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HALE AP Technical Manual

Single stage booster pumps
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TECHNICAL MANUAL
FOR HALE
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–00184
REV A
COPYRIGHT © 2002 – 2018 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED

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  • 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–00184 REV A COPYRIGHT © 2002 – 2018 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Title Page 1. SAFETY ............................. 1 1.1. PPE ............................1 1.2. Environmental Protection ......................1 1.3. Training ............................. 2 1.4. Safety Summary ........................2 2. INTRODUCTION..........................7 2.1. Overview ............................ 7 2.2. How To Use This Manual ......................7 2.3.
  • Page 4 TABLE OF CONTENTS – CONTINUED Section Title Page 3. MAINTENANCE OPERATING PROCEDURES ................. 17 3.1. Repair Verification Operations ....................18 3.2. Vacuum Test ........................... 20 3.3. Pressure Test ......................... 22 3.4. Pumping From Draft Verification Operations ............... 23 3.4.1 Draft Limiting Factors ....................... 25 3.5.
  • Page 5 TABLE OF CONTENTS – CONTINUED Section Title Page 4.4.4.1.2 Testing Equipment And Materials ..............38 4.4.4.1.3 Performance Testing Test Procedure ............... 41 4.4.5 Annual Pump Maintenance .................... 41 4.4.6 Triennium Pump Maintenance ..................42 4.4.6.1 Gearbox Fluid Change ....................42 5.
  • Page 6 MBP/RSD Impeller R&R ................... 81 5.8.4.7 AP Impeller R&R ......................83 5.8.4.8 CBP Impeller R&R ..................... 87 5.8.4.9 AP/CBP/MBP Mechanical Seal R&R ............... 90 5.8.4.10 RSD Mechanical Seal R&R ..................93 5.8.4.11 AP/CBP/MBP Pump Head R&R ................96 5.8.4.12 RSD Pump Head R&R ....................98 5.8.4.13...
  • Page 7 TABLE OF CONTENTS – CONTINUED Section Title Page 5.9. Gearbox ..........................118 5.9.1 Gearbox R&R ......................... 118 5.9.2 Gearbox Bench Procedures ..................120 5.9.2.1 Input Shaft ......................121 5.9.2.1.1 Input Shaft Oil Seal (ONLY)................126 5.9.2.1.2 Input Shaft Bearings (ONLY) ................127 5.9.2.1.3 Input Shaft Endcap (ONLY) ................
  • Page 8 TABLE OF CONTENTS – CONTINUED Section Title Page C.3.1.7 Check Roof and Bumper Turrets ................C–5 C.3.1.8 Check Auxiliary Fire Suppression Equipment ............C–6 C.3.2 Monthly Maintenance ....................C–6 C.3.2.1 Priming System Test (Dry Vacuum Test) ............... C–6 C.3.2.2 Drive Line And Flange Bolts .................. C–7 C.3.3 Annual Maintenance ....................
  • Page 9 Figure 2. Single Stage Water Flow ....................9 Figure 3. Clearance Ring Water Flow .................... 10 Figure 4. Parts Of The Hale Booster Pump ................... 11 Figure 5. Mechanical Seal ......................12 Figure 6. Direct Engine Mount ....................... 14 Figure 7.
  • Page 10 RSD Wrap Around Clearance Ring R & R ..............117 Figure 48. Pump Shaft Assembly ....................133 Figure 49. AP/CBP Pump Shaft ....................135 Figure 50. MBP/RSD Pump Shaft ..................... 136 Figure 51. Rotary Vane Positive Displacement Type Priming Pump ........C–1 Figure 52.
  • Page 11 Table 31. AP Impeller R&R Tools And Consumables List ............. 84 Table 32. CBP Impeller R&R Tools And Consumables List ............88 Table 33. AP/CBP/MBP Mechanical Seal Bench Procedure Tools And Consumables List..90 Table 34. RSD Mechanical Seal Bench Procedure Tools And Consumables List ....... 93 Table 35.
  • Page 12 Abbreviations And Acronyms The abbreviations used in this manual are limited to standard (commonly used and accepted) scientific units of measure and therefore are NOT defined or listed. The acronyms used in this manual are defined in this listing (in numerical-alphabetical order) and are NOT defined within the text.

  • Page 13: Safety

    1. SAFETY This section provides definitions for DANGERS, WARNINGS, CAUTIONS, NOTICES, and NOTES contained herein, precautions to be taken for pump repair as well as an alphabetical summary listing of the DANGERS, WARNINGS, CAUTIONS, and NOTICES used in this manual. DANGERS, WARNINGS, CAUTIONS, or NOTICES that immediately precede a step apply directly to that step and all sub steps.

  • Page 14: Training

    1.3. Training AP, CBP, MBP, and RSD pumps must only be operated and maintained by trained personnel. Training is available via the Hale Products Inc. website (www.haleproducts.com), Godiva √erified Training (godiva.co.uk), or through your local dealer or vehicle manufacturer. The Hale website provides a description of the course content and general information about the training, includ- ing an invitation to register with the EVT Certification Commission (www.evtcc.org) to take one...
  • Page 15 FAILING TO REDUCE SYSTEM PRESSURE BEFORE SYSTEM SHUTDOWN OR FLUSH- ING COULD RESULT IN WATER HAMMERING. THE AP PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 140 LBS (64 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE PUMP AND GEARBOX ASSEMBLY.
  • Page 16 THE RSD PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 225 LBS (102 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE PUMP AND GEARBOX ASSEMBLY. USE PPE TO PROTECT HANDS AND FINGERS FROM SHARP EDGES. THE EDGES OF THE BLADES ON THE INDUCER MAY BE SHARP. A MECHANICAL SEAL IS A PRECISION ENGINEERED DEVICE.
  • Page 17 DO NOT DRIVE THE CLEARANCE RING INTO THE /SUCTION HEAD/VOLUTE AT AN AN- GLE OR UNEVENLY (ALL THE WAY FROM ONE SIDE AT A TIME). BENDING, WARPING, OR CHIPPING THE CLEARANCE RING MAY RESULT IN POOR PERFORMANCE OR PUMP FAILURE. DO NOT INSTALL A USED COTTER PIN.
  • Page 18 IF A PUMP IS OPERATED WITHOUT WATER, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. FAILURE TO FLOW WATER MAY DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM. IF IN 30 TO 45 SECONDS ONE OF THE FOLLOWING (BULLETS) DOES NOT OCCUR STOP THE PUMP AND CHECK FOR AIR LEAKS OR A POSSIBLE PUMP TROUBLE.

  • Page 19: Introduction

    The AP, CBP, and MBP booster pump maintenance technics are similar and are therefore grouped in this manual. The RSD booster pump maintenance technics differ signif- icantly and are presented separate from the AP, CBP, and MBP booster pumps.

  • Page 20: Pump Specifications And Numbering

    The two Maintenance sections provide all aspects of maintaining the AP, CBP, MBP, and RSD pumps, including sparing, preventive and corrective maintenance (which includes troubleshoot- ing and remove and replace instructions). Notice that the use of this manual also requires maintenance personnel to have received Hale training prior to using it.

  • Page 21: Explanation Of Terms

    The following major terms are explained in sufficient detail to allow a maintainer to communicate pumping issues or troubles with Hale Customer Service personnel. As a basic understanding of the terms (and the principles associated with them) will assist operators (for both operations and maintenance purposes) utilize common terminology and understand accepted principles when communicating among each other.

  • Page 22: Cavitation

    The type of priming pump used (by Hale) for the AP, CBP, MBP, and RSD pumps is an electric motor driven rotary vane pump. Once the main pump is primed and pumping, the priming pump is turned off.

  • Page 23: Pm Relief Valve Control

    Impeller Gears (Drive, Mating/Pump) • • Mechanical Seal Shaft Assemblies (Input, Pump) Figure 3 shows these standard parts of a Hale booster pump. These parts are briefly described in the following paragraphs. Figure 4. Parts Of The Hale Booster Pump...

  • Page 24: Volute

    Depending on the model, the pumps provide between 12 and 24 different configurations (includ- ing both rotations – ER or OER). Refer to the Parts Manual For Hale Single Stage Booster Pumps (FSG–MNL–00185), Section 2, Hale Booster Pump Illustrated Breakdowns, ( Gearbox And Dis- charge Positions paragraphs) for a reference to the appropriate drawing and sheet number(s) providing the views of the volute positions.

  • Page 25: Gearbox

    Hale offers a variety of pump gear ratios to ac- commodate a wide range of end-user and apparatus manufacturer requirements based on the pump's intended use, horsepower and speed rating of the engine, or the torque rating of the transmission PTO.

  • Page 26: Optional Pump Components

    The Hale anode sys- tem is a sacrificial metal, which helps prevent corrosion. A Hale makes an anode that will fit on any Hale truck mounted pump, regardless of age or model. The RSD uses Hale anodes designed to be easily installed ONLY requiring four bolts and a gasket.

  • Page 27: Trvs

    120 ℉ (TRV–120) or 170 ℉ (TRV–170) and resets (closes) when the water cools. The RSD utilizes the standard Hale 115 series flange opening located on the side of the volute (K port) and a flange adaptor to house the TRV. For all other Flex series...

  • Page 29: Maintenance Operating Procedures

    Maintenance operating procedures differ greatly from typical operations. Typical operations are based on the pump being installed in a firefighting ap- paratus and include pumping from: an onboard tank, or a hydrant, or from draft. Operating pro-...

  • Page 30: Repair Verification Operations

    The Vacuum Test (paragraph 3.2 on page 20) is intended as the initial check to determine if a pump leaks. This test quickly and safely indicates if a leak exists however it typically ONLY indi- cates a leak is present and usually does NOT locate the leak (or leaks). If a pump fails the Vacu- um Test utilize the Pressure Test (paragraph 3.3 on page 22) to locate the leak (or leaks).

  • Page 31: Figure 9. Pump Operator Panel

    ONLY after completing ALL previous steps, exit driving compartment. DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. SEE FIGURE 8. Figure 9. Pump Operator Panel Verify pump panel shift indicator light is on. Set wheel chocks. Complete all hose connections.

  • Page 32: Vacuum Test

    If pump is NOT equipped with a Hale TRV valve, open appropriate valve(s) (usually tank fill or gutter line) to provide a bypass line. b) If pump is furnished with a Hale TRV valve, open valve to booster tank (both suc- tion and discharge sides) to circulate water (and/or fill water tank).
  • Page 33 NFPA. In reality, the 10 inHg. in 5 minutes was allotted for pump shaft packing adjustment and not for plumbing or valve leaks. Since all Hale two stage booster pumps utilize a mechanical seal, the vacuum drop over a 5-minute period should be insignificant.

  • Page 34: Pressure Test

    If the apparatus priming pump was used for the Vacuum Test (or was attached to the pump dur- ing pressure testing) and no external leaks are apparent, first check the primer (ONLY if the ap- paratus is so equipped and the primer was attached during testing). Primer points to check are: •...

  • Page 35: Pumping From Draft Verification Operations

    3.4. Pumping From Draft Verification Operations This test is ONLY conducted to verify a pump can now pump from draft when the fault repaired prevented the failed pump from pumping from draft. Perform the following test ONLY when re- quired to verify a pump repair has corrected a failure to pump from draft (lakes, ponds, streams and other non-pressurized water supplies).
  • Page 36 If pump is NOT equipped with a Hale TRV valve, open appropriate valve(s) (usually tank fill or gutter line) to provide bypass line. b) If pump is furnished with a Hale TRV valve, open valve to booster tank (both suc- tion and discharge sides) to circulate water (and/or fill water tank).

  • Page 37: Draft Limiting Factors

    D. Begin shutdown. Reduce engine speed to idle. Close discharge valves. If opened, close bypass line valve(s) or TRV. Close suction valve. Place transmission in NEUTRAL. Disengage PTO. E. Disconnect all hose connections and stow hoses and strainers. F. Make all appropriate Maintenance Log entries. G.

  • Page 38: Cavitation (Details)

    3.5. Cavitation (Details) Cavitation (see definition – paragraph 2.4.1.2 on page 10) can occur while pumping from draft, in relay, or from a hydrant. The operator must be aware of the warning signs and correct the sit- uation, or serious damage to the pump and impeller will occur. Figure 9 shows the results of cav- itation.

  • Page 39: Warning Signs Of Cavitation

    Figure 11. Low Pressure Regions B. The pressure of the water in the pump drops as it flows from the suction flange through the suction nozzle and into the impeller. C. As flow from the pump increases, the vacuum at the impeller increases. As the vacuum increases, the boiling point of water in that vacuum decreases until it reaches a point near the impeller eye where it boils and vaporizes.

  • Page 40: General Considerations

    When pumping from a hydrant, a soft sleeve has an advantage over a hard sleeve because it will partially collapse providing an immediate indication to the operator that cavitation is imminent. A hard sleeve indicates problems only at the intake gauge which is not the best or most reliable indicator.

  • Page 41: During Operations

    3.5.3.2 During Operations During operations, additionally consider the following to further avoid conditions that lend them- selves to cavitation. Being aware of the pumping environment can contribute greatly to avoiding cavitation. Use Table 5 and Table 6 to help predict lift losses when operations dictate pumping from draft.

  • Page 42: Post Operation Procedure

    Open discharge valves, remove suction tube caps, and discharge valve caps. Open volute drain cocks or Hale multiple drain valve. If a multiple drain valve is used, all pump drain lines should be connected to this valve. After pump is completely drained, replace all caps and close all valves.

  • Page 43: Preventive Maintenance

    4.1. Preventive Maintenance Plan And Schedule Hale Products recommends the preventive maintenance and inspections listed in Table 7 be per- formed as scheduled. The booster pump requires very little care and maintenance, however, the preventive maintenance and inspections required are important.

  • Page 44: Table 8. Recommended Preventive Maintenance - Ancillary Equipment

    Table 8 lists the projected preventive maintenance on a weekly, monthly, quarterly, and annual basis. Table 8. Recommended Preventive Maintenance – Ancillary Equipment Interval Check/Test Action Required Item(s) Required Weekly Test Relief Valve System Operate the relief valve system to verify PM valve control &...

  • Page 45: Maintenance Log

    Table 8 Recommended Preventive Maintenance – CONTINUED Interval Check/Test Action Required Item(s) Required Monthly Test Priming System Dry Vacuum Test per NFPA 1901 or Inlet and outlet caps NFPA 1911 Vacuum gauge (or manometer) 5 min timer Check Drive Line Bolts Inspect for missing bolts.

  • Page 46: Extreme Conditions Maintenance Guidelines

    Use this Log to record all maintenance actions and problems (faults, part replacements, tear downs, and major overhauls – as a minimum). Please contact Customer Services at Hale Prod- ucts Inc. prior to any proposed return of either a single part, or a complete assembly.

  • Page 47: Contaminated Water

    In freezing weather, drain the pump as follows. A. Open discharge and suction valves, remove suction tube caps and discharge valve caps. B. Open volute drain cocks and drain valves. C. After pump is completely drained, replace all caps and close all valves. 4.3.2 Contaminated Water After pumping salt water, contaminated water or foam solution, or if water containing sand or...

  • Page 48: Quarterly Maintenance

    F. If procedures call for a wet pump, open tank fill valve (removes trapped air). Close valve after several minutes. Check apparatus for signs of leaks. 4.4.3 Quarterly Maintenance Perform the following procedure every three months. 4.4.3.1 Check Gearbox Oil Level The gearbox is drained of oil at the factory prior to shipment.

  • Page 49: Perform Vacuum Test

    B. If oil is NOT visible in sight glass, or if oil is below midpoint of sight glass, add oil as follows. Remove fill/vent cap (Figure 11). ALWAYS USE PROPER PPE. OIL MAY BE TOXIC TO PEOPLE AND/OR THE ENVIRON- MENT.

  • Page 50: Annual Pump Maintenance

    C. Use primer to pull vacuum of at least 22 (±2) inHg. D. Verify apparatus maintains vacuum for 5 minutes. NOTES A vacuum loss of up to 2 inches per minute is the maximum loss permitted. The above stated loss should only occur when a packing type pump seal is utilized and all Flex Series Booster pumps utilize a mechanical type pump seal that, if operat- ing properly, produces little or no loss.

  • Page 51: Table 10. Pressure And Flow For Various Size Nozzles

    NOTES Refer to local procedures for pump testing procedures and practices. Use a fog nozzle ONLY in conjunction with flow meters, Use ONLY a nozzle rated for the required flows. Conduct testing between 60 and 70 psi for most accurate results. For pitot gauge accuracy, the pressures should be between 30 and 120 psi.
  • Page 52 Table 10. Pressure And Flow For Various Size Nozzles – CONTINUED Nozzle Size 1 1/2 1 5/8 1 3/4 1 7/8 2 1/4 2 1/2 Pitot Pressure Flow (gpm) 1017 1464 1098 1581 1174 1691 1009 1245 1793 1063 1313 1890 1115 1377...

  • Page 53: Performance Testing Test Procedure

    50 RPM off from original recorded RPM correct problem/RPM before testing.) NOTE The loss is specified to account for packing seals (the Hale Flex Series pumps use mechanical seals) therefore the loss should NOT occur. B. Check dry vacuum. (Check with two 10 ft lengths of correct sized suction hose attached and using suction tube cap[s].) Use vacuum gauge.

  • Page 54: Triennium Pump Maintenance

    4.4.6 Triennium Pump Maintenance Perform the following as a minimum to maintain pump dependability and optimum performance. • Perform the gearbox fluid change at a minimum of every three years (36 months) or more often if conditions indicate. 4.4.6.1 Gearbox Fluid Change Use the lubricant listed in the paragraph 7.4.4.1.1, Recommended Gearbox Lubricants, in the Flex Series Single Stage Booster Pump OIM (FSG–MNL–00183), when lubricating the gearbox.

  • Page 55: Corrective Maintenance (Repair)

    Other parts can be ordered by calling 800–533–3569 (Hale Products Custom- er Service). NOTE: Using your pumps serial number and the Hale website (or Customer Service) is the best way to ensure you receive/utilize the correct replacement parts for your pump. The de- scriptions of the maintenance levels and how each kit supports the maintenance along with the general contents of that kit are provided in paragraphs 5.2, Maintenance Level 1 (see page 48)

  • Page 56: Pump Priming Problems

    5.1.2 Pump Priming Problems Table 12. Pump Priming SCR Table SYMPTOM CAUSE REMEDY Pump Loses Prime Electric Priming System No recommended engine speed is required Or Will NOT Prime to operate the electric primer. However, an engine RPM of 1,000 will maintain the elec- trical system while providing enough speed for initial pumping operation.

  • Page 57: Insufficient Pump Capacity

    5.1.3 Insufficient Pump Capacity Table 13. Insufficient Pump Capacity SCR Table SYMPTOM CAUSE REMEDY Insufficient Pump Capacity Insufficient Engine Power Engine power check or tune up may be re- quired for peak engine and pump perfor- mance. Refer to rotation symptoms later in this sec- tion.

  • Page 58: Relief Valve Problems

    Table 14. Engine Speed SCR Table – CONTINUED SYMPTOM CAUSE REMEDY Engine Speeds Too High – Worn Pump Impeller(s) Installation of new parts required. CONTINUED And/or Clearance Rings Impeller Blockage Blockage in the impeller can prevent loss of both capacity and pressure. Back flushing the pump from discharge to suction may free blockage.

  • Page 59: Cavitation

    5.1.8 Cavitation Table 18. Cavitation SCR Table SYMPTOM CAUSE REMEDY Pump Is Cavitating Discharging More Water Increase the flow into the pump with more Than The Pump Is Taking In and/or larger intake lines. Gate the discharge valves to reduce flow and maintain pressure.

  • Page 60: Maintenance Level 1

    (and/or O-rings), impeller(s), clearance rings, a set of drive gears, and shaft keys. Before attempt- ing a level 3 repair contact with Hale Customer Service (see Section 5.1, TROUBLESHOOTING) is recommended. The Customer would need to be prepared to provide ID plate information (COM- PLETE INFORMATION FROM ALL ID PLATES) for the affected pump and gearbox.

  • Page 61: Miscellaneous Maintenance

    Miscellaneous maintenance procedures are included to replace all major components (cooler parts, shafts, inducers, impellers, clearance rings, gears, etc.) however when Hale Customer Service (see Section 5.1, TROUBLESHOOTING) is contacted it will evaluate the cost associated with the requested components and advise if a replacement pump (including a new warranty) would be more cost effective.

  • Page 62: Cleaning And Lubrication Required For Mechanical Seal Installation

    5.7.3 Cleaning And Lubrication Required For Mechanical Seal Installation Before installing the mechanical seal, use the alcohol swabs provided by Hale Products Inc. to clean all grease or oil from the pump shaft and pump head. ALWAYS USE AND ONLY USE PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUIVA- LENT) WHEN INSTALLING THE MECHANICAL SEAL.

  • Page 63: Circlip/Snap Ring Installation

    Cleaning And Inspection Guidelines Wherever a procedure calls for cleaning and inspection, these guidelines should be followed. A. Inspect all components for excessive or abnormal wear. B. Wherever a requirement for new parts is indicated, obtain new components from Hale Products Inc.

  • Page 64: Recommended Cleaners

    NOTE If either the impeller hub or clearance rings are out-of-tolerance, both rings and the impeller must be replaced as well as the mechanical seal. 5.7.7.1 Recommended Cleaners Hale recommends the following: • Safety Kleen • Stoddard Solvent •...

  • Page 65: Figure 15. Measuring For Worn Clearance Rings And Impeller Hubs

    Table 23. Impeller And Clearance Ring Diameters And Clearance Values Maximum Minimum Maximum Booster Clearance Ring Impeller Hub Acceptable Pump Inner Diameter Outer Diameter Radial Clearance Model in (mm) in (mm) in (mm) 4.777 4.760 0.006 — 0.0085 (121.336) (120.904) (0.153 —...

  • Page 66: Removal And Replacement Instruction Guidelines

    The R&R procedures are written to provide three layers of detail. The “A” steps provide an expe- rienced technician (who is very familiar with a Hale booster pump) a Top Level View of the steps required to R&R the titled component. The “A” steps along with the “1” steps provide an experi- enced technician (who is NOT familiar with a Hale booster pump but is familiar with pumps in general) a more detailed set of steps to R&R the titled component.

  • Page 67: General Pump Disassembly For Access Guidelines

    Label/tag and then disconnect all wiring leaving the sensor/switch/valve on the pump. The Hale booster pump design allows two methods of pump maintenance. If only pump compo- nents require removal and replacement the maintainer may be able to repair the pump without pump removal from apparatus depending on the apparatus configuration (pump access).

  • Page 68: General Pump Removal From The Apparatus

    NOT allow pump access the maintenance method requires both pump and gearbox be removed as an assembly from the apparatus. (See paragraph 5.8.2.1, AP Removal From The Apparatus.) When AP gearbox and/or pump maintenance or repairs (which required method two, which sup-...

  • Page 69: Figure 18. Pump And Gearbox Assembly R&R

    Set parking brake and chock front and rear wheels. B. Disassemble/remove all items required to access pump and gearbox. See Figure 17. Support pump and gearbox using appropriately sized lifting device and rigging or jack. Match mark and tag all items/connections before removal. Remove ONLY items/connections required to access pump and gearbox.

  • Page 70: General Pump Disassembly Methodology

    The Hale Flex Series single stage booster pumps design separates the four pumps into two groups based on the volute. The first group (the AP, CBP, and MBP) utilizes a one-piece volute (see Figure 18) while the second (the RSD) utilizes a three-piece volute (see Figure 19). This makes the RSD pump disassembly unique among the Hale booster pumps.

  • Page 71: Figure 19. One-Piece Volute (Ap, Cbp, Mbp)

    Figure 19. One-Piece Volute (AP, CBP, MBP) Figure 20. Three-Piece Volute (RSD)
  • Page 72 From The Apparatus for generalized removal instructions. No matter which method of removal is utilized; Figure 20 provides an exploded view of the AP pump, Figure 21 provides an exploded view of the CBP pump, and Figure 22 provides an explod- ed view of the MBP pump, and Figure 23 provides an exploded view of the RSD pump to support Level 1 maintenance procedures.

  • Page 73: Figure 21. Ap Pump Exploded View

    Figure 21. AP Pump Exploded View...

  • Page 74: Figure 22. Cbp Pump Exploded View

    Figure 22. CBP Pump Exploded View...

  • Page 75: Figure 23. Mbp Pump Exploded View

    Figure 23. MBP Pump Exploded View...

  • Page 76: Figure 24. Rsd Pump Exploded View

    Figure 24. RSD Pump Exploded View...

  • Page 77: Figure 25. Gearbox Exploded View (All Except 3.74:1 Gr)

    Figure 25. Gearbox Exploded View (All Except 3.74:1 GR)

  • Page 78: Figure 26. Gearbox Exploded View (3.74:1 Gr)

    Figure 26. Gearbox Exploded View (3.74:1 GR)

  • Page 79: Level 1 Procedures

    5.8.4 Level 1 Procedures If pump access permits, selected pump components (see Figure 20, Figure 21, or Figure 22) can be removed and replaced without removing the pump and gearbox assembly from the apparatus. Discharge and suction port hoses/plumbing may require removal before the selected pump component R&R procedure can be performed.
  • Page 80 Perform the following to remove and replace the suction head. NOTES Remove any suction tube and/or piping blocking access to the pump per OEM/equipment manufacturer instructions. Remove any discharge piping blocking access to the pump per OEM/equipment manufacturer instructions. RSD Suction Head Removal A.

  • Page 81: Rsd Volute R&R

    NOTES Unless match marking differs, place the two (2) casting bosses at the 6 o-clock posi- tion on the volute (see Figure 19) regardless of volute orientation. Gentile tapping with a non-marring hammer may be required to seat the suction head on the volute.

  • Page 82: Table 26. Rsd Volute R&R Tools And Consumables List

    Table 26. RSD Volute R&R Tools And Consumables List Standard Tools Special Tools Consumables None Shop Rag(s) (As Required) (Eye and Hand Protection) 5/8-in Wrench O-ring Lubricant (See Table 20.) (Or Ratchet Wrench) (Or Pass Thru Ratchet) Hooked-end Dental Pick (or O-RING <See FSG–PL-01487, Sheet 4, Item 30>...
  • Page 83 F. Remove volute from pump head. NOTE Gentile tapping with a non-marring hammer may be required to loosen the volute from the pump head. G. Remove all remaining gasket material from mating surfaces of volute and pump head. Measure clearance rings and impeller hub (see Table 23.), replace if out-of-tolerance. If the clearance rings have failed, perform RSD Clearance Ring R&R (see paragraph 5.8.7.2 on page 110).

  • Page 84: Ap/Mbp Volute R&R

    In addition to gasket/O-ring failure the volute requires removal to examine or access internal pump components (clearance rings, impeller, mechanical seal, etc.). See Figure 26 for AP volute removal. Typically the volute would not require replacement unless it has been damaged by al- lowing the pump to freeze with water in it or a large piece of debris was allowed into the pump by not using or maintaining strainers.
  • Page 85 OEM/equipment manufacturer instructions. Remove any discharge piping blocking access to the pump per OEM/equipment manufacturer instructions. AP/MBP Volute Removal A. If pump is still in apparatus, match mark/note/tag and then disconnect suc- tion, discharge, and cooling lines. B. If pump is still in apparatus, tag and disconnect any electrical wiring.

  • Page 86: Cbp Volute R&R

    5.8.4.4 CBP Volute R&R The primary difference between the CBP and the AP/MBP volute removal is the number of screws that hold the volute to the pump head, the CBP uses only eight (8) 3/8-in–16 by 0.88 in long screws instead of the twelve (12) larger screws.
  • Page 87 Table 28. CBP Volute R&R Tools And Consumables List – CONTINUED Standard Tools Special Tools Consumables Hooked-end Dental Pick O-RING, <See FSG–PL–01482 Sheet 4 Item 9> (or Hose Removal Tool) (Volute to Pump Head) Gasket <See FSG–PL–01482 Sheet 4 Item 10> (Volute to Pump Head) Loctite Clean-Up Solvent Perform the following to remove and replace the volute.

  • Page 88: Mbp/Rsd Inducer R&R

    B. Using care NOT to damage clearance rings or impeller, install volute onto pump head. C. Install volute fasteners. Clean original fastener threads (or replace with the correct new fasteners) and volute screw hole threads. (Loctite Clean-Up Solvent) Apply Loctite™ 243 (or equivalent) to threads of fasteners. Hand start eight (8) 3/8 —...

  • Page 89: Figure 28. Mbp Inducer R&R

    Figure 28. MBP Inducer R&R If the pump is a RSD, prior to performing this procedure, remove the suction head as described in paragraph 5.8.4.1, RSD Suction Head R&R (on page 67). Figure 28 shows the RSD pump with the suction head removed and depicts the inducer removal. Figure 29.

  • Page 90: Table 29. Mbp/Rsd Inducer R&R Tools And Consumables List

    Refer to Table 29 for a list of tools and/or consumables required for this procedure. Table 29. MBP/RSD Inducer R&R Tools And Consumables List Standard Tools Special Tools Consumables Torque Limiting Exten- Shop Rag(s) (As Required) (Eye and Hand Protection) sion 210 ft-lb (285 Nm) 2-1/2-in Socket and Torque Limiting Exten-...
  • Page 91 Using plyers (or hammer and pin punch), pull (or drive) cotter pin out of castle nut. B. Remove inducer nut. If pump is a RSD. a) If using a 2-1/2-in socket and impact driver (set CCW). i. Hold inducer (or input shaft) by hand. (Use proper PPE.) ii.
  • Page 92 Inspect and clean all components. See paragraph 5.7.7, Cleaning And Inspection Guidelines, on page 51. If volute is removed and inspection indicates any of the following require replacement. • Clearance rings require replacement see paragraph 5.8.7.2 (page 110), Pump Clearance Ring R&R.

  • Page 93: Mbp/Rsd Impeller R&R

    5.8.4.1, RSD Suction Head R&R) or the RSD volute (see paragraph 5.8.4.2 on page 69). If the pump is an MBP, after performing this procedure, install the volute as described in para- graph 5.8.4.3, AP/MBP Volute R&R. 5.8.4.6 MBP/RSD Impeller R&R Prior to performing this procedure, remove the volute as described in paragraph 5.8.4.3, Volute...

  • Page 94: Figure 30. Mbp Impeller R&R

    Figure 30. MBP Impeller R&R Refer to Table 30 for a list of tools and/or consumables required for this procedure. Table 30. MBP/RSD Impeller R&R Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) Puller Set Shop Rag(s) (As Required) (See APPENDIX B) Brush (For Grease)

  • Page 95: Ap Impeller R&R

    (and the clearance rings) must be replaced to maintain pump performance specifications. Re- fer to Table 23 for the AP impeller wear specifications. If the impeller requires replacement al- ways inspect (measure) the clearance rings before installing the new impeller. If the clearance rings are out-of-tolerance they require replacement, see paragraph 5.8.7.2 on page 110.

  • Page 96: Figure 31. Ap Impeller R&R

    Figure 31. AP Impeller R&R Refer to Table 31 for a list of tools and/or consumables required for this procedure. Table 31. AP Impeller R&R Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) 1 3/4-in Torque Limiting Socket...
  • Page 97 Perform the following to remove and replace AP pump impeller. Impeller Removal A. Remove cotter pin that secures impeller nut. Using flat blade screwdriver, pry bent portion of cotter pin so bend can be cut off. Using heavy wire cutters, cut off bent portion of cotter pin. (Or using ply- ers, bend cotter pin straight.)
  • Page 98 Ensure cut away excess cotter pin is removed from the pump. After performing this procedure, install the volute as described in the AP Volute Installation por- tion of paragraph 5.8.4.3, Volute R&R, on page 72.

  • Page 99: Cbp Impeller R&R

    5.8.4.8 CBP Impeller R&R Prior to performing this procedure, remove the volute as described in paragraph 5.8.4.4, Volute R&R. (See page 74.) Typically, the impeller would not require replacement for many years unless it has been damaged by allowing the pump to freeze with water in it or a large piece of debris was allowed into the pump by not using or maintaining strainers.

  • Page 100: Table 32. Cbp Impeller R&R Tools And Consumables List

    Refer to Table 31 for a list of tools and/or consumables required for this procedure. Table 32. CBP Impeller R&R Tools And Consumables List Standard Tools Special Tools Consumables Torque Limiting Extension 110 ft-lb Shop Rag(s) (As Required) (Eye and Hand Protection) (149 Nm) 1 1/16-in Socket Puller Set...

  • Page 101: Figure 33. Nord-Lock Washers Installation Details

    b) Place 1/2-in (M12) flanged nut (flange toward pump shaft) between pump shaft and puller drive screw (protects shaft threads). c) Using a wrench (or socket and ratchet), tighten puller drive screw until impeller comes loose. d) Remove 1/2-in (M12) flanged nut and puller. Then pull impeller off pump shaft by hand.

  • Page 102: Ap/Cbp/Mbp Mechanical Seal R&R

    74) for instructions to R&R the volute and if applicable (pump is an MBP) refer to para- graph 5.8.4.5 (page 76) for instructions to R&R the inducer and then refer to paragraph 5.8.4.6 (page 81), (AP or MBP) 5.8.4.7 (page 83), or paragraph 5.8.4.8 (CBP on page 87) for instructions to R&R the impeller.

  • Page 103: Figure 34. Typical Mechanical Seal Detail

    Figure 34. Typical Mechanical Seal Detail Perform the following to remove and replace the pump seal. Mechanical Seal Removal A. Remove mechanical seal. Pull spring off pump shaft. Remove diaphragm assembly. a) Place two small screwdrivers (or two hook-type tools) between diaphragm assem- bly and stationary seat.
  • Page 104 TION. SEAL FACES MUST BE CLEANED WITH THE ALCOHOL WIPES PROVIDED WITH THE REPAIR KIT. OIL AND GREASE (INCLUDING SKIN OILS) WILL DAMAGE THE MECHANICAL SEAL FACE. NEVER TOUCH THE MATING FACES OF THE MECHANICAL SEAL. WEAR PRO- TECTIVE GLOVES TO PREVENT TOUCHING THE SEAL FACES WITH YOUR BARE HANDS. (USE RUBBER, ACRYLIC, LATEX, ETC.

  • Page 105: Rsd Mechanical Seal R&R

    E. Perform applicable Impeller Installation portion of Impeller R&R procedure. (See paragraph 5.8.4.6, [MBP] 5.8.4.7, paragraph 5.8.4.7 [AP], or para- graph 5.8.4.8 [CBP].) F. If applicable (pump is an MBP), perform Inducer Installation portion of the In- ducer R&R procedure. (See paragraph 5.8.4.5 on page 76.) G.

  • Page 106: Figure 35. Rsd Mechanical Seal Notch

    Pull spring off of pump shaft. Remove diaphragm assembly. a) Place two small screwdrivers (or two hook-type tools) between diaphragm assem- bly and stationary seat. Note: Place tools 180° apart. b) Using steady, gentle pressure, pry diaphragm off of shaft. Remove stationary seat portion of mechanical seal from pump head.

  • Page 107: Figure 36. Align Slot On Seal With Pin In Pump Head

    NOTE If the roll pin requires replacement perform RSD Mechanical Seal Anti Rotation Pin Bench Procedure. See paragraph 5.8.4.13.2 on page 103. RSD Mechanical Seal Installation A MECHANICAL SEAL IS A PRECISION ENGINEERED DEVICE. CARE MUST BE TAKEN NOT TO DAMAGE THE MATING FACES (SEAL FORMING PORTION) OF THE SEAL. EN- SURE THE FACES REMAIN ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLA- TION.

  • Page 108: Ap/Cbp/Mbp Pump Head R&R

    J. Return apparatus to service. 5.8.4.11 AP/CBP/MBP Pump Head R&R Water leaking from pump head is typically NOT an indication of a failed pump head. The pump head openings are designed to allow water out when a mechanical seal is bypassing water. Simi-...

  • Page 109: Table 35. Ap/Cbp/Mbp Pump Head R&R Tools And Consumables List

    5.8.4.9. This process will leave the pump head isolated from the rest of the pump. Refer to Table 35 for a list of tools and/or consumables required for this procedure. Table 35. AP/CBP/MBP Pump Head R&R Tools And Consumables List Standard Tools Special Tools...

  • Page 110: Rsd Pump Head R&R

    With only the pump head installed on the pump, use the instructions in paragraph 5.8.4.9, Me- chanical Seal R&R, and paragraph 5.8.4.6 (MBP), 5.8.4.7 (AP), or 5.8.4.8 (CBP) to install the seal and impeller. If the pump is an MBP, install the inducer, see paragraph 5.8.4.5. Then install the volute and test the pump as described in paragraph 5.8.4.3 or 5.8.4.4, Volute R&R.

  • Page 111: Table 36. Rsd Pump Head R&R Tools And Consumables List

    Table 36. RSD Pump Head R&R Tools And Consumables List Standard Tools Special Tools Consumables None Shop Rag(s) (As Required) (Eye and Hand Protection) 3/4-in (19 mm) Wrench O-ring Lubricant (See Table 20) (Or Ratchet Wrench) (Or Pass Thru Ratchet) Drift Punch Grease (See paragraph 5.7.2, Recommended Lubricants.)

  • Page 112: Figure 37. Pump Head (Pump Side)

    Measure impeller hub (see Table 23.), replace if out-of-tolerance. If the impeller has failed, per- form MBP/RSD Impeller R&R (see paragraph 5.8.4.5). Always replace the mechanical seal, per- form RSD Mechanical Seal R&R (see paragraph 5.8.4.10). RSD Pump Head Installation A.

  • Page 113: Figure 38. Pump Head (Drive Side)

    a) Lubricate new O-ring (gearbox to pump head). Refer to Table 20. b) Install new O-ring on pump head. c) Lightly lubricate (grease) mating surface of new oil seal (and pump head bore). (Refer to paragraph 5.7.2 on page 49). d) Install new oil seal in pump head.

  • Page 114: Pump Head R&R Bench Procedures

    • Inducer R&R for an MBP/RSD pump use paragraph 5.8.4.5 • Impeller R&R for an AP pump use paragraph 5.8.4.7, for a CBP pump use paragraph 5.8.4.8, and for an MBP/RSD pump use paragraph 5.8.4.6. • Mechanic Seal R&R for an AP/CBP/MBP pump use paragraph 5.8.4.9 and for a RSD use paragraph 5.8.4.10.)

  • Page 115: Rsd Mechanical Seal Anti Rotation Pin Bench Procedure

    For an AP/CBP/MBP use a 65 mm (or larger) seal driver. For a RSD use an 81 mm (up to 88 mm) seal driver. B. Perform Installation portion of Pump Head R&R. (For an AP/CBP/MBP pump use paragraph 5.8.4.11 and for a RSD use paragraph 5.8.4.12.) 5.8.4.13.2...

  • Page 116: Table 38. Mechanical Seal Pin Bench Procedure Tools And Consumables List

    Table 38. Mechanical Seal Pin Bench Procedure Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) PPE (for Handling Oil) Compressed Air Shop Hammer Penetrating Oil 1/16-in Pin Punch Grease (See paragraph 5.7.2 on page 49.) Loctite LB 8008 (Anti seize Compound) Drill...

  • Page 117: Level 2 Procedures

    NOTE ONLY use a screwdriver turned by hand to remove the pin. Do NOT use an electric, battery, or pneumatic type driver to tighten the screw. a) Hand start screw in pin. b) Using screwdriver (turn CW), screw #2 screw into pin until screw bottoms out in blind hole.

  • Page 118: Miscellaneous Procedures

    The cooling system is an option for all of the Hale Flex Series single stage booster pumps and can be included with the initial purchase or added after the pump has been in service for any period of time.

  • Page 119: Table 39. Gearbox Cooling Tube R&R Tools And Consumables List

    <See FSG–PL-01487, Sheet 4, Item 6> (RSD) ** 5/8-in Wrench Elbow 3/8 Comp X 3/8 Comp <See FSG–PL-01483, Sheet 4, Item 19 *> (AP) <See FSG–PL-01482, Sheet 4, Item 17 *> (CBP) <See FSG–PL-01486, Sheet 4, Item 22> (MBP) <See FSG–PL-01487, Sheet 4, Item 14> (RSD)

  • Page 120: Cooling Tube R&R

    5.8.7.1.1 Cooling Tube R&R Perform the following to remove and replace the gearbox cooling tube. Cooling Tube Removal A. Disconnect both cooling water lines (at gearbox end of water line). Remove 90° elbow from cooling tube (supply line). a) Using 1/2-in wrench (or adjustable wrench), hold 90° elbow stationary. b) Using 5/8-in wrench (or adjustable wrench), loosen nut (turn CCW) on cooling tube side of elbow.
  • Page 121 Inspect and clean all components. See paragraph 5.7.7, Cleaning And Inspection Guidelines. Clean mating surfaces of cover and gearbox. (Do NOT allow gasket material to fall into the gear- box.) When opening a gearbox, as a minimum, inspect the following. •...

  • Page 122: Pump Clearance Ring R&R

    If pump is an AP, CBP, or MBP; refer to paragraph 5.8.4.3 (see page 72) or paragraph 5.8.4.4 (see page 74) for volute removal. If the pump is a RSD refer to paragraph 5.8.4.1 (see page 67) for suction head removal.

  • Page 123: Figure 39. Slots Cut In Clearance Ring-Volute

    Perform the following to remove and replace pump clearance ring(s). AP/CBP/MBP Volute Clearance Ring Removal NOTE Use cribbing to prevent volute from tipping or moving if required. A. Place volute on stable work surface with suction opening down. DO NOT CUT THRU THE CLEARANCE RING. CUTTING THRU THE CLEARANCE RING WILL DAMAGE THE VOLUTE AND MAY RESULT IN PUMP FAILURE.
  • Page 124 E. Using hydraulic press, install clearance ring into volute. AP/CBP/MBP Pump Head Clearance Ring Removal The AP and MBP utilize the same pump head however; each pump utilizes a different sized wrap around clearance ring. The AP wrap around clearance ring presses onto the inside shoulder of the pump head cavity while the MBP wrap around clearance ring presses on to the outside shoulder.

  • Page 125: Figure 41. Wrap Around Clearance Rings - Pump Heads

    Figure 41. Wrap Around Clearance Rings – Pump Heads C. Drill thru clearance ring but NOT into pump head. See Figure 41. Figure 42. Clearance Ring Drilled Out (MPB Pump Head) D. Using a chisel and hammer, bend clearance ring slightly inward at holes. Then cut clearance ring thru with chisel.
  • Page 126 AP utilizes the inner surface of the pump head cavity to provide that interference fit. If the pump under repair is an AP or an MBP ensure the correct clearance ring is be- ing installed (since both rings will fit in the pump head but ONLY the correct ring will mate with the impeller).

  • Page 127: Figure 44. Slots Cut In Clearance Ring - Suction Head

    Figure 44. Slots Cut In Clearance Ring - Suction Head C. Place suction head on stable work surface with suction opening up. D. Using a chisel and hammer, drive clearance ring out of suction head. See Figure 44. Figure 45. Clearance Ring Driven Out –...

  • Page 128: Figure 46. Rsd Wrap Around Clearance Rings

    D. Align new clearance ring to suction head. DO NOT DRIVE THE CLEARANCE RING INTO THE SUCTION HEAD AT AN ANGLE OR UNEVENLY (ALL THE WAY FROM ONE SIDE AT A TIME). BENDING, WARPING, OR CHIPPING THE CLEARANCE RING MAY RESULT IN POOR PERFORMANCE OR PUMP FAILURE.

  • Page 129: General Install On The Apparatus

    Figure 47. RSD Wrap Around Clearance Ring R & R C. Apply force to pry bars (two-at-a-time works best) to remove clearance ring. RSD Pump Head Clearance Ring Installation A. Clean pump head to remove old Loctite. (Use Loctite Clean-Up Solvent and a wire brush.) B.

  • Page 130: Gearbox

    (3) years. It previously took three separate gear- boxes to provide the 22 various gear ratios (1.14:1 to 4.93:1) used for all models of Hale booster pumps. The Flex series gearbox provides eight (8) gear ratios (1.14:1, 1.31:1, 1.65:1, 1.90:1, 2.33:1, 2.60:1, 2.91:1, and 3.74:1) in a single gearbox which is now used for all Hale Flex Series...
  • Page 131 If pump is a RSD, perform Removal portion of RSD Volute R&R (see para- graph 5.8.4.2 on page 69). If pump is an AP or MBP, perform Removal portion of AP/MBP Volute R&R (see paragraph 5.8.4.3 on page 72). If pump is a CBP, perform Removal portion of CBP Volute R&R (see para- graph 5.8.4.4 on page 74).

  • Page 132: Gearbox Bench Procedures

    If pump is an MBP or RSD, perform Installation portion of MBP/RSD Im- peller R&R (see paragraph 5.8.4.6 on page 81). If pump is an AP, perform Installation portion of AP Impeller R&R (see paragraph 5.8.4.7 on page 83). If pump is a CBP, perform Installation portion of CBP Impeller R&R (see paragraph 5.8.4.8 on page 87).

  • Page 133: Input Shaft

    Gearbox bench procedures consist of removal and replacement procedures of all gearbox com- ponents (with the exception of pump shafts and gear ratios). Gearbox bench procedures are identical for all four Flex series single stage pumps once the pump has been removed from the gearbox.
  • Page 134 Perform the following to remove and replace an input shaft. Input Shaft Removal A. Remove input shaft oil seal. Drain any remaining gear oil from gearbox. a) Position oil safe catch container under drain plug. b) Remove magnetic (and/or adjacent) drain plug(s). i.
  • Page 135 Discard endcap. D. Remove input shaft and drive side bearing. NOTES Both keyways on the input shaft are in line with each other. The drive gear is keyed to the input shaft, do NOT allow key to fall into gearbox while removing the shaft and bearing.
  • Page 136 Input Shaft Installation A. Prepare new input shaft for installation. Install drive side bearing on input shaft. NOTE The preferred method of assembly is to heat the bearing and cool the input shaft to allow a slip fit. Using a bearing heater, heat bearing to 250 ℉ (121 °C) (Do NOT ex- ceed 8 hrs.).
  • Page 137 NOTES The input shaft should slide easily through the drive gear; however, a light tap from a non-marring hammer may be required. If the input shaft does not slip through the drive gear with a light tap, STOP, remove input shaft, and check for burrs on and alignment of the key and shaft. If required, using a non-marring hammer, tap input shaft and bearing into gearbox until drive side bearing seats in gearbox.

  • Page 138: Input Shaft Oil Seal (Only)

    Using 95 mm seal driver, press endcap into gearbox until flush. F. Install new input shaft oil seal. Turn gearbox over. Coat outer surface (mates with gearbox) of input shaft oil seal with Loc- tite 680™ (or equivalent). Place input shaft oil seal onto input shaft with smooth part of seal body facing end of shaft (outward).

  • Page 139: Input Shaft Bearings (Only)

    A. Remove input shaft oil seal. Drain any remaining gear oil from gearbox. a) Position oil safe catch container under drain plug. b) Remove magnetic (and/or adjacent) drain plug. i. Using 9/16-in wrench (or 8 pt. socket and ratchet – set for CCW), loosen mag- netic drain plug.

  • Page 140: Input Shaft Endcap (Only)

    The input shaft utilizes two (2) double row angular contact roller ball bearings; one located on the drive side and the other located on the pump side of the input shaft. Both of these bearings are one-piece bearings installed in the gearbox housing. Using good practices; whenever a shaft bearing requires replacing ALL bearings on that shaft should be replaced at the same time.

  • Page 141: Drive Gear (Input Shaft)

    ii. Remove drain plug(s). c) Inspect magnetic drain plug for metal fragments or other abnormalities that may provide clues as to condition of internal gearbox components. (See Section 5.1, Troubleshooting.) d) Install magnetic (and/or adjacent) drain plug(s). i. Hand start drain plug. ii.

  • Page 142: Table 44. Drive Gear Bench Procedure Tools And Consumables List

    Additionally, perform this procedure after the Removal portion of the procedures listed and in the listed order. NOTES For this procedure, reuse the existing input and pump shafts (if serviceable), the pump gear (if serviceable), and the gearbox cover (if serviceable). Do NOT reuse bearings, gaskets, gear oil, mechanical (pump) seal, O-rings, oil seals, and retaining rings.

  • Page 143: Pump Shaft

    Endcap (80 mm) (Eye and Hand Protection) (17 Nm or 12 ft-lb) <See FSG–PL-01482, Sheet 5, Item 13>(CBP) <See FSG–PL-01483, Sheet 5, Item 13>(AP) <See FSG–PL-01486, Sheet 5, Item 14>(MBP) <See FSG–PL-01487, Sheet 5, Item 14>(RSD) Snap Ring (Drive Side) (for Handling Oil) (Pump Shaft Retainer –...
  • Page 144 Bearing And Seal Driver Set Snap Ring (Pump Side Pump Shaft Retainer) (81 mm) <See FSG–PL-01482, Sheet 5, Item 5>(CBP) <See FSG–PL-01483, Sheet 5, Item 5>(AP) <See FSG–PL-01486, Sheet 5, Item 6>(MBP) <See FSG–PL-01487, Sheet 5, Item 6>(RSD) Hydraulic Press (a large ar-...

  • Page 145: Figure 48. Pump Shaft Assembly

    Figure 48. Pump Shaft Assembly C. Remove pump shaft assembly. Using a hydraulic press (a large arbor press may work), press pump shaft assembly out of drive side bearing and gearbox as follows. NOTES If the pump head studs are in place the bolster plate bore diameter should be at least 6.25-in (~16 cm).
  • Page 146 NOTE The drive side pump shaft bearing is held in place by a snap ring, Do NOT place ex- cessive pressure on the gearbox by allowing the press to exert force on the bearing. The pump shaft must pass thru the bearing with the force applied to the shaft and NOT the bearing.

  • Page 147: Figure 49. Ap/Cbp Pump Shaft

    3.74:1 GR. See Figure 48 for an AP or a CBP and Figure 49 for a MBP or RSD pump shaft differences detailed. Note drive side shaft diameters and the difference in spacers.

  • Page 148: Figure 50. Mbp/Rsd Pump Shaft

    Figure 50. MBP/RSD Pump Shaft A. Prepare new pump shaft for installation. Install pump side bearing on pump shaft. NOTE The preferred method of assembly is to heat the bearing and cool the pump shaft to allow a slip fit. Using a bearing heater, heat bearing to 250 ℉ (121 °C) (Do NOT ex- ceed 8 hrs.).
  • Page 149 d) Place drive end of pump shaft squarely into bearing. (Threaded end for impel- ler/inducer nut facing away from bearing.) e) Press pump shaft into bearing until seated against shaft collar. NOTES If the preferred method or a press is NOT available, use a 6 inch long piece of 2-in DOM steel tube (Use ONLY 0.188 wall tube.) and a dead-blow hammer to assemble the bearing and shaft.
  • Page 150 d) Release and remove snap ring pliers. e) Verify retaining ring is seated in groove. NOTES The notch in the spacer faces the pump gear. The 3.74:1 GR configuration spacer does NOT have a notch. For ONLY 1.90, 1.64, 1.31 and 1.14:1 gear ratio pumps, install pump gear.

  • Page 151: Pump Shaft Bearings (Only)

    Add pusher tube and continue pressing bearing until seated against gearbox housing snap ring. E. Install pump shaft snap ring. See Figure 47. Compress a new pump side bearing snap ring. a) Using snap ring pliers, expand pump shaft snap ring. Do NOT release pliers until instructed.
  • Page 152 Oil Safe Catch Container Endcap (80 mm) (1.5 L or larger) <See FSG–PL-01482, Sheet 5, Item 13>(CBP) <See FSG–PL-01483, Sheet 5, Item 13>(AP) <See FSG–PL-01486, Sheet 5, Item 14>(MBP) <See FSG–PL-01487, Sheet 5, Item 14>(RSD) 9/16-in Wrench (or 8 pt. socket)

  • Page 153: Pump Gear (Only)

    NOTES The endcap is NOT serviceable after removal. If a heavy enough tool is NOT available, using a hammer drive a long thin chisel into the endcap, then use a short length of steel rod as a fulcrum and pry (the hammer may again be used) the endcap out of the gearbox.

  • Page 154: Table 47. Pump Gear Bench Procedure Tools And Consumables List

    (Eye and Hand Protection) (ONLY ONE REQUIRED – SELECT FROM ASSOCIATED TABLE:) <See FSG–PL-01482, Sheet 5, Item 7>(CBP) <See FSG–PL-01483, Sheet 5, Item 7>(AP) <See FSG–PL-01486, Sheet 5, Item 8>(MBP) <See FSG–PL-01487, Sheet 5, Item 8>(RSD) A PRESS PRESENTS A POTENTIAL CRUSH HAZARD (FROM MOVING PARTS) AND/OR STRIKE HAZARD (FROM EJECTED PARTS).
  • Page 155 Release and remove snap ring pliers. Discard snap ring. B. Remove pump side bearing from pump shaft. Using a hydraulic press (a large arbor press may work), press pump shaft out of pump side bearing. NOTE The bolster setup for the press must allow the pump shaft to pass thru the bearing and the bolster while securely supporting the bearing.
  • Page 156 Pump Gear Installation NOTE The pump gear (ONLY 3.74, 2.91, 2.60, and 2.33:1 gear ratios) will pass thru the gearbox bore when the pump shaft assembly is installed. All other ratio pump gears will NOT pass thru the bore of the gearbox housing and must be installed from the top of the gearbox with the cover and cooling tube removed.
  • Page 157 b) Align bearing outer race squarely in gearbox housing bore. c) Push pump side bearing (already installed on pump shaft) into gearbox housing bore until seated in housing. NOTES If required, use a non-marring hammer to tap bearing into place. Do NOT strike pump shaft threads.) C.
  • Page 158 THIS PAGE INTENTIONALLY BLANK.

  • Page 159: Appendix A. Tightening (Torque) Information

    APPENDIX A. TIGHTENING (TORQUE) INFORMATION Utilize the torque specifications provided within each procedure if one is stated, otherwise use the torques provided below. Screws and Studs FASTENER USED ON FT-LB IN-LB M8–1.25 Screw Gearbox Cover (20 mm Long) M10–1.5 Full Nut Gearbox (Drive Side) M10–1.5 Stud Gearbox (Drive Side)
  • Page 160 Tighten until flush or below flush to provide flat mounting surface for OEM. Use grease and impact gun to drive these plugs. Nuts FASTENER USED ON FT-LB IN-LB 1–12 Castle Nut Inducer Nut (RSD) (MBP) Brass 110-7040-00-0 1-1/8–12 Castle Nut Impeller Nut (AP) Brass 110-7040-00-0 3/4–16 Nut Impeller Nut (CBP) (Nylon-Lock SS)

  • Page 161: Appendix B. Test Equipment And Special Tool Information

    APPENDIX B. TEST EQUIPMENT AND SPECIAL TOOL INFORMATION B.1. SPECIAL TOOL INFORMATION Torque Limiting Sockets A precision torque limiter can be attached to any standard drive tool to provide torque control. Torque limiters are available in two types: adjustable and preset. Once an adjustable torque lim- iter is set, the torque limiter prevents the applied force from exceeding the setting.
  • Page 162 Removable leg type pullers (middle picture – Snap On OG270 with OG250-10 legs) are easier to attach to the impeller since the legs detach allowing them to be turned/maneuvered between the volute and impeller and then reattached to the puller. Puller For The Impeller Or Bearings Infrared Thermometer (Precise Non-Contact IR) Always use an infrared thermometer to determine the temperature of an expected hot item.

  • Page 163: Appendix C. Ancillary Pump Equipment

    APPENDIX C. ANCILLARY PUMP EQUIPMENT In addition to the basic parts of Hale booster pumps described above, the following items are available to enhance pump operation: • Priming Systems • Temperature Control Devices C.1. PRIMING SYSTEMS Priming pumps are used to evacuate air in the suction hose and the pump. The vacuum created allows atmospheric pressure to push water from the static source through the suction hose and into the pump.

  • Page 164: Priming Valves

    Figure 52 shows an ESP priming pump. Figure 53. ESP Priming Pump A Hale ESP priming pump utilizes a single control, the PVG (opens the priming valve and turns on the ESP), which is located between the booster pump and the priming pump. C.1.2 Priming Valves Hale priming valves open when the priming pump is operated to control priming of the booster pump.

  • Page 165: Figure 54. Pvg Priming Valve

    The PVG (Figure 53) is mounted on the pump operator panel. The PVG is a combination valve and switch. When the PRIME handle is pulled out, the valve opens and the switch energizes the primer motor. Pushing the handle de-energizes the motor and closes the valve. Figure 54.

  • Page 166: Temperature Control Devices

    After the temperature returns to a safe level, the valve closes. The TRV will flow up to 1-2 gpm (3-7 Lpm). For repair information see Hale Service Bulletin (SB–160) and PL729 on the Hale website (www.Haleproducts.com).

  • Page 167: Ancillary Equipment Preventive Maintenance Procedures

    Perform each the following procedures weekly. C.3.1.1 Pump Shift Warning Indicator Lights Verify the parking brake is set and the wheels are chocked to prevent any movement of the ap- paratus. A. Follow operating procedures in (Section 3 — OPERATING PROCEDURES) to en- gage pump if no local procedures exist.

  • Page 168: Check Auxiliary Fire Suppression Equipment

    C.3.1.8 Check Auxiliary Fire Suppression Equipment Visually inspect all piping and valves on the pump and auxiliary equipment for corrosion or dam- age. C.3.2 Monthly Maintenance Perform the following monthly. • Perform a dry Vacuum Test (primer pump) • Check the drive line bolts C.3.2.1 Priming System Test (Dry Vacuum Test) NOTE Refer to NFPA 1901 or NFPA 1911.

  • Page 169: Drive Line And Flange Bolts

    Test the suction hose as follows. A. Attach suction hose to pump. B. Place a suction tube cap on end of hose (in place of strainer). C. Close all valves and drains. Cap all suction openings and (if equipped) outlet of suction side relief valve.

  • Page 170: Annual Maintenance

    C.3.3 Annual Maintenance Perform the following as a minimum to maintain pump dependability and optimum performance. • Check individual drain lines from the pump to the multi-drain to ensure proper drainage and protection from freezing. • If installed, clean ESP primer. •...

  • Page 171: Esp Primer Maintenance

    C.3.3.3 ESP Primer Maintenance The Hale ESP primer (see Figure 60) is relatively maintenance free. If after testing the primer fails to pull 22 (± 2) inHg of vacuum one of the following may be the cause. • Vanes may be worn (require replacement) •...

  • Page 172: Figure 62. Esp-Pvg Primer Repair Kit (P/N 546-1410-03-0

    Inspect all components for corrosion, deposits, abnormal wear, or pinching, cuts, or cracking. Clean all components using Safety Kleen™ or Stoddard Solvent. Obtain new components if un- serviceable. Contact Hale Customer Service (800–533–3569) for information about ordering new components or the ESP-PVG Primer Repair Kit (P/N 546-1410-03-0). The kit contains new seal, O-rings, vanes, and panel mounted SPV switch as shown on Figure 61.
  • Page 173 DO NOT LUBRICATE VANES OR VANE SLOTS. USING LUBRICANT ON THE VANES OR VANE SLOTS DURING DISASSEMBLY, CLEANING, OR ASSEMBLY EVENTUALLY CAUS- ES A GUMMY RESIDUE TO DEVELOP, RENDERING THE SYSTEM INOPERATIVE. Slide new vanes into slots in rotor. Rotate rotor and shaft, verify vanes move freely in rotor slots. NOTE If required, install new pins in the pump head assembly.
  • Page 174 THIS PAGE INTENTIONALLY BLANK. C-12...

  • Page 175: Appendix D. Operator Maintenance Log

    Use this Log to record all maintenance actions and problems (faults, part replacements, tear downs, and major overhauls – as a minimum). Please contact Customer Services at Hale Prod- ucts Inc. prior to any proposed return of either a single part, or a complete assembly.
  • Page 176 HOURS MAINTENANCE/ PART(S) REASON DATE PROBLEM USED REPLACED INITIALS...

  • Page 177: Appendix E. Manufacturer's Information

    E.2. Warranty For all warranty information visit the Hale Products website (haleproducts.com) then search Warranty. Click on the Documents tab and then click on the Hale Warranty Statement link. E.3. Returned Goods Procedure lf you identify a component or assembly that is worn, defective, supplied in incorrect quantity or to an incorrect specification, please complete the online Returns Form (www.haleproducts.com, at the top...

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