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OPERATION INSTALLATION
MAINTENANCE
MANUAL
FOR HALE FLEX SERIES
SINGLE STAGE BOOSTER PUMPS
BY
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
607 NW 27th Ave, Ocala, FL 34475
(800) 533.3569
(800) 520.3473 (FAX)
www.haleproducts.com
MANUAL P/N FSG–MNL–00183 Revision B
COPYRIGHT © 2018 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED
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Related Manuals for HALE HALE FLEX Series
Summary of Contents for HALE HALE FLEX Series
- Page 1 SINGLE STAGE BOOSTER PUMPS HALE PRODUCTS, INC. A Unit of IDEX Corporation 607 NW 27th Ave, Ocala, FL 34475 (800) 533.3569 (800) 520.3473 (FAX) www.haleproducts.com MANUAL P/N FSG–MNL–00183 Revision B COPYRIGHT © 2018 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED...
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Page 3: Table Of Contents
Warnings And Cautions ......................11 5.2. Risk Assessment ........................11 5.3. Special Tools .......................... 11 5.4. Mounting A Hale Booster Pump ................... 11 5.4.1 Hardware Requirements ....................13 5.4.1.1 Mounting Hardware ....................13 5.4.1.2 Thread Lock, Bonding, Or Sealant Compound ............14 5.4.1.3... - Page 4 TABLE OF CONTENTS – CONTINUED Section Title Page 6.6. Pump Cavitation ........................18 6.6.1 Discharge Pressure Cavitation Warning Signs .............. 18 6.6.2 Vacuum Compound Gauge Warning Signs..............18 6.6.3 General Considerations to Prevent Cavitation .............. 19 6.7. Post Operation Notes ......................19 7.
- Page 5 Cavitation Fault Flow Chart ..................30 LIST OF TABLES Number Title Page Table 1. Hale Flex Series Single Stage Booster Pump Drawings ..........9 Table 2. Flex Series Inlet And Discharge Connections ............... 14 Table 3. Preventive Maintenance Plan and Schedule ..............21 Table 4.
- Page 6 Abbreviations And Acronyms Abbreviations used in this manual are commonly used units of measure and are NOT defined or listed. The acronyms used in this manual are defined below. Authority Having Jurisdiction Constant Velocity EN 1028-1 Fire-Fighting Pumps Centrifugal Pumps - General And Safety Requirements FAST Factory Authorized Service Team NFPA...
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Page 7: Safety
1.2. Training Pump Training is available through the Hale Training Academy and may be accessed via the Hale Products Inc. website (www.haleproducts.com), Godiva √erified Training (godiva.co.uk), or through your local dealer or vehicle manufacturer. - Page 8 ALWAYS FOLLOW LOCAL GUIDELINES FROM THE AHJ AND THE APPARATUS MANUFAC- TURER. ALWAYS FOLLOW PROPER OPERATING PROCEDURES. THE PUMP OPERATOR AND INDI- VIDUALS AROUND THE APPARATUS MUST BE FAMILIAR WITH THE PUMP OPERATING IN- STRUCTIONS AS WELL AS OTHER OPERATING GUIDELINES FOR THE APPARATUS, AND ACCESSORIES.
- Page 9 DO NOT REPLACE FASTENERS WITH OTHER THAN HALE PART NUMBERS PROVIDED. FOLLOW DEPARTMENT PROCEDURES TO SET WHEEL CHOCKS WHEN PUMPING. USE PPE TO PROTECT HANDS AND FINGERS FROM SHARP EDGES. THE EDGES OF THE BLADES ON THE INDUCER OR IMPELLER MAY BE SHARP.
- Page 10 FAILURE TO INSTALL THE ENGINE SPEED INTERLOCK SYSTEM PROPERLY MAY RESULT IN PTO DAMAGE. FOLLOW PTO AND VEHICLE MANUFACTURER PTO INSTRUCTIONS. HALE PUMPS ARE SHIPPED WITHOUT OIL. FILL GEARBOX WITH FLUID LISTED IN TABLE 5 BEFORE OPERATION. IF THE DISCHARGE PRESSURE DOES NOT INCREASE, AND INTAKE GAUGE READING...
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Page 11: General Instructions
This manual covers the Hale Flex Series of single stage booster pumps and provides basic infor- mation on Hale AP, CBP, MBP, or RSD Flex Series of booster pumps when local procedures do NOT exist. Basics of operation, installation verification, and maintenance are covered. -
Page 12: Identification Plate
The plate is stamped with the appropriate model, input drive type, capacity (NFPA rated flow shown) and units code, gear ratio code, gearbox type code, and serial number. Figure 1 is an example of Hale pump identification plate marking conventions Figure 2. -
Page 13: Transport And Storage
Lubricants. See paragraph 7.4.4.1, for instructions to fill the gearbox with fluid. 3.3. Storage Hale Flex Series pumps should be stored indoors in a protected environment before installation. If the pump needs to be stored for more than six months, see Hale Service Bulletin SB150 on the Hale website. - Page 14 THIS PAGE INTENTIONALLY BLANK.
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Page 15: Pump Overview
All bronze construction is an option. The pumps are designed for water and need an external primer (to evacuate air) to pump water from a static source. All Hale Flex Series single stage booster pumps support outlet rotation, see Table 1 for the applicable drawing. The drawings are located on the flash drive provided with the pump or on the Hale Products website (www.haleproducts.com). -
Page 16: Figure 5. Visually Determining Engine Or Opposite Engine Rotation
Figure 5. Visually Determining Engine Or Opposite Engine Rotation Additional theory of operation is provided in FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps that is located on the flash drive provided with the pump or available from the... -
Page 17: Installation
5. INSTALLATION This section provides basic information for the installation of Hale booster pumps. Installation per- sonnel should be qualified in pump and plumbing installation and vehicle manufacture. 5.1. Warnings And Cautions Before attempting to install the pump, read all of the following safety precautions and follow them carefully. -
Page 18: Figure 6. Typical Booster Pump Mounting
HEATING. OVERHEATING CAN DAMAGE THE PUMP SEAL, AND OTHER PUMP PARTS. Figure 6 shows the recommended mounting brackets an OEM should provide to mount a Hale Flex series single stage booster pump. (Hale does NOT supply mounting brackets.) Mount a pump using both the pump body and the gearbox. -
Page 19: Hardware Requirements
Attach an OEM provided secondary support bracket to the gearbox using a minimum of three (3) gearbox metric mounting studs. (The drive side of the gearbox provides ten (10) M10–1.5 threaded holes.) Hale supplies four (4) M10 studs, flat washers, lock washers, and nuts to secure the OEMs mounting bracket(s) to the gearbox. -
Page 20: Thread Lock, Bonding, Or Sealant Compound
Figure 8. Grade 8 And Class 10.9 Bolt Marking 5.4.2 Inlet And Discharge Connections Table 2 lists the available inlet and discharge connections for Hale Flex Series single stage booster pumps. Table 2. Flex Series Inlet And Discharge Connections PUMP... -
Page 21: Commissioning, Startup, Operation, And Shutdown
Form or similar guide as well as purchasing specs to inspect a new apparatus. 6.2. Performance Verification Hale provides the OEM/apparatus builder a certification that the pump meets or exceeds the per- formance requirements when the pump was manufactured. Once the OEM/apparatus builder has installed the pump the completed apparatus should be tested. -
Page 22: Figure 9. Check Gearbox Oil Level
FOLLOW PTO AND VEHICLE MANUFACTURER PTO INSTRUCTIONS. OPEN AT LEAST ONE DISCHARGE VALVE SLIGHTLY TO PREVENT THE PUMP FROM OVER- HEATING. OVERHEATING CAN DAMAGE THE PUMP SEAL, AND OTHER PUMP PARTS. Before the initial startup of pump check the following: •... -
Page 23: Draft Operation Notes
Keep all valves closed until discharge pressure is achieved. • Lift should not exceed 10 feet (3m) per NFPA. Lift capability can be reduced by different condi- tions. See FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps, Table 3, Table 5, and Table 6 for losses information. -
Page 24: Hydrant Or Relay Operation
To shut down, reduce throttle and close valves (to hold prime) before disengaging pump. For additional information, see FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps. The manual is contained on the flash drive provided with the pump or on the Hale Products website (www.haleproducts.com). -
Page 25: General Considerations To Prevent Cavitation
6.6.3 General Considerations to Prevent Cavitation Consider the following to avoid conditions that lead to cavitation. • Regularly inspect suction hoses and gaskets to check for air leaks. • Use the proper suction hose size and length for the pump flow rating. •... - Page 26 THIS PAGE INTENTIONALLY BLANK.
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Page 27: Preventive Maintenance
See FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps, on the flash drive provided with the pump or on the Hale website (www.haleproducts.com) for additional information. A local FAST can also be found on the Hale website and may be used for additional assistance with maintenance/service. -
Page 28: Freezing Weather
If the type of fluid found in the gearbox is unknown, perform a fluid change as instructed in para- graph 7.4.4.1, Fluid Change Procedure. A. Locate Oil Level Sight Glass. (See Hale drawing FSG–PL–01481, found on the flash drive provided with the pump or on the Hale website [www.haleproducts.com].) B. -
Page 29: Perform Vacuum Test
During annual test, pressure control functions, electrical systems and complete truck op- eration should be verified in addition to pump performance. If the apparatus does not reach performance levels, refer to FSG–MNL–00184, Tech- nical Manual For Hale Single Stage Booster Pumps. -
Page 30: Triennial Pump Maintenance
Oil Safe Catch Container (2 Qt or larger) Funnel (Optional) A. Locate magnetic Oil Drain Plug (See FSG–PL–01481 found on the flash drive provid- ed with the pump or on the Hale website [www.haleproducts.com].) (See Figure 10. for an example location.) Figure 10. -
Page 31: Figure 11. Fill Gearbox With Fluid
PRESENT, REPORT CONDITION TO AHJ SO SERVICE CAN BE PERFORMED. D. Inspect, clean, and install magnetic drain plug. (See FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps, if excessive metal is found on drain plug. This manual and additional information can be found on the flash drive provid- ed with the pump or on the Hale website [www.haleproducts.com].) -
Page 32: Recommended Gearbox Lubricants
The lubricant listed in Table 5 is required to ensure continued service and operation across the am- bient temperature range of 0º to +120 ºF (–20 º to +50 ºC). Additional information on lubricants is found in FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps. -
Page 33: Symptoms, Causes, And Remedies
Use the flow charts and/or the SCR table provided on the following pages to troubleshoot an opera- tor correctable fault. Refer to FSG–MNL–00184, Technical Manual For Hale Single Stage Booster Pumps, if the pump experiences a fault other than one listed herein. The technical manual and addi- tional information such as drawings, pump curves, and rating charts can be found on the flash drive provided with the pump or on the Hale website (www.haleproducts.com). -
Page 34: Figure 13. Loss Of Suction Fault Flow Chart
Figure 13. Loss Of Suction Fault Flow Chart... -
Page 35: Loss Of Suction Symptoms, Causes, And Remedies
IAW AHJ. See NOTE. NOTE: For troubleshooting information, refer to FSG-MNL-00184. The manual is contained on the flash drive provided with the pump or available from the TECH RESOURCE CENTER on the Hale Products website (www.haleproducts.com). -
Page 36: Cavitation Fault Flow Chart
8.2. Cavitation Fault Flow Chart Figure 14. Cavitation Fault Flow Chart... -
Page 37: Cavitation Symptoms, Causes, And Remedies
8.2.1 Cavitation Symptoms, Causes, And Remedies Table 7 provides the primary symptoms, causes, and remedies for troubleshooting cavitation issues. Cavitation limits pump performance and can damage the pump. Refer to Technical Manual for more information. Table 7. Cavitation SCR Table SYMPTOM CAUSE REMEDY... - Page 38 THIS PAGE INTENTIONALLY BLANK.
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Page 39: Appendix A. Manufacturer's Information
Godiva LTD Mailing: Tel: +44 (0) 1926 623600 (A Unit of IDEX Corp.) Charles Street, Warwick, England, CV34 5LR FAX: +44 (0) 1926 623666 Email: godiva@idexcorp.com WARRANTY See the Hale website (www.haleproducts.com) for product specific warranty and warranty proce- dures. A–1...