) (1892) (2839) (3785) (4731) (5678) (6624) (7570 (8516) 1000 1250 1500 1750 2000 2250 FULL 165 (11) (1892) (2839)
  • Page 34 TABLE 3-2. (Continued) NOZZLE GPM AT VARIOUS NOZZLE SIZES PRESS ½” 5/8” ¾” 7/8” 1" 1 1/8" 1 ¼” 1 3/8” GPM AT VARIOUS NOZZLE SIZES NOZZLE PRESS 1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3"...
  • Page 35 TABLE 3-2. (Continued) NOZZLE GPM AT VARIOUS NOZZLE SIZES PRESS 1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3" 1008 1276 1575 2268 1022 1293 1597 2299 1036 1311 1618 2330 1049 1328 1639 2361 1063 1345 1660...
  • Page 36 TABLE 3-3. HOSE FRICTION LOSS (PSI PER 100 FEET) 13.5 1000 1250 1500 1750 2000 1000 NOTE: Add 5 PSI for each story of building and each wye or siamese. Friction Loss Calculations courtesy of IFSTA.
  • Page 37 Because NFPA standards specify both GPM 5. If the apparatus does not reach performance (LPM) and pressure, it is usually necessary to levels, refer to the Hale diagnostic/service restrict the flow somewhat to build up the pump chart (Section 4).
  • Page 38 PER NFPA 1962 REQUIREMENTS, LARGE DIAMETER HOSE MARKED “SUPPLY HOSE” 6 5. Repack using Hale packing INCHES (152 MM) DIAMETER SHALL NOT BE recommended for your particular pump. For USED OPERATING PRESSURES most pumps, the packing is 7/16 inch square EXCEEDING 135 PSI (9 BAR).
  • Page 39 BAR). Test and set relief valve as necessary using 8. Lock the pressure setting by turning the the following procedures and figure 3-1. adjustment locking screw until tight. Lock screw in place with Loctite #290 or equivalent. 1. Open operator panel and gain access to the relief valve adjustment cap screw.
  • Page 40 In clear water, the clearance rings continue to 1. Close all discharge valves including pump and effectively seal for hundreds of hours of pumping. engine coolers so there is no flow through the In dirty or sandy water, the impeller hub and pump.
  • Page 41 Midship Pump Maintenance Check List Truck Manufacturer ________________________ Pump Model & Serial Number ________________ Year __________ Unit# _____________________ RECOMMENDED WEEKLY PROCEDURES Test relief valve system or governor at 150, 200, 250 PSIG. Test transfer valve (if applicable). Test the priming system (check lubrication level in priming tank were installed). Lubricate all valves, discharge, suction, hose, drain, and multi-drain.

  • Page 42: Troubleshooting

    Table 4-1 lists the symptoms of some common problems and possible corrective measures. Before calling Hale or a Hale authorized parts service center for assistance, eliminate problem causes using Table 4 -1. If you cannot correct a problem, please have the following information ready prior to calling the Hale Customer Service Technician Department for assistance.
  • Page 43 CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Automatic Transmission Insufficient air in shift system Repeat recommended shift procedures. With Power Shift System (continued) Air leaks in shift system Check system for loss of air. Check of leak in system. Employ manual override procedures if necessary.
  • Page 44 CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Air Trap in Suction Line Avoid placing any part of the suction hose PUMP LOSES PRIME higher than the suction intake. Suction hose OR IT WILL NOT should be laid with continuous decline to PRIME (CONTINUED) water supply.
  • Page 45 CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Insufficient engine power Engine power check or tune up may be INSUFFICIENT PUMP required for peak engine and pump CAPACITY performance. Transfer Valve not in proper TWO STAGE PUMPS ONLY. Place “Volume” position transfer valve in “Volume” position (parallel) when pumping more than 1/2 rated capacity.
  • Page 46 CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Packing out of adjustment or Adjust the packing per the procedure in LEAK AT PUMP worn. Section 3 of this manual (8 to 10 drops per PACKING minute leakage at 150 PSI (10 BAR) preferred). Replace pump packing per Section 3 of this manual.
  • Page 47 CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Dirt in system causing sticky Relief valve dirty or sticky. Follow RELIEF VALVE DOES or slow reaction instructions for disassembling, cleaning, and NOT RECOVER AND lubricating. RETURN TO ORGINAL PRESSURE Blocked relief valve. Clean the valve with a SETTING AFTER small wire or straightened paper clip.
  • Page 48 Glossary Atmospheric Pressure caused by the elevation of air above the earth. Pressure Auxiliary Permits water from a pump to cool the radiator water through a heat exchange. Cooling Valve Capacity Pump flow rating. Cavitation Caused by the pump attempting to deliver more water than is being supplied. This causes the formation of water vapor, and liquid water, under pressure, rushes in to fill the empty space.
  • Page 49 Glossary Gauge Pressure read from a gauge (PSIG). Pressure Governor Minimizes pressure changes by controlling engine speed. Horsepower A measure of mechanical work. Impeller The working part of a centrifugal pump that, when rotating, imparts energy to water. Essentially, an impeller consists of two disks separated by curved vanes. The vanes force the water to move outward between the disks so that it is thrown outward at high velocity by centrifugal force.
  • Page 50 Glossary Pump Shift A midship pump is usually mounted with a split gearbox installed in the drive shaft. The pump shift moves a sliding gear in the gearbox that transmits power either to the pump or the rear axle. In road position, power is transmitted to the rear axle for driving; in pump position, the rear axle is disconnected, and power is transmitted to the pump shaft.
  • Page 51 Let Us Put Out A Few Fires For You. IDEX CORPORATION...
  • Page 52 Fighting Fires Is Your Business. Looking Out For Your Pump Is Ours. Few things in life are more reliable than your new Hale midship pump. We do our best to keep it that way, too, with our standard two-year/2,000-hour warranty.
  • Page 53 (Continued on other side.) workmanship for the additional warranty period selected. The Midship Pump Registration Form Complete and return (with your check payable to Hale Products, Inc.) to the address below. Equipment Description Purchasing Company/Department Pump Model #: ______________________________________...
  • Page 54 PRODUCT; INCONVENIENCE; TRADE OR OTHER COMMERCIAL LOSSES shall apply: ARISING, DIRECTLY OR INDIRECTLY, OUT OF THE PRODUCT FAILURE. • Any notice to Hale must be in writing, identifying the Product (or component) claimed defective and circumstances surrounding its failure; • Hale reserves the right to physically inspect the Product and Hale Products, Inc.

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