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HALE Manuals
Water Pump
AP
Technical manual
HALE AP Technical Manual
Single stage booster pumps
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Operation and maintenance manual
(70 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
1 Safety
Ppe
Environmental Protection
Training
Safety Summary
2 Introduction
Overview
How to Use this Manual
Pump Specifications and Numbering
Principles of Operation
Figure 1. Centrifugal Force from a Rotating Disk
Explanation of Terms
Atmospheric Pressure (Static Air Pressure)
Figure 2. Single Stage Water Flow
Cavitation
Dead Heading
Impeller and Clearance Rings
Priming Pump
Relief Valve
Figure 3. Clearance Ring Water Flow
PM Relief Valve Control
Volute
Standard Booster Pump Components
Figure 4. Parts of the Hale Booster Pump
Volute
Impeller and Shaft Assembly
Mechanical Seal
Figure 5. Mechanical Seal
Gearbox
Pump Drives
Optional Pump Components
Anodes
Figure 6. Direct Engine Mount
Figure 7. Hale Anode
Trvs
3 Maintenance Operating Procedures
Repair Verification Operations
Figure 8. Driver Compartment Indicator Lights
Figure 9. Pump Operator Panel
Vacuum Test
Table 1. Vacuum Test Tools and Consumables List
Pressure Test
Table 2. Pressure Test Tools and Consumables List
Pumping from Draft Verification Operations
Draft Limiting Factors
Table 3. Additional Losses Beyond NFPA Rating Baseline
Cavitation (Details)
Process of Cavitation
Figure 10. Results of Cavitation
Warning Signs of Cavitation
Discharge Pressure
Vacuum Compound Gauge
How to Prevent Cavitation
Figure 11. Low Pressure Regions
General Considerations
Table 4. Hose Sizes for Pump Rating Capacity
During Operations
Table 5. Lift Loss from Barometric Pressure
Post Operation Procedure
Table 6. Lift Loss from Elevation
4 Preventive Maintenance
Preventive Maintenance Plan and Schedule
Table 7. Recommended Preventive Maintenance - Pump
Table 8. Recommended Preventive Maintenance - Ancillary Equipment
Maintenance Log
Extreme Conditions Maintenance Guidelines
Freezing Weather
Contaminated Water
Booster Pump Preventive Maintenance Procedures
After each Use (Flush Pump)
Leakage Checks
Quarterly Maintenance
Check Gearbox Oil Level
Figure 12. Typical Gearbox Oil Fill/Level Component Locations
Perform Vacuum Test
Annual Pump Maintenance
Performance Testing
Testing Overview
Testing Equipment and Materials
Table 9. Example Performance Test
Table 10. Pressure and Flow for Various Size Nozzles
Performance Testing Test Procedure
Annual Pump Maintenance
Triennium Pump Maintenance
Gearbox Fluid Change
5 Corrective Maintenance (Repair)
Troubleshooting
PTO or Pump Engagement Problems
Table 11. Engagement SCR Table
Pump Priming Problems
Table 12. Pump Priming SCR Table
Insufficient Pump Capacity
Engine Speed Problems
Table 13. Insufficient Pump Capacity SCR Table
Table 14. Engine Speed SCR Table
Relief Valve Problems
Gearbox Problems
Discharge Valve Problems
Table 15. Relief Valve SCR Table
Table 16. Gearbox SCR Table
Table 17. Discharge Valve(S) SCR Table
Cavitation
Figure 13. Engine or Opposite Engine Rotation
Table 18. Cavitation SCR Table
Table 19. Rotation SCR Table
Maintenance Level 1
Maintenance Level 2
Maintenance Level 3
Maintenance Impeller Renew
Miscellaneous Maintenance
General Repair Guidelines
Match Mark or Note Component Orientation
Recommended Lubricants
Table 20. Recommended O-Ring Lubricant
Cleaning and Lubrication Required for Mechanical Seal Installation
Replacement Fasteners
Table 21. Recommended Mechanical Seal Lubricant
Table 22. Maximum Torque Values
Circlip/Snap Ring Installation
Thread Lock or Sealant Compound
Cleaning and Inspection Guidelines
Figure 14. Circlips (How to Recognize and Remove Them)
Recommended Cleaners
Repair Kits
Impeller Renew Kits
Worn Clearance Rings and Impeller Hubs
Figure 15. Measuring for Worn Clearance Rings and Impeller Hubs
Table 23. Impeller and Clearance Ring Diameters and Clearance Values
Removal and Replacement Instruction Guidelines
Tools Required/Suggested
General Pump Disassembly for Access Guidelines
Figure 16. Seal Removal Tool and Seal Driver Kit
Figure 17. Caliper (Depth Rod Extended)
General Pump Removal from the Apparatus
Table 24. Pump R&R from the Apparatus Tools and Consumables List
Figure 18. Pump and Gearbox Assembly R&R
General Pump Disassembly Methodology
Figure 19. One-Piece Volute (AP, CBP, MBP)
Figure 20. Three-Piece Volute (RSD)
Figure 21. AP Pump Exploded View
Figure 22. CBP Pump Exploded View
Figure 23. MBP Pump Exploded View
Figure 24. RSD Pump Exploded View
Figure 25. Gearbox Exploded View (All Except 3.74:1 GR)
Figure 26. Gearbox Exploded View (3.74:1 GR)
Level 1 Procedures
RSD Suction Head R&R
Table 25. RDS Suction Head R&R Tools and Consumables List
RSD Volute R&R
Table 26. RSD Volute R&R Tools and Consumables List
AP/MBP Volute R&R
Figure 27. AP/MBP Volute R&R
Table 27. AP Volute R&R Tools and Consumables List
CBP Volute R&R
Table 28. CBP Volute R&R Tools and Consumables List
MBP/RSD Inducer R&R
Figure 28. MBP Inducer R&R
Figure 29. RSD Inducer R&R
Table 29. MBP/RSD Inducer R&R Tools and Consumables List
MBP/RSD Impeller R&R
Figure 30. MBP Impeller R&R
Table 30. MBP/RSD Impeller R&R Tools and Consumables List
AP Impeller R&R
Figure 31. AP Impeller R&R
Table 31. AP Impeller R&R Tools and Consumables List
CBP Impeller R&R
Figure 32. CBP Impeller R&R
Table 32. CBP Impeller R&R Tools and Consumables List
Figure 33. NORD-Lock Washers Installation Details
AP/CBP/MBP Mechanical Seal R&R
Table 33. AP/CBP/MBP Mechanical Seal Bench Procedure Tools and Consumables List
Figure 34. Typical Mechanical Seal Detail
RSD Mechanical Seal R&R
Table 34. RSD Mechanical Seal Bench Procedure Tools and Consumables List
Figure 35. RSD Mechanical Seal Notch
Figure 36. Align Slot on Seal with Pin in Pump Head
AP/CBP/MBP Pump Head R&R
Table 35. AP/CBP/MBP Pump Head R&R Tools and Consumables List
RSD Pump Head R&R
Table 36. RSD Pump Head R&R Tools and Consumables List
Figure 37. Pump Head (Pump Side)
Figure 38. Pump Head (Drive Side)
Pump Head R&R Bench Procedures
Pump Shaft Oil Seal Bench Procedure
Table 37. Pump Shaft Oil Seal Bench Procedure Tools and Consumables List
RSD Mechanical Seal Anti Rotation Pin Bench Procedure
Table 38. Mechanical Seal Pin Bench Procedure Tools and Consumables List
Level 2 Procedures
Level 3 Procedures
Miscellaneous Procedures
Cooling System
Table 39. Gearbox Cooling Tube R&R Tools and Consumables List
Cooling Tube R&R
Pump Clearance Ring R&R
Table 40. Pump Clearance Ring R&R Tools and Consumables List
Figure 39. Slots Cut in Clearance Ring-Volute
Figure 40. Clearance Ring Driven Out-Volute
Figure 41. Wrap Around Clearance Rings - Pump Heads
Figure 42. Clearance Ring Drilled out (MPB Pump Head)
Figure 43. Clearance Ring Bent Inward and Cut Thru
Figure 44. Slots Cut in Clearance Ring - Suction Head
Figure 45. Clearance Ring Driven out - Suction Head
Figure 46. RSD Wrap Around Clearance Rings
General Install on the Apparatus
Figure 47. RSD Wrap Around Clearance Ring R & R
Gearbox
Gearbox R&R
Gearbox Bench Procedures
Input Shaft
Table 41. Input Shaft Bench Procedure Tools and Consumables List
Input Shaft Oil Seal (ONLY)
Table 42. Input Shaft Oil Seal Bench Procedure Tools and Consumables List
Input Shaft Bearings (ONLY)
Input Shaft Endcap (ONLY)
Table 43. Input Shaft Endcap Bench Procedure Tools and Consumables List
Drive Gear (Input Shaft)
Table 44. Drive Gear Bench Procedure Tools and Consumables List
Pump Shaft
Table 45. Pump Shaft Bench Procedure Tools and Consumables List
Figure 48. Pump Shaft Assembly
Figure 49. AP/CBP Pump Shaft
Figure 50. MBP/RSD Pump Shaft
Pump Shaft Bearings (ONLY)
Pump Shaft Endcap (ONLY)
Table 46. Pump Shaft Endcap R&R Tools and Consumables List
Pump Gear (ONLY)
Table 47. Pump Gear Bench Procedure Tools and Consumables List
Appendix A. Tightening (Torque) Information
Appendix B. Test Equipment and Special Tool Information
Special Tool Information
Appendix C. Ancillary Pump Equipment
Priming Systems
Priming Pump
Figure 51. Rotary Vane Positive Displacement Type Priming Pump
C.1. Priming Systems
Priming Valves
Figure 52. Rotor and Vanes
Figure 53. ESP Priming Pump
C.1.2 Priming Valves
Figure 54. PVG Priming Valve
Figure 55. SPVR Priming Valve
Temperature Control Devices
Trv
TRV-L Kit
Ancillary Equipment Preventive Maintenance Procedures
Weekly Maintenance
Pump Shift Warning Indicator Lights
Check Valves
Check and Clean Intake Strainers
Check All Gauges
Check Pump Controls
Inspect Water and Foam Tanks
Check Roof and Bumper Turrets
Check Auxiliary Fire Suppression Equipment
Monthly Maintenance
Priming System Test (Dry Vacuum Test
Drive Line and Flange Bolts
Figure 59. Grade 8 Bolt Marking
Figure 60. Class 10.9 Bolt Marking
Annual Maintenance
Check Drain Lines to Multi-Drain
Tank to Pump Flow Rate Test
C.3.3 Annual Maintenance
ESP Primer Maintenance
Figure 61. ESP Exploded View
Figure 62. ESP-PVG Primer Repair Kit (P/N 546-1410-03-0
Appendix D. Operator Maintenance Log
Appendix E. Manufacturer's Information
Manufacturer's Information
Warranty
Returned Goods Procedure
E.1. Manufacturer's Information
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Pump Specifications and Numbering
2
Gearbox
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Operation & Maintenance Manual
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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