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HALE Silencer APS Series Installation, Operation And Service Maintenance Manual

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APS / APS -M / MBP / MBP -M
AP -M / MG -A / MG -M / TBP /
TBP-M
Installation, Operation and Service
Maintenance Manual
Hale Products Inc.
A Unit of IDEX Corporation
700 Spring Mill Avenue
Conshohocken, PA 19428 U.S.A.
Telephone: 610-825-6300
FAX: 610-825-6440
Web..........www.haleproducts.com
Manual p/n: 029-0020-83-0

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Summary of Contents for HALE Silencer APS Series

  • Page 1 APS / APS -M / MBP / MBP -M AP -M / MG -A / MG -M / TBP / TBP-M Installation, Operation and Service Maintenance Manual Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone: 610-825-6300 FAX: 610-825-6440 Web..www.haleproducts.com...
  • Page 2 NOTICE ! Hale Products, Inc. (Hale) cannot assume responsibility for product failure result- ing from improper maintenance or operation. Hale is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice.
  • Page 3 PTO, hydraulic drive (-H) or direct engine mount (-M). The Hale line of booster pumps are the favorites of fire fighters throughout the world. Booster pumps can be used as initial attack pumps or as auxil- iary pumps in conjunction with the apparatus main pump.
  • Page 4 Overview well as the drive unit. Table A-1: Booster Pump Model Number Matrix Silencer Series Booster Pump p/n: 029-0020-83-0...
  • Page 5 Overview For shim installa- tion, see Step Fig- ure B: “Overview, Silencer Booster Figure B: Overview, Silencer Booster Pump Silencer Series Booster Pump p/n: 029-0020-83-0...
  • Page 6 Overview Silencer Series Booster Pump p/n: 029-0020-83-0...

  • Page 7: Safety Precautions

    BEFORE ATTEMPTING TO INSTALL OR OPERATE THE PUMP. WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCE- DURES, INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN. Hale is a registered trademark of Hale Products, Incorporated. All other brand and product names are the trademarks of their respective holders. DEFINITIONS...
  • Page 8 Installation should be performed by a trained and qualified installer, such as your authorized Hale representative. Be sure the installer has suffi- cient knowledge, experience and the proper tools before attempting any installation.
  • Page 9 Doing so voids the Hale pump warranty. Also see heading “Express Warranty” on page 145. Any of the above could affect system capacity and/or safe operation of the system and is a serious safety violation which could cause personal injury or could affect safe operation of the pump.
  • Page 10 ON. Also see Section 3 “Basic Operation” on page 33 for additional information. DO NOT advance the throttle unless the OK TO PUMP indicator is ON. Also see Section 3 “Basic Operation” on page 33 for additional information. Section 1: Safety Precautions Hale Products, Inc., August 2006 Rev-B...
  • Page 11 Before connecting any cord sets or wiring harnesses, inspect the seal washer in the connector. If the seal washer is missing or damaged, water can enter the connector causing corrosion. This could resulting in possible system failure. Section 1: Safety Precautions Hale Products, Inc., August 2006, Rev-B...
  • Page 12 ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ Section 1: Safety Precautions Hale Products, Inc., August 2006 Rev-B...
  • Page 13 Introduction PRINCIPLES OF OPERATION Centrifugal Force Hale pumps are centrifugal pumps that operate on the principle of centrifu- gal force created by a rapidly spinning disk. (See Figure 2-1: “Centrifugal Force - Rotating Disk.”) As the disk rotates, it throws water from the center toward the outer circumference of the disk.

  • Page 14: Pump Components

    Pump Stages The number of pump stages is determined by the number of impellers on a common shaft. The Hale series of single and two-stage pumps provide the same normal operating and rating test pressures. The two-stage pump pro- vides an additional level of operating pressures if required. See page ___ for single and two-stage pump ratings.
  • Page 15 Introduction Gearbox Bearings The Hale two-stage booster pump consists of the same major compo- nents as the single-stage pump, with the addition of a few more: Impeller (2) and Clearance Ring (3) Transfer Valve Check Valve Volute, Pump Body (See Figure 2-3: “Typical Pump and Gearbox Overview,” on page 15.) Water discharging from the impeller enters the volute (pump body).
  • Page 16 NFPA standards for satisfactory performance. Mechanical Seal The “maintenance-free,” mechanical seal is common to Hale pumps. (See Figure 2-5: “Typical Mechanical Seal Overview.”) Section 2: Introduction Hale Products, Inc., May 2006, Rev-B...
  • Page 17 Figure 2-5: Typical Mechanical Seal Overview Note: Mechanical seals do not drip like other pump packing. A Hale pump with a drip from the seal requires service. WARNING ! IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT COULD OVERHEAT.
  • Page 18 Introduction TWO-STAGE BOOSTER PUMPS The Hale series of two-stage booster pumps provide the same normal oper- ating and rating test pressures as the Hale series of single-stage pumps, but the two-stage pump provides an additional level of operating pressures if required.
  • Page 19 If your fire department does not have a policy to follow, here are general guidelines: 1. Hale pumps ar designed to pump up to 200 PSI (13 BAR) net pressure in volume operation at reasonable engine speeds.
  • Page 20 PUMP DRIVES Hale pumps produce the volumes and pressures shown on their perfor- mance curves. However, maximum pump performance is sometimes lim- ited by the power capacity and speed limits of the engine, transmission, and PTO, as applicable.
  • Page 21 Hale gearboxes also feature, as standard equipment, a cooling tube to maintain proper operating temperatures. HALE Power Takeoff (PTO) Driven Pumps Hale pumps feature a 1-1/2” (38 mm) input (drive) shaft for connection to a PTO driveline. Optional 1410, 1510 and 1610 companion flanges are also available.
  • Page 22 Introduction Section 2: Introduction Hale Products, Inc., May 2006, Rev-B...
  • Page 23 The Anode kit is designed for installation in the standard Hale 115 series flange opening. It is recommended that one anode be installed on each suc- Section 2a: Accessories...
  • Page 24 Heat Exchanger, “K” Series The Hale Model “K” heat exchangers, meet NFPA 1901 requirements. These units are used with any size radiator and use water from the pump to help maintain the proper temperature of the engine coolant during pumping.
  • Page 25 Note: For additional information about the pressure and relief valves in your sys- tem, see the separate manual provided with the valves. Also see Section 9, “Drawing Package” on page 23. Figure 2a-3: Model “K” Heat Exchanger P Series Relief Valve System Section 2a: Accessories Hale Products, Inc., May 2006, Rev-B...
  • Page 26 Thermal Relief Valves (TRV) Thermal Relief Valves (TRV) protect the pump from overheating. (See Figure 2a- Figure 2a-4: P Series Relief Valve 5: “Thermal Relief Valve, TRV,” on page Control 27.) Section 2a: Accessories Hale Products, Inc., May 2006, Rev-B...
  • Page 27 The RED light illuminates when the TRV is open and discharging water. (See Figure 2a-5: “Thermal Relief Valve, TRV.”) An optional buzzer, mounted on the operator panel, provides an audible warning. Section 2a: Accessories Hale Products, Inc., May 2006, Rev-B...
  • Page 28 See separate manual, Hale p/n: 029-0810-01-0, for addi- tional installation and operating instructions. Priming Valves Hale priming valves open when the priming pump is operated to allow the air to escape from the pump. Two priming valves are offered: Hale Semi-Automatic Priming Valve (SPVR), for Remote Mounting A single push button on the operator’s panel starts the priming pump...
  • Page 29 Figure 2a-8: PVG Priming Valves 2A.5 PUMP SHIFT, AUTOMATIC (VPS / KPS) The Hale Automatic Pump Shift, Models VPS or KPS, is a remote, pneu- matically operated, shifting device to shift the pump transmission from ROAD-to-PUMP and back again. (See Figure 2a-9: “Automatic Pump Shift Overview,”...
  • Page 30 (See Figure 2a-10: “Pump Shift Control Valve.”) The system includes a three-position pump shift control valve assembly and indicator lights (GREEN), mounted in the operator’s cab and on the operator’s panel. Section 2a: Accessories Hale Products, Inc., May 2006, Rev-B...
  • Page 31 Figure 2a-10: Pump Shift Control Valve 2A.6 TORRENT SVS VALVES Torrent SVS valves control the flow to and from the full range of Hale pumps. SVS valves enable the operator to shut off flow completely, or throt- tle the flow rate from a trickle to full flow. (See Figure 2a-11: “Typical SVS Valve Primary Components.”)
  • Page 32 Accessories / Options Section 2a: Accessories Hale Products, Inc., May 2006, Rev-B...
  • Page 33 Tandem (series) pumping - on page 44. Pump and Roll - on page 45. Post-operation procedures - on page 50. Note: Also refer to NFPA 1901 Regulations for additional information for apparatus split-shaft and PTO requirements. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 34 ON. CAUTION ! DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL GREEN PUMP LIGHTS IN THE CAB ARE ON. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 35 Open the suction valve to allow water flow into the pump. Open the appropriate valve to expel air or prime the pump, if so equipped. Also see heading “Pumping From Draft” on page 38. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 36 To increase pressure, reduce the pump flow. However, the master intake gauge reading must be maintained at 5 PSI (0.34 BAR / 0.04 MPa), minimum. As the throttle (engine speed) is increased, the pressure gauge reading increases. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 37 Open the discharge valves. IMPORTANT ! IF THE PUMP OVERHEATS AND IS NOT EQUIPPED WITH THE HALE TRV, OPEN THE VALVE TO ACCESS THE PUMP AUXILIARY COOLING SYSTEM, OR SLIGHTLY OPEN THE TANK FILL LINE TO CIRCULATE WATER.

  • Page 38: Pumping From Draft

    For most pumpers this is direct drive (1:1) ratio. The speedometer should register after the shift has been completed. If the shift does not complete, shift the transmission back to NEUTRAL (N) and repeat the entire procedure. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 39 STRAINER OR REDUCE FLOW. As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pres- sure, the pump may be cavitating. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 40 “TPM Operation from a Hydrant” on page 37. To avoid pump overheating, if not equipped with the Hale TRV valve, open the pump auxiliary cooling system valve, or slightly open the tank fill line.
  • Page 41 As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pres- sure, the pump may be cavitating. Also see Section “Appendix F: Cavita- tion” on page 139. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 42 If your fire department does not have a policy, see heading “TPM Operation from a Hydrant” on page 37. To avoid pump overheating, if not equipped with the Hale TRV valve, open the pump auxiliary cooling system valve, or slightly open the tank fill line.
  • Page 43 Observe the gauges carefully, and adjust the pressure or flow as needed. Shutdown starts from the fire ground pump and works toward the water source. Gradually reduce pressure at the fire ground pump until you can disengage the pump. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 44 Tandem Procedures Using the large intake hose, connect the first pumper to the hydrant steamer. Open the hydrant until the pump is primed. Position the second pumper “discharge-to-intake” with the first pumper. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 45 CHARGE HOSES. PUMP AND ROLL IMPORTNAT ! DURING PUMP AND ROLL OPERATION, IT IS NECESSARY TO SLOW THE FOR- WARD MOTION OF THE APPARATUS TO THE PTO MANUFACTURER'S RECOM- MENDED ENGAGEMENT SPEED. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 46 When the pump is put into operation again, reset the valve to the desired operating pressure. More complete and detailed information is found in the relief valve manual. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 47 Move the TPM handwheel counterclockwise until the relief valve opens and the AMBER pilot light illuminates. Turn the handwheel slowly clockwise until the AMBER light just goes out. Then turn the handwheel one additional full turn clockwise. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 48 Turn the handwheel slowly clockwise until the AMBER light just goes out. Then turn the handwheel one additional full turn clockwise. CAUTION ! THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION. Section 3: Operating Hale Products, Inc., May 2005, Rev-B...
  • Page 49 If the shift stroke cannot be completed manually, turn the driveshaft slightly by hand to realign the internal gears and repeat the manual shift. Note: Certain apparatus may offer a manual shift override handle or separate cable for activation. Section 3: Operating Hale Products, Inc., May 2006, Rev-B...
  • Page 50 Open the discharge valves, remove suction tube caps, and discharge valve caps. Open the pump body drain cocks or Hale multiple drain valve. If a multi- ple drain valve is used, all pump drain lines should be connected to this valve.

  • Page 51: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance OVERVIEW Hale Silencer Series Booster Pumps require minimal care and maintenance. Preventive maintenance tasks take little time to perform and consist primarily of leak testing, lubrication and cleaning. The following procedures are for normal use and conditions. Extreme condi- tions may indicate a need for increased maintenance.

  • Page 52: Table Of Contents

    Preventive Maintenance Open pump body drain cocks and/or Hale multiple drain valve. After the pump is completely drained, replace all caps and close all valves. Pumping from Salt Water, Contaminated Water, or with Foam Solution Thoroughly flush the pump and suction hoses using fresh water from a hydrant or other clean water source.

  • Page 53: Test The Priming System

    Preventive Maintenance normal operating pressure. (See Figure 3-3: “TPM / PMD Relief Valve Control” on page 47.) Prepare to pump from the onboard water tank, having the discharge flow directed back to the water tank. Increase the pump pressure up to normal operating pressure as indicated on the master pressure gauge per normal operating procedures.

  • Page 54: Perform Valve Maintenance

    Preventive Maintenance Verify that the warning indicators in the cab and the pump control panel function properly and agree with the indicators in the cab. CAUTION ! MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS. VERIFY THE PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT ANY MOVE- MENT OF THE APPARATUS.

  • Page 55: Check And Clean The Intake Strainers

    Preventive Maintenance transfer the valve to verify that the valve operates freely. Set the truck up for pumping per the procedures in Section 2, with the trans- fer valve in volume position. Note the discharge gauge readings. Leave the engine at idle speed and move the transfer valve to the pressure position.

  • Page 56: Inspect Water And Foam Tanks

    Preventive Maintenance Inspect Water and Foam Tanks Visually inspect water and foam tanks for proper level and gauge readings. If any debris is present, flush the tanks to protect the pump from wear caused by dirty water or foam concentrate. Check Roof and Bumper Turrets If the apparatus is so equipped, verify that the turrets function properly, and no leaks are present.
  • Page 57 At installation and before operating the first time, oil must be added to the appropriate level. Note: Hale recommends using an SAE EP-90, 80W90 Lubricant or “RoadRanger” ® Full Synthetic SAE 50 Transmission Lubricant, manufactured by the Eaton Corpora- tion, or equivalent.
  • Page 58 Preventive Maintenance Priming System Test (Dry Vacuum Test) (Refer to NFPA 1901 or NFPA 1911) Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if equipped). Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel.
  • Page 59 Preventive Maintenance IMPORTANT ! IF LEAKS CANNOT BE DETECTED BY FOLLOWING THE PROCEDURE, IT IS ADVISABLE TO TEST THE PUMP HYDROSTATICALLY. TO TEST: OPEN ALL VALVES PLACE CAPS ON ALL VALVES CONNECT A POSITIVE PRESSURE SOURCE INSPECT THE PUMP FOR LEAKS ANNUALLY Annual maintenance consists of post-operation, weekly and monthly mainte- nance.
  • Page 60 Preventive Maintenance Inspect the magnetic drain plug. If metal filings are present on the drain plug, remove the cover plate to visually inspect and clean the internal com- ponents. Repair or replace components as necessary. See Section 6 “Repair” on page 75.
  • Page 61 Disassemble the priming pump and clean the housing and vanes. Inspect the vanes for wear and replace as needed. Reassemble the pump and test for proper operation. (See separate manual provided, Hale p/n: 101-2850-02-0.) IIMPORTANT ! DO NO USE A LUBRICANT ON THE PUMP VANES AND VANE SLOTS. LUBRI- CANT AND COLD WATER FORM AN EVENTUAL GUMMY RESIDUE THAT REN- DERS THE PRIMING SYSTEM INOPERATIVE.
  • Page 62 Preventive Maintenance A pump must be able to pump FULL capacity at 150 PSI, 70% capacity at 200 PSI and 50% capacity at 250 PSI. Tank-to-Pump Flow Rate Test Note: This procedure is provided as a reference only. It does not supersede any local procedures.
  • Page 63 Preventive Maintenance accuracy. A stream straightener, just upstream of the nozzle is advisable. REFER TO LOCAL PROCEDURES FOR PUMP TESTING PROCEDURES AND PRACTICES AS WELL AS APPLICABLE NFPA STANDARDS. For Pitot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 6.0 BAR / 0.21 and 0.6 MPa).
  • Page 64 Preventive Maintenance exceed 30 PSI (2 BAR / 0.21 MPa), or approximately 180 PSI (12 BAR / 1.2 MPa) operating pressure. SLOWLY open the discharge valves to re-establish the original pressure (150 PSI). Perform steps 2 and 3 of the Post-Operation procedures. Also see 3.10 “Post Operation Procedures”...
  • Page 65 See Section 6 “Repair” on page 75 for maintenance and repair information if pump disassembly is required. Anode Check Hale offers two types of anodes (consumables): Zinc anode - recommended for all pumps where corrosion is an issue, including brackish or salt water exposure.
  • Page 66 Preventive Maintenance Silencer Series Booster Pump p/n: 029-0020-83-0...

  • Page 67: Troubleshooting

    Troubleshooting Troubleshooting Table 5-2 lists conditions, possible causes and suggested corrective action measures. Before calling Hale Products or your Hale authorized parts service center for assis- tance, eliminate problem causes using the following table. If you cannot correct a problem, please have the following information prior to calling the Hale Customer Service for assistance.
  • Page 68 (AIR LEAKS OR BLOCKED SUCTION HOSES). Pump pressure too low • Prime pump again and maintain higher pump pressure while open- when nozzle is opened. ing the discharge valve slowly. Chart continued on next page. Figure 5-2: Troubleshooting Chart Troubleshooting Hale Series Pumps, Nov.-05, Rev-A...
  • Page 69 • Remove any debris restricting entrance of water at the strainer. line at strainer. • Also see Section 4 Preventive Maintenance, heading “Intake Chart continued on Strainers” on page 55. next page. Figure 5-2: Troubleshooting Chart Troubleshooting Hale Series Pumps, Nov.-05, Rev-A...
  • Page 70 • Follow recommended practices for laying suction hose. • Keep off the bottom of the fluid supply by at least 2’ (0.6 meters) Chart continued on next page. below the surface of the fluid. Figure 5-2: Troubleshooting Chart Troubleshooting Hale Series Pumps, Nov.-05, Rev-A...
  • Page 71 (PMD) Valve. system. Not Relieve Pres- sure When Relief • See Section 3 Operation, heading 3.8 “Relief Valve Procedures” on Valves are Closed. page 46. Chart continued on next page. Figure 5-2: Troubleshooting Chart Troubleshooting Hale Series Pumps, Nov.-05, Rev-A...

  • Page 72: Relief Valve Test

    • Recommended weekly lubrication of discharge and suction valve. Are Difficult to • Use a good grade, petroleum based, silicone grease. Operate. • For Hale Products, SVS Valves, etc., use Never-Seez White ® Food Grade with PTFE. • Also see Section “Appendix C1: Lube and Sealant Specifica- tions”...
  • Page 73 NOTICE ! IT IS POSSIBLE TO REASSEMBLE THE PUMP INCORRECTLY OR WITH THE WRONG PARTS. ALWAYS COMPARE THE REPLACEMENT PARTS WITH THE ORIGINAL HARDWARE. CONTACT CUSTOMER SERVICE AT HALE PRODUCTS TO ANSWER QUESTIONS OR CONCERNS. Figure 5-2: Troubleshooting Chart Troubleshooting...
  • Page 74 Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Troubleshooting Hale Series Pumps, Nov.-05, Rev-A...
  • Page 75 OVERVIEW This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Hale pump and gearbox compo- nents. Follow the disassembly instructions in the order in which they appear in this section. At any point in the disassembly process, the unit can be reassembled by following the instructions in the reverse.
  • Page 76 ING FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY. ALL FASTENERS ON THE PUMP, GEARBOX AND PEDESTAL ASSEMBLIES ARE SELECTED FOR THEIR APPLICATION. HALE PRODUCTS DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTER- NATIVE POSES A SERIOUS SAFETY RISK.
  • Page 77 (or equivalent) to all bolts on the Pump. Before installing the mechanical seal, use alcohol swabs provided by Hale Products Inc. to clean all grease or oil from the pump shaft and mechanical seal running faces. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equivalent) on the rubber seal parts to ease installation.
  • Page 78 Lightly oil or grease the shaft, O-ring seals and lip seals with a coating of general-purpose grease before reinstalling, especially when pressed-in. For Hale recommended cleaners, see “Appendix C1: Lube and Sealant Specifications” on page 133. Replace any hardware that shows signs of excessive wear.

  • Page 79: Tools Required

    Torque wrench capable of 40, 65, and 135 ft.-lbs. (54, 88, and 183 N-m) Pan (to collect drip oil) Disposable rags Oil dry Wedges Bearing puller Pusher tube (a small section of PVC tubing to fit over the shaft) Section 6: Corrective Maintenance Hale Products, Inc., May 2005, Rev.-B...
  • Page 80 Corrective Maintenance N-06 or N-07 bearing nut socket or spanner wrench, available from: Whittet-Higgins at www.whittet-higgins.com 35 Higginson Avenue P O Box 8 Central Falls, RI 02863 Phone ....(401) 728-0700 Section 6: Corrective Maintenance Hale Products, Inc., May 2006, Rev.-B...
  • Page 81 Corrective Maintenance SILENCER BOOSTER PUMP OVERVIEW For shim installa- tion, see Step 11. “Shaft End Play / Float” on page 92. Figure 6-2: Silencer Series Booster Pump Silencer Series Booster Pump p/n: 029-0020-83-0...
  • Page 82 Corrective Maintenance REMOVING THE ASSEMBLY Removing the Assembly First, review preceding Section “Before You Begin...” on page 81. Note: Before beginning the removal process, you may want to make a sketch (or photograph) the plumbing and component configuration to aid in re-assembly. Remove the pump and any piping drain plugs to drain the inlet (suction) side of the pump body per your required procedures.
  • Page 83 Corrective Maintenance Installing the Assembly First, review preceding Section “Before You Begin...” on page 81. Attach proper supporting devices and stabilize the assembly for transport to the apparatus. Also see WARNINGS ! note on page 82. Place the pump assembly into position within the apparatus. Apply Loctite™...
  • Page 84 Review preceding sections “Before You Begin...,” on page 81 and “Clean- ing and Inspection Guidelines,” on page 84. Evenly press-in a new oil seal (Hale, p/n: 296-2650-00-0) in the gearbox housing until flush against the roller bearing. Silencer Series Booster Pump...
  • Page 85 Corrective Maintenance Lightly tap the seal around the edges to ensure an “even” seat. Note: It is recommended to manufacture insertion tools to assure a correct installa- tion of the input shaft bearing and oil seal. See Figure 6-4: “Typical Bearing and Seal Insertion Tool Drawings’...
  • Page 86 Corrective Maintenance Figure 6-5: Oil Seal Replacement / Pump Head Remove the following to replace the pump head oil seal - Volute (All Except TBP) on page 93 and Impeller (All Except TBP) on page 95. Volute and Impeller (TBP Only) on page 99. Mechanical seal on page 103.
  • Page 87 Review preceding sections “Before You Begin...” beginning on page 81 and “Cleaning and Inspection Guidelines” beginning on page 84. Install a new oil seal (Hale p/n: 296-2850-00-0) and clearance ring into the pump head. See Figure 6-5: “Oil Seal Replacement / Pump Head” on page Make sure to install the oil seal with the spring side of the seal facing into the gearbox.
  • Page 88 Corrective Maintenance See heading “Removing the Assembly” on page 82. For shim installa- For shim installa- tion, see Step 11. tion, see Step 11. “Shaft End Play / “Shaft End Play / Float” on page 92. Float” on page 92. Figure 6-6: B Gearbox Parts Identification Remove the volute, impeller, mechanical seal, pump head and pump shaft oil seal.
  • Page 89 Remove the input shaft key and the flange retaining ring. Remove (pry out) the oil seal making sure not to damage the bore, shaft or bearing. Removing the oil seal renders it defective. Replace with Hale P/N: 296-2650-00-0. Using a brass drift punch, remove the knock-out plug and push the input shaft out of the gear box while protecting the input gear from falling out of the housing.
  • Page 90 Install the snap ring against the roller bearing. See Figure 6-3: “Oil Seal, Input Shaft” on page 84. Evenly press-in a new oil seal (Hale p/n: 296-2560-00-0) until flush against the snap ring. Lightly tap the seal around the edges to ensure an “even, flush”...
  • Page 91 Corrective Maintenance cover to the gearbox. Remove the bearing cover and shim spacers. Strike the pump shaft on the bearing cover end with a rubber mallet to push the pump shaft assembly out of the pump head side of the gearbox housing, while protecting the pump gear, spacer and shaft key from falling out of the housing.
  • Page 92 Corrective Maintenance The pump head is secured to the gearbox housing using four (4) 7/16”-14 hex screws with Loctite (#242). Note: On applications with aluminum heads, such as the 4DB, washers must be used underneath the screws. Lay the gearbox flat on the face of the pump head. Use wood blocks or sim- ilar supports to stabilize the gearbox.
  • Page 93 Corrective Maintenance SERVICING THE BOOSTER PUMP (ALL EXCEPT TBP) APS series volutes are mounted for either engine rotation (clockwise), as viewed from the suction inlet, or opposite engine rotation (counterclockwise). MBP series pumps are available in the engine rotation (clockwise) only. Note the direction of flow of the impeller for proper mounting of the volute.
  • Page 94 Corrective Maintenance Figure 6-8: Booster Pump Parts Breakdown Silencer Series Booster Pump p/n: 029-0020-83-0...
  • Page 95 Corrective Maintenance Installation Notes - Volute (All Except TBP) To install, follow the preceeding steps in reverse order, paying attention to the following: Review preceeding sections “Before you Begin...“ on page 73 and “Cleaning and Inspection Guidelines,” on page 76. Replace all gaskets.
  • Page 96 Corrective Maintenance Inspect the rear clearance ring for wear and replace accordingly. See head- ing “Clearance Rings, Impeller Measurement“ on page 97. Note: Removing the rear clearance ring from the pump head renders the ring defective and it must be replaced. Removing the impeller may disturb the mechanical seal.
  • Page 97 Corrective Maintenance Clearance Rings, Impeller Measurement Figure 6-9: Clearance Ring ID and Impeller ID / OD Measurement Inspect both clearance ring IDs for signs of wear. Using a caliper, measure the inside diameter of each ring in several places.If the nominal dimension does not fall within the acceptable range specified below, the clearance ring must be replaced.
  • Page 98 If the clearance rings on the booster pump show significant wear but the impel- ler itself is within the size tolerance, “undersized” clearance rings can be installed to delay a complete rebuild. Contact Customer Service at Hale Products at 610-825-6300.
  • Page 99 Corrective Maintenance 6.10 SERVICING THE TWIN BOOSTER PUMP (TBP) Before servicing the TBP, it is important to note the orientation of the volute and the direction of rotation of each impeller. During reassembly, it is possible to install the volute and impellers backwards. Careful notes, pictures, and match- marks will ensure that the pump is reassembled correctly.
  • Page 100 Corrective Maintenance DISCHARGE MANIFOLD TRANSFER VALVE SCREWS, 7/16-14 DISCHARGE VOLUTE BODY MANIFOLD (12) CLEARANCE RING GASKET, PUMP (CENTER) HEAD / VOLUTE CLEARANCE RING (INNER) COTTER PIN IMPELLER KEY IMPELLER NUT MECHANICAL SEAL CUP SUCTION INLET MECHANICAL SEAL PUMP HEAD ASSEMBLY (OUTBOARD) SCREWS, 7/16-14, PUMP HEAD /...
  • Page 101 Corrective Maintenance Inspect outer clearance rings for wear and replace accordingly. See “Clearance Rings, Impeller Measurement” on page 97. Remove cotter pin and impeller nut, and set aside. Remove the outboard impeller from the pump shaft by using a bearing puller. To avoid causing damage place the puller at the impeller vane area where the metal is the heaviest.
  • Page 102 Corrective Maintenance If necessary, replace the mechanical seal using instructions beginning on page 103. If necessary, install new clearance rings. See heading “Clearance Rings, Impel- ler Measurement” on page 97. Reinstall the impeller shaft key and slide the inboard impeller back on the pump shaft.
  • Page 103 Corrective Maintenance 6a Mechanical Seal Assembly IMPORTANT ! IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE VOLUTE IS NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED. WHENEVER A MECHANICAL SEAL IS REMOVED, IT MUST BE REPLACED WITH A NEW SEAL.
  • Page 104 Carefully inspect clearance rings and other internal parts for excessive wear or damage. Replace accordingly. It is recommended to always use Hale genuine replacement parts for opti- mum safety of the equipment and its operators and to avoid unnecessary downtime.
  • Page 105 The seal insertion tool is available from Hale (order P/N: 029-0760-00-0). If necessary, the seal insertion tool can be made of plastic or brass to the dimensions in Figure 6a-2: “Typical Mechanical Seal Insertion Tool”...
  • Page 106 Corrective Maintenance 6A.2 MECHANICAL SEAL (TBP ONLY) Mechanical Seal Removal (TBP Only) Two-Stage Pumps SOCKET HEAD SCREW (STAINLESS STEEL) SPRING Remove volute DIAPHRAGM DRIVE RING and impeller per RETAINER CUP RETAINER RETAINING RING instructions on O-RING SEAL HOUSING page 99. SEAT (PTFE) O-RING...
  • Page 107 Corrective Maintenance It is recommended to always use Hale genuine replacement parts for opti- mum safety of the equipment and its operators and to avoid unnecessary downtime. Mechanical Seal Installation (TBP Only) CAUTION ! MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICE. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE MATING FACES.
  • Page 108 Corrective Maintenance dimensions in Figure 6a-2: “Typical Mechanical Seal Insertion Tool” on page 105. Keep the seal well lubricated and verify that the seal seats against the sta- tionary seat. If binding occurs, apply additional Pac-Ease lubricant. Place the spring on the diaphragm assembly, making sure to locate the spring on the diaphragm assembly’s pilot.
  • Page 109 Corrective Maintenance 6b Transfer Valve (TBP Only) 6B.1 TRANSFER VALVE REMOVAL Refer to Figure 6b-1 on page 115 for an exploded view. Disconnect any extensions or air cylinders from cam handle. The handle can then be removed. Remove the bolt and washer securing the handle. Note the orientation of the handle with respect to the “V”...
  • Page 110 Corrective Maintenance Bolt and Washer Cam Handle Cover Retainer Stop Non-locking Cover Retaining Ring Transfer Valve Cover 2x Bronze Bushings Locating Pin O-ring Square Seal Ring Transfer Drum Transfer Drum Sleeve Bore Figure 6b-1: Exploded TBP Transfer Valve and Parts Silencer Series Booster Pump p/n: 029-0020-83-0...
  • Page 111 Corrective Maintenance cover. If removed, install the bronze bushings in the top and bottom of the transfer valve cover. If removed, install the locating pin into the bottom of the transfer valve cover. Apply grease to bores of bronze bushings and insert the stem of the transfer drum up through the center of the transfer valve cover bushings.
  • Page 112 Corrective Maintenance 6c Available Options 6C.1 HYDRAULIC DRIVE OPTION ( -H SERIES) Figure 6c-1: Hydraulic Drive Option, * -H Review preceeding sections “Before You Begin...” on page 73 and “Cleaning and Inspection Guidelines” on page 76. Remove the hydraulic motor from the hydraulic adapter flange. Unbolt motor and pull back to slide motor shaft (splined) from the input shaft coupling.
  • Page 113 Corrective Maintenance Inspect and clean all components according to the Cleaning and Inspection Guidelines on page 76. Installation Notes (See Figure 6c-1: “Hydraulic Drive Option, * -H” on page 112.) To install, follow the preceeding steps in the reverse order. Using Loctite #242 (removable medium strength thread lock) install the 1/2”- 13 and 7/16”-14 mounting screws and hardware.
  • Page 114 Corrective Maintenance Unthread the adapter fitting from the bearing cover. Installation Notes (See Figure 6c-2: “Tachometer Drive Option” on page 113.) To install, follow the preceeding steps in reverse order. 6C.3 ENGINE DRIVE, * -M SERIES (FLYWHEEL MOUNT) (See Figure 6c-3: “Engine Drive Option, * -M” on page 115) To service the input shaft oil seal, elastomeric drive disk and/or pump input shaft assembly you must disassemble the flywheel housing adapter from the engine.
  • Page 115 Corrective Maintenance For shim installation, see Step 4, see heading “Shaft End- Pay/ Float” on page 116 Figure 6c-3: Engine Drive Option, * -M With the pump and gearbox assembly properly supported and balanced, remove the screws and hardware that secure the flywheel housing adapter to the engine bell housing.
  • Page 116 Corrective Maintenance Remove the input shaft center screw (1/2”13) and washer to separate the elas- tomeric drive disc assembly from the input shaft. (See Figure 6c-3: “Engine Drive Option, * -M” on page 115.) Remove the eight (8) 7/16”-14 screws securing the flywheel housing to the gearbox housing.
  • Page 117 Corrective Maintenance Reinstall the flywheel housing adapter and gasket and tighten the eight (8) 7/16- 14 screws (apply Loctite #242) in a staggered pattern to insure a proper seal. Apply a small amount of grease to the gasket to help hold it in place. Refer to Table 6-1: “Typical Torque Values Chart”...
  • Page 118 PACKAGE” ON PAGE 133, LOCATED AT THE BACK OF THIS MANUAL. WARNING! THE HALE PUMP AND GEARBOX ASSEMBLY ARE HEAVY AND BULKY. ADDING ACCESSORIES INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING FOR THE APPROXIMATE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVERHEAD CRANE, JACK, CHAINS,...
  • Page 119 Drive Line and Flange Bolts Ensure that: All bolts are tight. Use a torque wrench to torque bolts to the drive train manufacturer's recommended specifications. Bolts used are “Grade 8” strength. Basic Installation Hale Products, Inc., August - 06, Rev-B...
  • Page 120 ADHESIVE/SEALANT, SUCH AS LOCTITE® #246 FOR GEARBOX AND #242 FOR PUMP. Wherever there is a requirement for new parts, it is recommended to use only Hale authorized replacement parts for optimum safety of the equip- ment and its operators and to reduce unnecessary “downtime.” Issues It is critical to use computer driveline analysis software, such as Dana’s...
  • Page 121 Note: Hale assumes no liability for any information provided under this heading “Driveline Issues.” Driveline design and truck system integration is the responsi- bility of the apparatus manufacturer. Failure to comply with the driveline parame- ters set forth can result in termination of Hale’s warranty on driveline related issues. PLUMBING CONNECTIONS...
  • Page 122 For example: Suction, victaulic and/or flange-type Discharge, typically flange-type Various flanges and manifolding are also available. Contact Hale Products at 610-825-6300 for additional information. FLUID LEVELS To meet various shipping regulations, ALL fluids within the pump and gear- box assemblies are drained prior to shipping from the factory.
  • Page 123 This contact causes friction which increase the forces required to operate the valve handle. Figure 7-3: Adjustable Valve Linkage Guidelines-- Top View Figure 7-4: Adjustable Valve Linkage Guidelines-- Side View Basic Installation Hale Products, Inc., August - 06, Rev-B...
  • Page 124 Installation Basic Installation Hale Products, Inc., August - 06, Rev-B...
  • Page 125 Dead Heading ..Operating a pump without any discharge. The lack of flow causes temperatures to rise inside the pump. Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 126 Pitot Gauge..Measures velocity head at the discharge of a nozzle and can be converted to flow using a chart or simple calculation. Positive ....A pump with a fixed flow delivered to the discharge with each revolution. Displacement Pump Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 127 Service Test..Pump test performed to determine if the apparatus can deliver its rated volume and pressure. Shrouds ....Sides of an impeller that confine the fluid. Slinger Ring..Prevents fluid from continuing to travel down a shaft to the gears and ball bearings. Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 128 Water....Amount of energy in the water stream. Horsepower Wear Rings ..See Clearance rings. Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 129 HP (Horsepower) KW (Kilowatts) 0.7457 One Pound per Square Inch (PSI) One BAR 0.0690 One Pound per Square Inch (PSI) 0.001 Pounds per Square Inch (PSI) Feed Head 0.433 Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 130 Glossary and Measurements Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone....1-610-825-6300 Fax ......1-610-825-6440 ..www.haleproducts.com Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.-B...
  • Page 131 Alternate Lubricant Manufacturers Appendix C: Alternate Lubricant Manufacturers In addition to the Hale recommended lubricants: FULL SYNTHETIC SAE 50 Transmission Lubricant (Cognis 2924/2833) DEXRON III SYNTHETIC (Cognis 2803) for temperatures below 32°F (0°C) the following list of alternate oils and suppliers is provided .
  • Page 132 Table C-1: Alternate Lubricant Manufacturers Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ..... 1-610-825-6300 Fax ......1-610-825-6440 Web..www.haleproducts.com Appendix C: Alternate Lubricant Manufacturers Hale Products, Inc., Nov. 2005, Rev.-A...
  • Page 133 80W-90 (Lubricants must meet service rating API GL-5.) CBP4 / CBP5 0.95 SAE EP90; 80W-90 (Lubricants must meet service rating API GL-5.) Table continued on next page 2CBP4 / 2CBP5 Table C1-2: Oil Capacity and Recommendation Appendix C1: Lube Specifications Hale Series Pumps, July 2007, Rev-D...
  • Page 134 80W-90 (Lubricants must meet service rating API GL-5.) 609FBG Table C1-2: Oil Capacity and Recommendation * For domestic use, Hale recommends using an SAE EP-90, 80W-90 Lubricant or “Roadrunner” Full Synthetic SAE 50 Trans- mission Lubricant, manufactured by the Eaten ®...
  • Page 135 (2.6) (1,230) (1.5) (0.6) (568) (3.7) (1,325) (1.7) (0.6) (1,893) (1.4) (1.2) (2,839) (3.1) (2.5) 1,000 (3,785) (5.5) (4.7) Table D-1: Hose Friction Loss (PSI / BAR 100 Feet) Appendix D: Hose Friction Loss Hale Products, Inc., July 2006, Rev-B...
  • Page 136 Hose Friction Loss Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone....1-610-825-6300 Fax ......1-610-825-6440 ..www.haleproducts.com Appendix D: Hose Friction Loss Hale Products, Inc., July 2006, Rev-B...
  • Page 137 319 (1,208) 403 (1,526) 498 (1,885) 602 (2,279) 120 (8.3) 81 (307) 127 (481) 183 (712) 249 (943) 325 (1,203) 412 (1,560) 509 (1,927) 615 (2,328) Chart E-1: Nozzle Flow and Pressure Ratings, Part 1 Appendix E: Nozzle vs. Pressure Ratings Chart Hale Products, Inc., Nov.-2005, Rev.-A...
  • Page 138 Chart E-2: Nozzle Flow and Pressure Ratings, Part 2 Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ..... 1-610-825-6300 Fax ......1-610-825-6440 Web..www.haleproducts.com Appendix E: Nozzle vs. Pressure Ratings Chart Hale Products, Inc., Nov.-2005, Rev.-A...
  • Page 139 Once the vapor pockets (bubbles) enter the impeller, the process begins to reverse itself. As the vapor reaches the discharge side of the pump, it is sub- jected to a high positive pressure and condenses back to a liquid. Appendix F: Cavitation Hale Products, Inc., Nov.2005, Rev-A...
  • Page 140 However, this also results in a reduction of flow. Cavitation is also eliminated by increasing the pump inlet pressure. This is accomplished with reduced vertical lift, reduced inlet losses, or running from positive pressure supplies. Appendix F: Cavitation Hale Products, Inc., Nov.2005, Rev-A...
  • Page 141 Capacity” on page 142, lists the NFPA pre-selected hose sizes for each pump-rating capacity. Using the appropriately sized hose minimizes the occurrence of cavitation. An undersized suction hose can lead to cavitation. Appendix F: Cavitation Hale Products, Inc., Nov.2005, Rev-A...
  • Page 142 Basket strainers are preferred by Hale due to their overall suction and straining area. Turbulence or whirlpools in the hose line can be caused by excessive oper- ating pressures from the intake source.
  • Page 143 Cavitation Appendix F: Cavitation Hale Products, Inc., Nov.2005, Rev-A...
  • Page 144 Cavitation Appendix F: Cavitation Hale Products, Inc., Nov.2005, Rev-A...
  • Page 145 EXPRESS WARRANTY: Hale Products, Inc. (HALE) hereby warrants to the original Buyer that prod- ucts manufactured by Hale are free of defects in material and workmanship for two (2) years or 2,000 hours usage, whichever shall first occur. The “Warranty Period” commences on the date the original Buyer takes delivery of the product from the manufacturer.
  • Page 146 Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone....1-610-825-6300 Fax ......1-610-825-6440 ..www.haleproducts.com...

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