Product specifications contained in this manual are subject to change ... MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual ... the gearbox internals a quick and practical part of gearbox maintenance.
MUSCLE (Midship) Pumps
("Q" Series)
Installation, Operation and Maintenance Manual
Part 1
Hale Products Inc. u A Unit of IDEX Corporation 607 NW 27th Ave, Ocala, FL 34475 U.S.A.
Telephone: 800.533.3569 u FAX: 800.520.3473 Web..........www.haleproducts.com
Manual p/n: 029-0020-63-0
NOTICE !
Hale Products, Inc. (Hale) cannot assume responsibility for product failure resulting 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.
All Hale products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN YOUR CORRESPONDENCE.
ECO NO 0956
REV C
C-Chg1 C-Chg2
CHANGE FROM Series Upgrade Address & Phone Updated Added Appendix I
BY LwH RVK RVK
DATE 01/20/2006 12/20/2016 08/22/2019
APVD MAL
MAL
HALE PRODUCTS, INC.
A Unit of IDEX Corporation Conshohocken, PA 19428 USA
DRAWN BY LwH CHECKED BY PRW
ISSUE DATE 01/20/2006
COPYRIGHT © NOT TO BE REPRODUCED OR USED TO MAKE OTHER DRAWINGS OR MACHINERY.
Manual p/n: 029-0020-63-0, Rev. -C Chg1 Printed in U.S.A.
© Hale Products, Inc. 2009 All Rights Reserved
Table of Contents
Contents
MUSCLE Pump (Midship) Operation and Maintenance
Page
1 Safety Precautions................................................................................................. 13
1.1 Definitions......................................................................................................................... 13 1.2 Guidelines ......................................................................................................................... 14
2 Introduction ........................................................................................................... 19
2.1 Description........................................................................................................................ 19 2.2 Principle of Operation...................................................................................................... 19
Centrifugal Force .............................................................................................................................. 19 Figure 2-1: Centrifugal Force - Rotating Disk ..................................................................... 19
Pump Stages .................................................................................................................................... 20 Single-Stage............................................................................................................................... 20 Figure 2-2: Water Flow, Typical Hale Single-Stage Pump ................................................. 20 Figure 2-3: Single-Stage Pump Overview .......................................................................... 21 Two-Stage.................................................................................................................................. 22 Volume (Parallel) Operation....................................................................................................... 22 Figure 2-4: Two-Stage Pump VOLUME Operation............................................................. 22 Figure 2-5: Two-Stage Pump Overview.............................................................................. 23 Pressure (Series) Operation ...................................................................................................... 24 Figure 2-6: Two-Stage Pump PRESSURE Operation ........................................................ 24 Volume vs. Pressure Operation ................................................................................................. 24 Transfer Valve............................................................................................................................ 25 Choosing Volume or Pressure Operation .................................................................................. 25 General Guidelines .................................................................................................................... 25
2.3 Muscle Pump Components ............................................................................................. 26
Pump Body ....................................................................................................................................... 26 Qmax, Qmid, and Qtwo Pumps ................................................................................................. 26 Figure 2-7: Typical Midship Two-Stage Centrifugal Pump ................................................. 27 Qpak, Qflo and Qflo-Plus Pumps ............................................................................................... 27
Impeller ............................................................................................................................................. 27 Figure 2-8: Impeller Operation............................................................................................ 28
Clearance Rings ............................................................................................................................... 28
2.4 Pump Seals ....................................................................................................................... 28
Packing Seals ................................................................................................................................... 29 Figure 2-9: Pump Packing Seal Assembly ......................................................................... 29
Mechanical Seal ............................................................................................................................... 30 Figure 2-10: Mechanical Seal Assembly ............................................................................ 30
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Auto Lube ®...................................................................................................................................... 31 Figure 2-11: AutoLube Feature........................................................................................... 31
2.5 Pump Drives ..................................................................................................................... 31
Table 2-1: Pump vs. Gearbox / Gear Ratio Comparison ....................................................32
2.6 Gearbox ............................................................................................................................ 32
Figure 2-12: Typical Gearbox Overview ............................................................................. 33 A-Series ............................................................................................................................................ 33 G-Series............................................................................................................................................ 34 K-Series ............................................................................................................................................ 34 J-Series............................................................................................................................................. 34 R-Series ............................................................................................................................................ 34 Power Shift - Optional ....................................................................................................................... 34 Engine Rotation Option - Qmax-U and Qtwo-U ................................................................................ 34
Figure 2-13: Pump/Engine Rotation ................................................................................... 35 HALE Power Takeoff (PTO) Driven Midship Pumps......................................................................... 35
2.7 Serial Number Identification ........................................................................................... 35
Figure 2-14: Typical Midship Pump Serial Number Location.............................................. 36
3 Accessories / Options .............................................................................................37
3.1 Anodes .............................................................................................................................. 37
Figure 3-1: Hale 1-1/4" NPT Anode .................................................................................... 37
3.2 Auxiliary Cooling.............................................................................................................. 38
Heat Exchanger, "K" Series .............................................................................................................. 38 Figure 3-2: Model "K" Heat Exchanger ............................................................................... 38
3.3 Pressure and Relief Valve Control ................................................................................. 39
Relief Valve System.......................................................................................................................... 39 Figure 3-3: PMD Series Relief Valve Control (Shown) ....................................................... 39
Thermal Relief Valves (TRV) ............................................................................................................ 39 Figure 3-4: Thermal Relief Valve, TRV............................................................................... 40
TRV-L Kit.................................................................................................................................... 40
3.4 Priming Systems .............................................................................................................. 41
Figure 3-5: Rotary Vane ESP Priming Pump...................................................................... 41 Priming Valves .................................................................................................................................. 41
Figure 3-6: SPVR Priming Valve (Shown) .......................................................................... 42 Figure 3-7: PVG Priming Valves......................................................................................... 42
3.5 Pump Shift, Automatic (VPS / KPS)................................................................................ 42
Figure 3-8: Automatic Pump Shift Overview....................................................................... 43 Figure 3-9: Pump Shift Control Valve ................................................................................. 43
3.6 Torrent SVS Valves .......................................................................................................... 44
Figure 3-10: Typical SVS Valve Primary Components ...................................................... 44
3.7 Additional Midship Accessories..................................................................................... 44
Auxiliary Heat Exchanger / Cooler, Model K..................................................................................... 44 Figure 3-11: Model "K" Heat Exchanger ............................................................................. 45
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Booster Pump Option, 2HP .............................................................................................................. 45 Figure 3-12: 2HP Booster Pump Option ............................................................................ 45
In-Line / Discharge Valves ............................................................................................................... 45 Drain Valves ..................................................................................................................................... 46 Suction Valves.................................................................................................................................. 46
Figure 3-13: Master Intake Valve (MIV) ............................................................................. 47 Tank Suction Valves......................................................................................................................... 47 Total Pressure Master (TPM) Relief Valve System .......................................................................... 47
Figure 3-14: Hale (TPM) Total Pressure Master Relief Valve System ............................... 48 How the TPM Works.................................................................................................................. 48
Figure 3-15: Typical TPM Relief Valve System, Condition 1 ............................................. 50 Figure 3-16: Typical TPM Relief Valve System, Condition 2 ............................................. 51 Figure 3-17: Typical TPM Relief Valve System, Condition 3 ............................................. 52
4 Basic Operation ..................................................................................................... 53
4.1 Overview ........................................................................................................................... 53 4.2 Fluid Levels ...................................................................................................................... 54 4.3 Stationary Pumping Operations ..................................................................................... 54
Pumping From a Hydrant, General Operation.................................................................................. 54 Figure 4-1: Driver's Compartment Indicator Lights ............................................................ 55 Figure 4-2: Pump Operator's Panel ................................................................................... 56
TPM Operation from a Hydrant ........................................................................................................ 57 Draft Limiting Factors ....................................................................................................................... 57 Pumping From Draft ......................................................................................................................... 58 Pumping from On Board Water Tank (Split-Shaft PTO)................................................................... 60
4.4 Pumping In Relay ............................................................................................................. 62
Relay Procedures............................................................................................................................. 62
4.5 Tandem (Series) Pumping............................................................................................... 64
Tandem Procedures......................................................................................................................... 64
4.6 Pump-To-Road Shift Procedures.................................................................................... 65 4.7 Pump and Roll .................................................................................................................. 65 4.8 Relief Valve Procedures .................................................................................................. 66
Standard Relief Valve Procedures ................................................................................................... 66 TPM Relief Valve Procedures .......................................................................................................... 66
Figure 4-3: TPM / PMD Relief Valve Control ..................................................................... 67 TPM System with Engine Governor ................................................................................................. 67
Increasing Pressure................................................................................................................... 68 Decreasing Pressure ................................................................................................................. 68
4.9 Emergency Pump Shift Procedures ............................................................................... 69 4.10 Post Operation Procedures............................................................................................. 69
5 Preventive Maintenance........................................................................................ 71
5.1 Overview ........................................................................................................................... 71
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5.2 Post Operation ................................................................................................................. 71 5.3 Extreme Conditions ......................................................................................................... 71
During Freezing Weather.................................................................................................................. 71 Pumping Salt Water, Contaminated Water, or Foam Solution ................................................... 72
5.4 Weekly............................................................................................................................... 72
Relief Valve and TPM Test ............................................................................................................... 73 Governor Test ................................................................................................................................... 73 Transfer Valve Test (Two-Stage Pumps Only) ................................................................................. 73 Priming System Test......................................................................................................................... 74 Pump Shift Warning Lights ............................................................................................................... 74 Valve Maintenance ........................................................................................................................... 74 Intake Strainers................................................................................................................................. 75 Verify All Gauges are in Working Order............................................................................................ 75 Operate Pump Controls .................................................................................................................... 75 Inspect Water and Foam Tanks........................................................................................................ 75 Check Auxiliary Engine ..................................................................................................................... 75
5.5 Monthly ............................................................................................................................. 75
Valve Lubrication .............................................................................................................................. 76 Suction Check Valve Testing, Two-Stage Pumps ............................................................................ 76 Gearbox Lubrication ......................................................................................................................... 76 Packing Gland Adjustment ............................................................................................................... 77
Adjustment ................................................................................................................................. 77 Pump, Drive Line and Flange Bolts .................................................................................................. 77 Priming System Test (Dry Vacuum Test)..........................................................................................78
Figure 5-1: Priming Valve Handle....................................................................................... 78
5.6 Annual ............................................................................................................................... 79
Replace Gearbox Oil ........................................................................................................................ 80 Relief Valve System Check .............................................................................................................. 80 Check Drain Lines to Multi-Drain ...................................................................................................... 81 Clean Priming Pump ......................................................................................................................... 81 MIV Relief Valve Test and Adjustment ............................................................................................. 81 Performance Testing Overview ........................................................................................................ 82
Table 5-1: Pump Ratings (GPM / LPM) .............................................................................. 82 Tank-to-Pump Flow Rate Test ................................................................................................... 82 Performance Testing Equipment and Materials................................................................................ 83 Performance Testing ........................................................................................................................ 84 Thermal Relief Valve Test ............................................................................................................... 85
Table 5-2: Maximum Pump Run Time ................................................................................ 85 Repacking the Seal........................................................................................................................... 85
Figure 5-2: Pump Packing Seal Assembly ......................................................................... 86 Worn Clearance Rings and Impeller Hubs........................................................................................ 86 Anode Check .................................................................................................................................... 87
Figure 5-3: Hale 1-1/4" NPT Anode .................................................................................... 87 Figure 5-4: Muscle Pump Service Chart, Part 1 of 3 .......................................................... 88
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Figure 5-5: Muscle Pump Service Chart, Part 2 of 3.......................................................... 89 Figure 5-6: Muscle Pump Service Chart, Part 3 of 3.......................................................... 90
Midship Pump Maintenance Check List............................................................. 91
Recommended "Weekly" Procedures......................................................................................91 Recommended "Annual" Procedures......................................................................................92
6 Troubleshooting..................................................................................................... 93
Table 6-1: Muscle (Midship) Pump Troubleshooting........................................................ 93 PTO Will Not Engage. ...................................................................................................... 93 Pump Will Not Engage. .................................................................................................... 93 Pump Loses Prime or Will Not Prime. .............................................................................. 94 Insufficient Pump Capacity, Single Stage. ....................................................................... 96 Leak at Pump Packing. .................................................................................................... 97 Remote Control Difficult to Operate. ................................................................................ 97 Engine Speeds Too HIGH for Required Capacity or Pressure. ....................................... 98 Cavitation ......................................................................................................................... 99 Relief Valve Does Not Relieve Pressure When Relief Valves are Closed. ...................... 99 Relief Valve Does Not Recover and Return to Original Pressure Setting After Opening Valves............................................................................................................................... 99 Relief Valve Opens When Control Valves are Locked Out. ............................................. 99 Unable to Obtain Proper Setting on Relief Valves. ........................................................ 100 Discharge Valves Are Difficult to Operate. ..................................................................... 100 Water/Moisture in Pump Gearbox. ................................................................................. 101 Rotation Symptoms. ....................................................................................................... 101
7 Repair and Corrective Maintenance ................................................................. 103
7.1 Overview ......................................................................................................................... 103 7.2 General Repair Guidelines ............................................................................................ 103
Before You Begin... ........................................................................................................................ 103 Table 7-1: Typical Torque Values Chart .......................................................................... 105
Remove the Gearbox Assembly..................................................................................................... 105
7.3 Cleaning and Inspection Guidelines ............................................................................ 106
Bearings ......................................................................................................................................... 106 Tools Required ............................................................................................................................... 107
7.4 Removing the Pump Assembly .................................................................................... 108
Figure 7-1: Typical Muscle (Midship) Pump Overview ..................................................... 108 Figure 7-2: Lifting Eyebolt Attachment Layout ................................................................. 109 Installing the Assembly to the Apparatus ....................................................................................... 110
7.5 Removing the Gearbox.................................................................................................. 110
G Series Gearbox........................................................................................................................... 110 Figure 7-3: Typical G Series Gearbox Removal .............................................................. 111
Removal - G Series ................................................................................................................. 111 Installation - G Series .............................................................................................................. 112
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J Series Gearbox ............................................................................................................................112 Removal - J Series...................................................................................................................112 Figure 7-4: Typical J Series Gearbox Removal ................................................................113 Installation - J Series................................................................................................................113
K Series Gearbox ...........................................................................................................................114 Removal - K Series ..................................................................................................................114 Installation - K Series ...............................................................................................................115
7.6 QMID/QMAX/QTWO AutoLube ® Service .................................................................... 115
Figure 7-5: AutoLube Assembly Overview .......................................................................116
7.7 Impeller Assembly ......................................................................................................... 118
QMID/QMAX/QTWO Removing Impeller and Clearance Rings .....................................................118 Figure 7-6: Qmax / Qtwo Assembly Overview..................................................................119
Disassembly - QMAX/QMID Single-Stage Pump ...........................................................................120 Assembly - QMAX/QMID Single-Stage Pump ................................................................................121 Disassembly - QTWO Two-Stage Pump ........................................................................................122 Assembly - QTWO Two-Stage Pump .............................................................................................123 Inspection Clearance Rings .........................................................................................................124
Figure 7-7: Clearance Ring and Impeller ID / OD Measurement......................................124 Installing the Impeller and Clearance Rings ...................................................................................125
8 Packing and Mechanical Seal Maintenance......................................................127
8.1 Packing Seal Replacement............................................................................................ 127
Figure 8-1: Pump Packing Seal Overview ........................................................................127 Figure 8-2: Packing / Mechanical Seal Assembly Overview.............................................128
8.2 Mechanical Seal Replacement ...................................................................................... 129
Qmax and Qtwo Pumps with G Series Gearbox.............................................................................129 Figure 8-3: Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview......................130
Removing the Seal...................................................................................................................130 Figure 8-4: Mechanical Seal Overview / Replacement.....................................................131
Installing the Seal.....................................................................................................................132 Qmax and Qtwo Pumps with K Series Gearbox .............................................................................134
Removing the Seal...................................................................................................................134 Figure 8-5: QmaxK and QtwoK Mechanical Seal Assembly Overview.............................135 Figure 8-6: Mechanical Seal Overview / Replacement.....................................................135
Installing the Seal.....................................................................................................................136 Impeller Assembly and Mechanical Seal Qflo, Qflo-Plus and Qpak Pump.....................................138
Removing the Mechanical Seal................................................................................................138 Figure 8-7: Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview .......................139 Figure 8-8: Mechanical Seal Overview / Replacement.....................................................140
Installing the Seal ...........................................................................................................................140 K-Gearbox Mechanical Seal ...........................................................................................................142
Figure 8-9: Housing on shaft ............................................................................................143 Figure 8-10: Retaining ring ...............................................................................................143 Figure 8-11: Seal seat into cover......................................................................................144
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Figure 8-12: Pump shaft gear and top space installed..................................................... 145 Figure 8-13: Install bearing lock nut ................................................................................. 146
9 Gearbox Maintenance......................................................................................... 149
9.1 G Series Gearbox Maintenance .................................................................................... 149
Disassembly ................................................................................................................................... 149 Intermediate and Sliding Gear Shaft Assemblies .................................................................... 149 Figure 9-1: Intermediate Shaft and Sliding Gear, Typical G Series Gearbox .................. 149 Tail Shaft Assembly ................................................................................................................. 150 Figure 9-2: Tail Shaft Assembly ....................................................................................... 150 Power Gearshift Assembly ...................................................................................................... 151 Figure 9-3: Power Gearshift Assembly ............................................................................ 152 Sliding Gear and Fork.............................................................................................................. 152 PTO Drive Option, Qflo / Qflo Plus / Qpak Series Pump ......................................................... 153 Figure 9-4: PTO Drive Option .......................................................................................... 154
Assembly........................................................................................................................................ 154 Gearshift Cap........................................................................................................................... 154 Sliding Gear Assembly ............................................................................................................ 154 Tail Shaft and Gear Shift Assemblies ...................................................................................... 155 PTO Drive Option .................................................................................................................... 156 Intermediate Shaft Assembly................................................................................................... 156
9.2 J Series Gearbox Maintenance ..................................................................................... 157
Disassembly ................................................................................................................................... 157 Idler Shaft Disassembly ........................................................................................................... 157 Figure 9-5: Typical J Series Gearbox Assembly .............................................................. 158 Input Shaft Disassembly .......................................................................................................... 159
Assembly and Installation............................................................................................................... 159 Input Shaft Assembly............................................................................................................... 159 Idler Shaft Assembly................................................................................................................ 160
9.3 K Series Gearbox Maintenance .................................................................................... 161
Oil seals (Input/Tail Shafts) ............................................................................................................ 161 Figure 9-6: Oil Seal Replacement .................................................................................... 161
Tail Shaft Assembly........................................................................................................................ 162 Figure 9-7: Tail Shaft Assembly ....................................................................................... 162
Removal And Disassembly...................................................................................................... 162 Inspection ................................................................................................................................ 163 Reassembly and Installation.................................................................................................... 163
Figure 9-8: Shaft End Gap ............................................................................................... 164 Input Shaft ...................................................................................................................................... 165
Figure 9-9: Input Shaft Assembly ..................................................................................... 165 Removal and Disassembly ...................................................................................................... 165 Inspection ................................................................................................................................ 166 Reassembly and Installation.................................................................................................... 166 KPS Power Shift Assembly ............................................................................................................ 167
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Figure 9-10: KPS Shift Cylinder Assembly .......................................................................167 Removal ...................................................................................................................................167 Installation ................................................................................................................................168 KPS Shift CAP and Switch .............................................................................................................169
Figure 9-11: KPS Shift Cap Assembly..............................................................................169 Removal ...................................................................................................................................169 Installation ................................................................................................................................169 Gear Shift Fork ...............................................................................................................................170 Removal ...................................................................................................................................170 Installation ................................................................................................................................170 Idler Shaft.................................................................................................................................171
Figure 9-12: Idler Shaft Assembly ....................................................................................171 Removal ...................................................................................................................................171 Inspection ................................................................................................................................. 172 Installation ................................................................................................................................172
10 Installation............................................................................................................173
10.1 Overview ......................................................................................................................... 173 10.2 Mounting ......................................................................................................................... 173
Mounting Holes ...............................................................................................................................173 Figure 7-1: Lifting Eyebolt Attachment Layout..................................................................174
10.3 Driveline Issues.............................................................................................................. 175
Drive Line and Flange Bolts............................................................................................................175 Issues .............................................................................................................................................175
Table 10-1: Maximum Recommended Driveline Lengths.................................................176
10.4 Plumbing Connections .................................................................................................. 177 10.5 Panel Mounted Accessories ......................................................................................... 177 10.6 Fluid Levels .................................................................................................................... 177
Appendix A: Glossary.................................................................................................179
Appendix B: Measurements and Conversions .........................................................183
Table B-1: Conversion Chart ............................................................................................183
Appendix C: Alternate Lubricant Manufacturers...................................................185
Table C-1: Alternate Lubricant Manufacturers..................................................................185
Appendix D: Lube and Sealant Specifications ........................................................187
Table D-1: Oil Capacity and Recommendation ................................................................187 Grease ............................................................................................................................................188 Loctite Sealant ................................................................................................................................188 Oil ...................................................................................................................................................188 Recommended Cleaners ................................................................................................................188
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Appendix E: Hose Friction Loss ............................................................................... 189
Table E-1: Hose Friction Loss (PSI (kPa) / 100 Feet) ...................................................... 189
Appendix F: Nozzle Size vs. Pressure ....................................................................... 191
Table F-1: Nozzle Flow and Pressure Ratings (Part 1).................................................... 191 Table F-2: Nozzle Flow and Pressure Ratings (Part 2).................................................... 192
Appendix G: Cavitation.............................................................................................. 193
Figure G-1: Sample, Cavitation Regions.......................................................................... 193
G.1 Process of Cavitation .................................................................................................... 193 G.2 Warning Signs of Cavitation (Discharge and Gauges)............................................... 194
Discharge Pressure........................................................................................................................ 194 Vacuum Compound Gauge............................................................................................................ 194
G.3 Eliminating Cavitation ................................................................................................... 194
During Operations .......................................................................................................................... 195 Table G-1: Lift Loss from Elevation .................................................................................. 195 Table G-2: Lift Loss from Temperature ............................................................................ 195 Table G-3: Lift Loss from Barometric Reading ................................................................. 196
Preventive Measures...................................................................................................................... 196 Table G-4: Hose Size vs. Pump Rating Capacity ............................................................ 196
Strainers ......................................................................................................................................... 197
Appendix H: Midship Flow Rates.............................................................................. 199
Table F-1: Midship Flow Rates ........................................................................................ 199
Appendix I: General Gearbox Inspection................................................................... 201
Express Warranty ............................................................................................... 206
Drawing Package ....................................................................................................... 208
Part 2 (Section 8) ........................................................................................................ 208
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Safety Precautions
1 Safety Precautions
IMPORTANT!
HALE PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL.
ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDERSTOOD AND STRICTLY ADHERED TO BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE PUMP. WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCEDURES, 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.
1.1 DEFINITIONS
DANGER!
DANGER - IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH IF THE WARNING IS IGNORED.
WARNING!
WARNING - HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH IF THE WARNING IS IGNORED.
CAUTION!
CAUTION - HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR OR MODERATE PERSONAL INJURY IF THE WARNING IS IGNORED.
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Safety Precautions
IMPORTANT!
IMPORTANT - PRACTICES WHICH COULD RESULT IN DAMAGE TO THE APPARATUS OR OTHER PROPERTY.
1.2 GUIDELINES
IMPORTANT!
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES, OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED IN THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS (TO PREVENT ANY MOVEMENT OF THE APPARATUS), AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
ALL FASTENERS ON THE HALE PUMP AND GEARBOX ASSEMBLY ARE SELECTED FOR THEIR APPLICATION. HALE PRODUCTS DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTERNATIVE POSES A SERIOUS SAFETY RISK.
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC ADHESIVE/ SEALANT, SUCH AS LOCTITE® #242 OR EQUIVALENT.
Use care when removing the pump assembly from its packaging to prevent personal injury and/or damage to the system.
Use all mounting bolt holes provided on the gearbox and/or the pump to support the assembly. See the pump assembly plate drawing, located at the back of this manual, for additional installation information.
Installation should be performed by a trained and qualified installer, such as your authorized Hale representative. Be sure the installer has sufficient knowledge, experience and the proper tools before attempting any installation.
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Safety Precautions
WARNING!
THE HALE PUMP AND GEARBOX ASSEMBLY CAN BE HEAVY AND BULKY. ADDING ACCESSORIES TO THE SYSTEM ALSO INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING FOR THE APPROXIMATE WEIGHT.
BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVERHEAD CRANE, JACKS, CHAINS, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE HALE PUMP AND GEARBOX ASSEMBLY.
The installer is responsible for observing all instructions and safety precautions in his or her daily routine as dictated by regional safety ordinances or departmental procedures.
Fluids - To meet various shipping regulations, oil is drained from the gearbox reservoir prior to shipping from the factory. At installation and before operation, oil must be added to the appropriate levels. (See Section 4, heading " Gearbox Lubrication," on page 76.) See separate documentation provided with the engine and pump and gearbox assemblies for proper fluids to use and quantities required.
DO NOT permanently remove or alter any protective feature, guard or insulating devices, or attempt to operate the system when these guards are removed. Doing so voids the Hale pump warranty. Also see heading "Express Warranty" on page 201.
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.
WARNING!
NO MODIFICATIONS MAY BE MADE TO THE HALE PUMP AND GEARBOX ASSEMBLY WITHOUT PRIOR WRITTEN PERMISSION FROM:
Hale Products, Incorporated
Fire Suppression Division 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone: 800.533.3569 Fax: 800.520.3473 Web: www.haleproducts.com
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Safety Precautions
Rotating drive line parts can cause injury. Be extremely careful that NO part of your body (head, feet, arms, legs, fingers, hair, etc.) is in an area of rotating parts where you could be subject to injury.
Make sure everyone is clear of the apparatus before shifting to the PUMP position. Verify the parking brake is set and the wheels are chocked to prevent any movement of the apparatus.
Make sure proper personal protective equipment is used when operating or servicing the apparatus.
WARNING!
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALLING FORCE (PRESS) FITTED PARTS. WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHEN HANDLING PARTS THAT REQUIRE HEATING FOR INSTALLATION AND/OR REMOVAL. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE OR HAND INJURY.
DO NOT OVERHEAT PARTS CONSTRUCTED OF BRONZE (E.G. IMPELLER). OVERHEATING (PART TURNS RED OR BLUE) CAN WEAKEN THE PART AND IT MUST THEN BE REPLACED.
DO NOT operate the system at pressures higher than the maximum rated pressure. Always use the lowest possible relief valve settings to enhance operator and equipment safety. Also see Section 2 "Introduction" on page 19 for additional information.
Relieve all system pressure, then drain all water from the system before servicing any of its component parts.
Use only pipe, hose and fittings which are rated at or above the maximum pressure rating at which the water pump system operates.
Per NFPA 1962 requirements, large diameter hose, marked "supply Hose 3-1/2" to 5" (89 - 127 mm) diameter" shall not be used at operating pressures exceeding 185 PSI (1,276 kPa). Large diameter hose, marked "Supply Hose 6" (150 mm) diameter" shall not be used at operating pressures exceeding 135 PSI (931 kPa).
If leakage from the drain hole in the pump head is noticed or suspected, the mechanical seal must be inspected and/or replaced.
If a pump is operated without water for extended periods, or without discharging water, it could overheat. This can damage the mechanical seal, impeller or the drive mechanism.
DO NOT attempt to pump until all the GREEN pump indicators in the cab and panel are ON. Also see Section 4 "Basic Operation" on page 53 for additional information.
DO NOT advance the throttle unless the OK TO PUMP indicator is ON. Also see Section 4 "Basic Operation" on page 53 for additional
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Safety Precautions
information. DO NOT leave the cab, after selecting the PUMP mode, until all the GREEN pump
indicators in the cab and panel are ON. Also see Section 4 "Basic Operation" on page 53 for additional information. DO NOT attempt emergency manual shift procedures while the engine is running. Also see Section 4 "Basic Operation" on page 53 for additional information. Never attempt to shift the pump (PUMP-to-ROAD, vise versa) while the apparatus transmission is in gear. Always shift the transmission to NEUTRAL (N) and verify the speedometer is at ZERO (0) before shifting the pump. Also see Section 4 "Basic Operation" on page 53 for additional information. DO NOT reduce the pressure on the INTAKE gauge below zero (0). Serious damage to the water main could result. Some vehicles maintain air on the shift cylinder continuously regardless of transmission setting, and some only have air applied when the vehicle transmission is in NEUTRAL. Use caution when servicing. Use only PAC-EASE Rubber Lubricant Emulsion (or equal) on the rubber mechanical seal parts to ease installation. DO NOT use other lubricant types as damage to the mechanical seal and seat could occur. 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.
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Safety Precautions
NOTES
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Introduction
2 Introduction
2.1 DESCRIPTION
Hale single-stage and two-stage Midship MUSCLE Pumps cover a range of capacities from 750 Gallons Per Minute (GPM) (3,000 Liters Per Minute, LPM) up to 2,250 GPM (9,000 LPM). Hale single and two-stage pumps are designed to mount on the chassis rails of commercial and custom apparatus. The pump is driven from the truck's main driveline.
Various models of the single-stage muscle pumps and one model of the two-stage muscle pump are offered. The use and position on the apparatus determines the model selected as well as the drive unit. Flow capacities (or rates) are shown in Appendix H: "Midship Flow Rates" on page 199, located at the back of this manual.
2.2 PRINCIPLE OF OPERATION
Centrifugal Force
Hale pumps are centrifugal pumps that operate on the principle of centrifugal 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. The velocity at which the water travels from the center directly relates to the diameter of the disk and the speed of rotation.
When water is confined in a closed container, such as the volute (pump body), the velocity of the water is converted to pressure that rises to a level dependent on the speed of rotation.
There are three interrelated factors that regulate the performance of a centrifugal pump:
Figure 2-1: Centrifugal Force - Rotating
Disk
SPEED (RPM) If the speed of rotation increases with flow held constant, fluid pressure increases.
PRESSURE If pressure changes with speed held constant, the flow, measured in gallons or liters per minute (GPM/LPM), changes inversely; if pressure increases, flow decreases. Pressure is measured in pounds per square inch (PSI) or pascals (kPa).
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Introduction
FLOW If the pressure (kPa) is held constant, the flow increases with an increase in the speed of rotation. Flow is measured in the number of gallons of fluid per minute (GPM or LPM) that a pump can deliver when supplied from draft.
A centrifugal pump has the ability to fully utilize any positive suction inlet pressure, reducing the amount of work done by the pump.
For example, if the required discharge pressure is 120 PSI (827 kPa) and the inlet pressure is 45 PSI (310 kPa), the pump must only produce the difference in pressure or 75 PSI (517 kPa). This contributes to improved performance with reduced maintenance. Additionally, decreased maintenance is aided by a centrifugal pump having few moving parts.
Pump Stages
The number of impellers on a common shaft determines the number of pump stages. The Hale single-stage pumps provide the same normal operating and rating test pressures as the Hale two-stage pumps. The two-stage pump provides an additional level of operating pressures if required.
Single-Stage Hale single-stage pumps use a one (1) impeller to develop the required volume and pressure. (See Figure 2-2: "Water Flow, Typical Hale Single-Stage Pump.")
Figure 2-2: Water Flow, Typical Hale Single-Stage Pump
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Introduction
Figure 2-3: Single-Stage Pump Overview
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Introduction
Water enters the suction channels on both sides of the impeller, thereby maintaining axial balance. Dual cutwaters1 on the Qmax and Qmid strip water from the rotating impeller and direct it to the discharge path. Radial hydraulic balance in the Qmax, Qmid, and Qtwo is maintained by the opposed discharge volute cutwaters.
The Qflo, Qflo Plus, and Qpak series pumps utilize an impeller with a single suction channel where water enters. The impeller develops discharge pressure and directs the water to a single cutwater* and then to the discharge valves. The impellers are radially and axially balanced.
Two-Stage
Hale two-stage pumps use two (2) impellers and a transfer valve / switch to develop the required volume and pressure. (See Figure 2-5: "Two-Stage Pump Overview" on page 23.)
Note: The transfer valve is a two-position valve that permits the impellers to be operated in parallel (volume) or series (pressure).
Volume (Parallel) Operation
In Volume operation, the pressure at the pump intake is added to the pressure developed by both impellers, and the amount of water delivered to the discharge is the sum of the flows of the two impellers. (See Figure 2-4: "Two-Stage Pump VOLUME Operation.")
Figure 2-4: Two-Stage Pump VOLUME Operation
1. The cutwater is a wedge that divides the water between the volute (pump body) and the pump discharge.
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Introduction
Figure 2-5: Two-Stage Pump Overview
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Introduction
For example, if the inlet pressure is 30 PSI (207 kPa) and the flow of each impeller is 500 GPM (1,892 LPM) at 150 PSI (1034 kPa), the pressure and volume at the discharge is: 180 PSI (1241 kPa).
Pressure (Series) Operation For Pressure operation the impellers are connected in series. The output of the impeller supplied from the pump intake is added to the input of the next impeller. (See Figure 2-6: "Two-Stage Pump PRESSURE Operation.").
Figure 2-6: Two-Stage Pump PRESSURE Operation
The pressure at the pump discharge is the sum of the pressure of the two impellers, plus the pressure of the intake. The amount of water delivered to the discharge is the same amount that entered the first impeller. Using the preceding example, when in series operation, the discharge pressure is 330 PSI, (2275 kPa) and the discharge volume is 500 GPM (1,892 LPM)
Volume vs. Pressure Operation
Selection of volume versus pressure operation is determined by three factors:
Generally, the pump should be operated so that the it provides the desired performance at the LOWEST engine speed.
Set to VOLUME (parallel) operation for higher flows. (See Figure 2-4: "Two-Stage Pump VOLUME Operation" on page 22.)
Set to PRESSURE (series) operation when higher water pressures are required. (See Figure 2-6: "Two-Stage Pump PRESSURE Operation" on page 24.)
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Introduction
Transfer Valve
A transfer valve, controlled from the apparatus pump control panel, allows the operator to select VOLUME or PRESSURE operations.
The valve transfers between pumping modes with two and one-half turns of its control hand wheel. The position of the valve is indicated on the apparatus pump control panel via a positive mechanical indicator. As an option, Hale also offers a power transfer valve.
Choosing Volume or Pressure Operation
In deciding which range to use (pressure or volume), choose the one that provides the desired flow and pressure at the LOWEST engine speed.
IMPORTANT!
REFER TO YOUR FIRE DEPARTMENT POLICY FOR WHEN TO USE "VOLUME" OR "PRESSURE" OPERATIONS. IF YOUR FIRE DEPARTMENT DOES NOT HAVE A POLICY, REFER TO THE FOLLOWING HEADING, "GENERAL GUIDELINES."
General Guidelines
1. Hale pumps are designed to pump up to 200 PSI (1379 kPa) net pressure in volume operation and at reasonable engine speeds.
2. The pump should be operated so that engine speed is within its best operating range.
3. Generally, volume operation should be used at any net pump pressure under 150 PSI (1034 kPa), especially when pumping from a hydrant.
4. When pumping from draft or a water tank, pressure operation may be used when the volume is less that one-half the pump capacity and when the desired pressure is over 150 PSI (1034 kPa).
5. Set to VOLUME operation if the pump has to discharge more than 50 percent of its rated capacity. Be certain to warn everyone involved before switching between volume and pressure operation.
6. Reduce the pump pressure to between 50 to 60 PSI (345 to 414 kPa) before switching. The engine speed should especially be reduced when switching from volume to pressure operation with hand held hoses in use.
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Introduction
Note: When shifting the transfer valve from volume to pressure, pressure (PSI / kPa) is doubled. You may hear a metallic click indicating as the check valve closes. If the clicking is too loud or somewhat violent, the pumping pressure is too HIGH for switching. Ease back on the engine throttle to reduce IDLE speed.
2.3 MUSCLE PUMP COMPONENTS
Hale muscle pumps are manifolded-type pumps. The pump volute, suction manifolding, and discharge manifolding are cast as one piece to simplify installation. (See Figure 2-7: "Typical Midship Two-Stage Centrifugal Pump" on page 27.)
Pump Body
The standard pump body and related parts are constructed from fine grain alloy cast iron, with a minimum tensile strength of 30,000 PSI (207 N/mm²). All moving parts subject to water contact. A bronze body, for use with saltwater or harsh water applications, is also available. Qmax, Qmid, and Qtwo Pumps The Qmax, Qmid, and Qtwo pump body is split horizontally on a single plane in two sections for easy removal of the impeller assembly, including clearance rings and bearings. The impeller assembly is removed from the bottom of the pump to avoid interference with the surrounding piping and pump mounting on the apparatus chassis. (See Figure 2-7: "Typical Midship Two-Stage Centrifugal Pump" on page 27.) Two tank suction valve locations are available to allow higher flows from the booster tank. Optional built-in check valves are available to prevent tank over-pressurization. Both pumps include two large suction inlets on the left and right side. Optionally, additional front and rear inlets may be added as needed. Impeller inlets are on opposite sides of the pump to balance axial forces; discharges are on opposite sides to balance radial forces.
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Introduction
Figure 2-7: Typical Midship Two-Stage Centrifugal Pump
Qpak, Qflo and Qflo-Plus Pumps
The pump bodies are a single piece construction. To avoid disturbing discharge or suction piping, the gearbox and rear pump head / bearing housing must be removed to service the impeller, clearance rings and mechanical seal.
The pumps include two large suction inlets on the left and right sides. The incoming water is directed to the impeller through the suction passages.
A tank suction valve opening, located on the rear of the pump, allows for high flows from the booster tank. An optional built-in check valve is available to prevent tank over-pressurization.
Discharge valves in the basic pump configuration are mounted at either side of the pump body. However, the manifolded pump body provides several additional discharge locations (facing front, back, or up) to accommodate additional discharge valves.
Impeller
The impeller provides velocity to the water. Water enters the rotating impeller at the intake (or eye), and is confined by the shrouds and the vanes to build pressure. (See Figure 2-8: "Impeller Operation" on page 28.)
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Introduction
The vanes guide water from the inlet to the discharge and reduce the turbulence of the spinning water.
Figure 2-8: Impeller Operation
As water discharges from the impeller, it enters the volute (pump body). The volute increases in size from the cutwater to its full capacity at the volute throat.
This gradual increase maintains a constant average velocity through the volute. Figure 2-8: "Impeller Operation," traces a drop of water from the intake of the impeller to the discharge outlet.
Clearance Rings
Clearance rings prevent pressurized water that is leaving the pump volute from returning to the intake of the impeller. Clearance rings at the impeller intake also prevent leakage, accomplished by limiting the radial clearance between the spinning impeller and the stationary clearance ring. Also see Figure 2-7: "Typical Midship Two-Stage Centrifugal Pump" on page 27.
Typically, a new clearance ring has a radial clearance of about 0.005" (0.127 mm) or a 0.008" (0.203 mm) diameter. However, due to foreign material found in the water, this clearance increases over time as the pump is operated. Clearance rings are designed for replacement when wear limits exceed NFPA satisfactory performance.
2.4 PUMP SEALS
Two types of seals are used - a packing seal or a mechanical seal.
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Introduction
Packing Seals
Packing, available on Qmax, Qmid, and Qtwo pumps, forms a watertight seal at the point where the shaft passes from the inside to the outside of the pump. The packing material is cooled with pump water. (See Figure 2-9: "Pump Packing Seal Assembly.")
Figure 2-9: Pump Packing Seal Assembly
The single packing gland is located on the low-pressure side of the pump. The packing rings are made of a combination of unique materials and have sacrificial zinc separators to protect the pump shaft from galvanic corrosion.
IMPORTANT!
THE PACKING GLAND SHOULD NOT BE OVER TIGHTENED, OR THE MATERIAL WILL LOSE ITS BUILT-IN LUBRICATION AND DRY OUT, WHICH MAY DAMAGE THE PUMP.
PACKING MATERIAL MAY ALSO DETERIORATE IF THE PUMP IS KEPT DRY FOR LONG PERIODS OF TIME (FOR EXAMPLE, TO PREVENT FREEZING). IN THIS CASE, CHARGING THE PUMP WITH WATER AT LEAST ONCE WEEKLY WILL PREVENT DETERIORATION. ALSO SEE SECTION 6 "TROUBLESHOOTING" ON PAGE 93.
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Introduction
Mechanical Seal
The mechanical seal is used on the Qpak, Qflo and Qflo-Plus pumps and is available as an option on the Qmax, Qmid, and Qtwo pumps. (See Figure 2-10: "Mechanical Seal Assembly.")
Figure 2-10: Mechanical Seal Assembly
A stationary seal seat is in constant contact with a rotating carbon face to prevent leakage. The sealing diaphragm is made of a rubber elastomer specifically designed for high-temperature operations. Also see drawing Plate No. 757A, located at the back of this manual, for additional information and a detailed illustration.
WARNING!
IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT COULD OVERHEAT. THIS CAN DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.
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Introduction
Auto Lube ®
A patented centrifugal pump is built into the shaft of Qmax, Qmid, and Qtwo pumps. (See Figure 2-11: "AutoLube Feature.")
This pump continuously forces oil from the reservoir, through the bearing, and back again. A balancing chamber, behind the oil reservoir, maintains the pressure in the oil reservoir equal to water pressure whether you are pumping at high inlet pressure or pulling vacuum.
The pump adds enough extra
pressure to maintain oil flow a
few PSI higher than water pres-
sure. Thus, oil pressure inside
the double lip-type seal is always slightly higher than water
Figure 2-11: AutoLube Feature
pressure outside. Dirt and water are repelled by this higher pressure.
Auto-Lube also ensures continuous lubrication, even when you are pumping dry. A compact, double lip-type oil seal, and maintains a constant film of oil under this seal to prevent shaft wear. AutoLube completely eliminates the need for a second set of packing, or mechanical seals.
2.5 PUMP DRIVES
Midship pumps are normally driven through an integral transmission that has a sliding gear shaft and sliding gear that selectively directs the engine power to the pump or the rear axle.
Four common centrifugal pump drives are used:
Operation from the truck chassis drive shaft (split-shaft gearbox) Also see Table 2-1: "Pump vs. Gearbox / Gear Ratio Comparison" on page 32.
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Table 2-1: Pump vs. Gearbox / Gear Ratio Comparison
Pump GPM (LPM) Stage Integral
Model
Range
s Manifold
Hale Available Gearbox Selection and Ratio
"J"
"L"
"S"
"X"
"LK" &"XK"
Qpak
5001,000 Single
Yes
1:1.64, 1.80, 1:1.58, 1.71,
(2,0003,000)
2.08, 2.35, 1.86, 2.05,
2.57
2.28
1:1.96, 2.13, 2.32, 2.55,
2.83
Qflo
7501,250 Single
Yes
(3,0004,000)
1:1.58, 1.71, 1.86, 2.05,
2.28
1:1.96, 2.13, 2.32, 2.55,
2.83
QfloPlus
7501,250 Single
Yes
(3,0005,000)
1:1.58, 1.71, 1.86, 2.05,
2.28
1:1.96, 2.13, 2.32, 2.55,
2.83
Qmax
1,0002,250 Single
Yes
(4,0008,000)
1:1.58, 1.71, 1:158, 1.71, 1:1.96, 2.13, 1:1.60, 1.71,
1.86, 2.05, 1.86, 2.05, 2.32, 2.55, 1.89, 2.04,
2.28
2.28
2.83
2.30, 2.52
Qmid
1,0001,250 Single
Yes
(4,0005,000)
1:1.58, 1.71, 1:158, 1.71, 1:1.96, 2.13,
1.86, 2.05, 1.86, 2.05, 2.32, 2.55,
2.28
2.28
2.83
Qtwo
1,0002,000 Two
Yes
(4,0007,000)
1:1.58, 1.71, 1:158, 1.71, 1:1.96, 2.13, 1:1.60, 1.71,
1.86, 2.05, 1.86, 2.05, 2.32, 2.55, 1.89, 2.04,
2.28
2.28
2.83
2.30, 2.52
Operation from a separate engine
Operation from the front of the truck chassis engine (front engine PTO) crankshaft
Operation from a PTO from the truck transmission, a PTO before the engine drive transmission or a PTO from the four-wheel drive transfer case.
Note: Also see plate No. 843 "Vehicle Mounted Pump Applications" located at the back of this manual (Section 8: Drawing Package).
The midship transmission is capable of handling full engine horsepower, enabling the pump to meet optimum performance levels as well as all torque requirements for over the road applications.
2.6 GEARBOX
The most common pump drive is the split-shaft gearbox. A variety of pump gear ratios is offered to accommodate a wide range of apparatus manufacturer requirements, based on engine speed and available horsepower. (See Figure 2-12: "Typical Gearbox Overview" on page 33.)
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Typically, the gearbox is constructed of fine grain alloy cast iron, with a minimum tensile strength of 30,000 PSI (207 N/mm2). These units can withstand the full torque of the engine in ROAD operating conditions up to 16,000 pounds-feet (21,693 N-m).
Figure 2-12: Typical Gearbox Overview
A-Series
The Hale A Series Gearbox is a 2-gear unit driven by a PTO and designed for top or rear-mount pump applications. This gearbox has a wide range of ratios available to allow for use on different engine, transmission and PTO combinations. (See Figure 212: "Typical Gearbox Overview.")
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G-Series
The Hale G-Series Split-Shaft Gearbox is available as a short (S), long (L), or extra long (X) model.
The S, L, or X designation indicates different distances from the pump center line / mount location to the center of the drive shaft for proper drive line angles. The location, pump, and drive line angle determine the optimum gearbox length selection.
K-Series
The Hale K-Series Gearbox, is available as a long (LK) or extra long (XK) model. The gearbox is capable of handling the required engine horsepower, enabling the pump to meet optimum performance levels as well as torque requirements for over-the-road applications. The gearbox consists of the housing, helical gear set, and input and output shafts that are made of heat-treated nickel steel. This unit can withstand the full torque of the engine in ROAD operating conditions up to 18,500 pound-feet (25,083 N-m).
J-Series
The Hale J-Series Gearbox, available for the Qpak pump, is an off-set gearbox that allows left-hand or right-hand side PTO hookup. The gearbox is heavy duty and driven from a transmission-mounted PTO allowing for pump and roll applications.
R-Series
The Hale R-Series Split-Shaft Gearbox is similar to the G-Series long (L) model, having a rear-mounted output shaft.
Power Shift - Optional
The power shift system includes an in-cab control valve for mode selection. This control locks in place for pump operation. Indicator lights are provided to alert the operator when the gearbox has fully shifted from ROAD to PUMP position. Additionally, manual shift is provided in the event of a power shift system failure.
Engine Rotation Option - Qmax-U and Qtwo-U
Hale Qmax-U and Qtwo-U midship pumps are available for either engine rotation (clockwise), or opposite engine rotation (counterclockwise) operation. (See Figure 213: "Pump/Engine Rotation" on page 35.)
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Introduction
Figure 2-13: Pump/Engine Rotation
HALE Power Takeoff (PTO) Driven Midship Pumps
Midship pumps feature a 1480 input flange for connection to a PTO driveline.
2.7 SERIAL NUMBER IDENTIFICATION
The midship pump assembly serial number is stamped in three locations on the assembly, dependent on system model. The serial number nameplate is always located on the gearbox, either on the very bottom of the housing or on one of the sides near the bottom. (See Figure 2-14: "Typical Midship Pump Serial Number Location" on page 36.)
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.
Figure 2-14: Typical Midship Pump Serial Number Location
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Accessories / Options
3 Accessories / Options
The following accessories and options are available to complete a system installation:
Anodes Auxiliary Cooling, standard on some equipment Pressure Control Devices (Relief Valves or Governors) Thermal Relief Valve (TRV) Priming Systems Torrent Stainless Steel SVS Valves
3.1 ANODES
The Hale Anode System helps prevent damage caused by galvanic corrosion in the pump. Galvanic corrosion occurs when different conducting materials are connected electrically and exposed to fluid. This results in corrosion of the less resistant of the two metals, while the more resistant metal is protected.
Hale offers two types of anodes:
Zinc anode - recommended for pumps where corrosion is an issue, including brackish or salt water exposure.
Magnesium anode - available for use if the pump already uses zinc anodes and galvanic corrosion is still a concern. Magnesium anodes contain a notch in the hex head for identification.
The Anode kit is designed for installation in the standard Hale 115 series flange
Figure 3-1: Hale 1-1/4" NPT Anode
opening. It is recommended that one anode be installed on each suction manifold and
one on the discharge side. Performance varies with water quality and PH.
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3.2 AUXILIARY COOLING
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.
Note: A valve is normally added at the operator's panel allowing the operator to control the amount of water supplied to the Model "K" heat exchanger. Note: For additional information about the pressure and relief valves in your system, see the separate manual provided with the valves.
Figure 3-2: Model "K" Heat Exchanger
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3.3 PRESSURE AND RELIEF VALVE CONTROL
Relief Valve System
The Hale Standard Relief Valve System consists of a panel mounted control valve (PM) and an internal relief valve, either a QG or a QD.
The relief valve system works as follows: The strainer mounted in the pump discharge pressure tap provides pressure to the diaphragm in the PM Control Valve. The handwheel on the PM control either increases or decreases spring tension on the diaphragm. The seat of the QD or QG relief valve is kept closed by pump discharge pressure.
As pump pressure increases, more pressure is applied to the diaphragm in the PM Control Valve. As the pressure on the diaphragm increases beyond the set point, the stem will move off its seat, allowing pump pressure to push on the piston in the relief valve. The pressure on the piston will cause the relief valve seat to lift, allowing excess discharge pressure to dump back to the pump suction.
The amber indicator light on the PM control illuminates when the relief valve is open.
Thermal Relief Valves (TRV)
Figure 3-3: PMD Series Relief Valve Control (Shown)
Thermal Relief Valves (TRV) protect the pump from overheating. (See Figure 3-4: "Thermal Relief Valve, TRV," on page 40.)
The valve monitors the water temperature in the pump. When temperatures exceed 120°F (49°C), the valve automatically OPENS. When the temperature returns to a safe level, the valve CLOSES.
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Figure 3-4: Thermal Relief Valve, TRV
TRV-L Kit
The TRV-L kit includes a chrome panel placard with a warning light, a light test button, and a pre-assembled wire harness. The RED light illuminates when the TRV is open and discharging water. (See Figure 3-4: "Thermal Relief Valve, TRV.") An optional buzzer, mounted on the operator panel, provides an audible warning.
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3.4 PRIMING SYSTEMS
Hale uses Rotary Vane Positive Displacement ESP pumps for priming. Priming pumps are used to evacuate air in the suction hose and pump.
Figure 3-5: Rotary Vane ESP Priming Pump
The Hale ESP series priming pump is an environmentally friendly primer that does not require a separate lubricant reservoir. The vanes and pump body are self-lubricating for maintenance free operation. An ESP priming pump also uses a single control to open the priming valve and start the priming motor. See separate manual, Hale p/n: 029-0810-01-0, for additional 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 (SPV) A single push button on the operator's panel starts the priming pump motor. When a vacuum is created, the SPV OPENS. (See Figure 3-6: "SPVR Priming Valve (Shown)," on page 42.) Releasing the push button stops the priming pump and the SPV CLOSES.
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Figure 3-6: SPVR Priming Valve (Shown)
The Hale PVG Priming Valve The PVG is a combination valve and switch and is mounted on the pump operator's panel. (See Figure 3-7: "PVG Priming Valves.") Pulling the handle out OPENS the valve and energizes the primer motor. Releasing the handle de-energizes the motor and CLOSES the valve.
Figure 3-7: PVG Priming Valves
3.5 PUMP SHIFT, AUTOMATIC (VPS / KPS)
The Hale Automatic Pump Shift, Models VPS or KPS, is a remote, pneumaticallyoperated device to shift the pump transmission from ROAD-to-PUMP and back again.
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Figure 3-8: Automatic Pump Shift Overview
It uses available apparatus air pressure for power and is activated by an in-cab pump shift control valve. (See Figure 3-9: "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.
Figure 3-9: Pump Shift Control Valve
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3.6 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 throttle the flow rate from a trickle to full flow.
Figure 3-10: Typical SVS Valve Primary Components
Numerous adapters tailor the valve to almost any installation requirement. See separate manual (Hale p/n: 029-0020-90-0) provided for detailed operating and service instructions.
3.7 ADDITIONAL MIDSHIP ACCESSORIES
Auxiliary Heat Exchanger / Cooler, Model K
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.
Note: A valve is normally added at the operator's panel allowing the operator to control the amount of water supplied to the Model "K" heat exchanger.
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Figure 3-11: Model "K" Heat Exchanger
Booster Pump Option, 2HP
Hale 2HP Booster Pumps offer low volume and high pressure for use with the midship pumps. The booster is ideal for high pressure, hose real operation and is designed for direct mounting at the accessory port of the Hale "L" and "X" Series gearboxes.
The pump is driven by the gearbox intermediate gear to provide a positive drive. Water is directed to the booster pump through a pre-piped supply hose.
In-Line / Discharge Valves
In-Line / discharge valves (Torrent SVS Valves) regulate the amount of water flowing through and leaving a pump. Each valve includes a locking device to permits opera-
Figure 3-12: 2HP Booster Pump Option
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tion in any position from fully opened to fully closed. Also see Section 3.6 "Torrent SVS Valves" on page 44.
Each discharge valve may be equipped with a drain. Opening the drain before uncoupling the hose relieves the pressure in the line and drains remaining water from the pump during freezing conditions.
Drain Valves
Various types and styles of manual and automatic drain valves are available, with both single and multiple ports opening.
The screw knob valve (MMD6) can connect up to six individual drain lines. The MMD12 can connect to 12 individual drain lines. Each connection is individual. The control knob is located on the operator's panel. Turning the knob counterclockwise OPENS the drain valve.
Suction Valves
Hale has valves that mount in the suction of the midship pump.
The Hale Master Intake Valve (MIV) becomes an integral part of the fire pump. When the valve is ordered as part of a Hale Midship fire pump, the pump will pass UL requirements up to 1,500 GPM (5,678 LPM) from the draft through a single 6" NST suction hose with the valve in place. When two valves are mounted to the fire pump, the pump can achieve NFPA Performance Point flows of 2,000 GPM (7,580 LPM) from draft with dual 6" NST suction hoses. NFPA Performance Point flows of 2,250 GPM (8,516 LPM) is achieved with two MIVs and three 6" NST suction hoses. The Hale MIV meets NFPA requirements for operations using a large diameter supply hose. (See Figure 3-13: "Master Intake Valve (MIV)," on page 47.) Further information on the MIV can be found in manual P/N 029-0020-35-0.
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Figure 3-13: Master Intake Valve (MIV)
Additional information on the MIV can be found in manual P/N 029-0020-35-0, supplied with the unit.
Tank Suction Valves
Hale offers the Torrent SVS Valve. Also see Section 3.6 "Torrent SVS Valves" on page 44.
Total Pressure Master (TPM) Relief Valve System
The Hale TPM system is a mechanical system, consisting of an internal relief valve (QG) which by-passes water to the suction side of the pump; an external relief (dump) valve (PG30, with sensing valve attached), to discharge water to the atmosphere; and a single panel mounted control valve (PMD), to provide control of pump pressure, within NFPA required limits.
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Figure 3-14: Hale (TPM) Total Pressure Master Relief Valve System
The TPM relief valve system automatically relieves excess pump pressure when operating from draft or positive incoming flows. The system self-restores to the non-relieving position when excessive pressure is no longer present. The PMD control permits the pump operator to "set" a desired pressure for both internal and external relief valves. The panel control has an easy-to-read and easy-to-set adjustment with an approximate pressure setting indication.
How the TPM Works
The TPM system monitors and controls pump pressure and relieves excessive pressure by first utilizing the internal relief valve (QG), thus returning flow to the pump suction.
If excessive pressure remains and there is positive pressure on the suction, a secondary external relief valve (PG30) responds by discharging excessive pressure to the atmosphere.
The staging of the internal and external relief valves to operate in series ensures maximum protection against over pressure and eliminates the indiscriminate discharging of water to the ground.
The external relief valve (PG30) is mounted on the discharge side of the pump. Discharged water flowing through the valve provides a self-cleaning process and nearly
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eliminates the possibility of the valve remaining in an open position due to contamination.
The amber indicator on the PMD control illuminates when the QG relief valve is open. The indicator flashes when both the QG and PG30 valves are open.
For sample TPM system overviews, see the following: Figure 3-15: "Typical TPM Relief Valve System, Condition 1" on page 50
All Relief Valve CLOSED, Pump operating from Draft Figure 3-16: "Typical TPM Relief Valve System, Condition 2" on page 51
QG Relief Valve OPEN, Pump operating from Draft Figure 3-17: "Typical TPM Relief Valve System, Condition 3" on page 52
QG and PG30 Relief Valve OPEN, Pump operating with Positive Suction Pressure (Hydrant)
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Figure 3-15: Typical TPM Relief Valve System, Condition 1
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Figure 3-16: Typical TPM Relief Valve System, Condition 2
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Figure 3-17: Typical TPM Relief Valve System, Condition 3
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4 Basic Operation
WARNING!
THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES. NOT ALL PROCEDURES IN THIS SECTION MAY APPLY TO YOUR SPECIFIC OPERATIONAL REQUIREMENTS. REFER TO ONLY THOSE SECTIONS WHICH APPLY TO YOUR OPERATIONAL REQUIREMENTS.
THESE PROCEDURES DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED IN THE APPARATUS MANUFACTURER'S MANUAL.
ALWAYS REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION FOR OPERATING PROCEDURES, SETTING WHEEL CHOCKS, AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS. ALL VALVES, DRAIN COCKS AND CAPS SHOULD BE CLOSED.
NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRANSMISSION TO NEUTRAL (N) AND VERIFY THE SPEEDOMETER IS AT ZERO (0) BEFORE MAKING A PUMP TRANSMISSION SHIFT.
4.1 OVERVIEW
The instructions provided are for "split-shaft" and "PTO" pump applications:
Fluids - on page 54. Pumping from a hydrant - on page 54. Pumping from draft - on page 58. Pumping from an onboard tank (Split-Shaft PTO) - on page 60. Pumping in relay - on page 62. Tandem (series) pumping - on page 64. Pump and Roll - on page 65. Post-operation procedures - on page 69.
Note: Also refer to NFPA 1901 Regulations for additional information for apparatus splitshaft and PTO requirements.
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4.2 FLUID LEVELS
To meet various shipping regulations, ALL fluids within the pump and gearbox assembly are drained prior to shipping from the factory.
IMPORTANT!
AT INSTALLATION AND BEFORE OPERATING FOR THE FIRST TIME, OIL MUST BE ADDED TO THE GEARBOX TO THE APPROPRIATE LEVEL. FOR THE PROPER OIL TO USE AND QUANTITY REQUIRED, SEE SECTION 4, HEADING "GEARBOX LUBRICATION" ON PAGE 76.
4.3 STATIONARY PUMPING OPERATIONS
Pumping From a Hydrant, General Operation
1. Position the apparatus for the best hydrant hookup and discharge hose layout. 2. Bring the truck to a complete stop, apply the truck parking brake, then shift the
truck transmission to the NEUTRAL position. See WARNING! note on page 53.
3. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP. Also see heading "Pump-To-Road Shift Procedures" on page 65. For PTO operation (Qmax-U, Qtwo-U, and Qpak-J pumps), engage the PTO (power take-off) per the PTO manufacturer's instructions (move the in-cab pump shift control valve to the PUMP position). The GREEN shift warning lights illuminate, indicating a complete shift. (See Figure 4-1: "Driver's Compartment Indicator Lights" on page 55.) For "Split-Shaft" operation, move the in-cab shift control from ROAD to PUMP Position. The Green PUMP ENGAGED indicator light on the panel control will light. Place the truck transmission in the proper pump operating range or gear. For most pumpers, this is direct drive (1:1) ratio. In addition, the speedometer should register after the shift has been completed. If the shift does not complete, then shift the transmission back to NEUTRAL (N) and repeat the entire procedure. Some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not register after shifting to the PUMP position. See the chassis manual for details.
Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
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4. Exit the driving compartment only after all the preceding steps are completed and you are sure the appropriate lights in the cab and panel are ON.
CAUTION!
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL GREEN PUMP LIGHTS IN THE CAB ARE ON.
Figure 4-1: Driver's Compartment Indicator Lights
CAUTION!
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (SEE FIGURE 4-2: "PUMP OPERATOR'S PANEL" ON PAGE 56.)
5. Verify that the pump panel GREEN shift indicator OK TO PUMP light illuminates and that all hose connections are complete. For "Split-Shaft" operation Place the truck transmission in the proper pump operating range or gear. For most pumpers this is direct drive (1:1) ratio. In addition, 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.
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Some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not register after shifting to the PUMP position. See the chassis manual for details.
6. Open the hydrant. Bleed off the air from the suction hose. 7. Open the suction valve to allow water flow into the pump. 8. Open the appropriate valve to expel air or prime the pump, if so equipped. Also
see heading "Pumping From Draft" on page 58.
Figure 4-2: Pump Operator's Panel
9. Note the discharge and intake pressures, then gradually open the engine throttle until the master discharge gauge indicates the desired pressure.
10. Set the automatic relief valve according to your fire department policy, if so equipped. If your fire department does not have a policy, see heading "TPM Operation from a Hydrant" on page 57.
CAUTION!
DO NOT REDUCE THE PRESSURE ON THE INTAKE GAUGE BELOW DEPARTMENT LIMITS. SERIOUS DAMAGE TO THE WATER MAIN COULD RESULT.
11. If the master intake gauge shows a vacuum before the desired discharge pressure or flow is achieved, you are receiving all the water that the suction piping (hydrant) can supply.
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12. If you need to increase pressure when this occurs, pump flow must be reduced or the water supply improved.
To increase pressure, reduce the pump flow. However, the master intake gauge reading must be maintained at 5 PSI (34 kPa), minimum.
13. As the throttle (engine speed) is increased, the pressure gauge reading increases.
14. Close the throttle slowly until the pressure begins to stabilize and track with engine speed. If this does not correct the problem, you may be pumping more capacity than is available from the supply. Also check the inlet strainers for possible blockage.
15. 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.
16. When pumping operations are completed, gradually reduce the pump pressure until the engine returns to IDLE speed. See heading "Pumping From Draft" on page 58. Disengage the PTO per the PTO manufacturer's instructions. Also see heading "Pump-To-Road Shift Procedures" on page 65.
TPM Operation from a Hydrant
When operating from a positive inlet pressure, it may be necessary to adjust the TPM relief valve to a point where water is dumping to the ground.
The internal relief valve is always opened first, and if it cannot handle the pressure rise, the external relief valve dumps water on the ground. When the internal relief valve opens, the panel light illuminates, and when the external dump valve opens, the light on the panel FLASHES.
Draft Limiting Factors
The effect of raised water temperatures when pumping from a positive pressure source (i.e., a hydrant) is negligible on fire pump performance. However, when pumping from draft (static source such as a pond, lake or basin), elevated water temperature does have a limiting effect.
Water temperatures above 95°F (35°C) cause a noticeable decrease in lift when drafting. Also see Table G-2: "Lift Loss from Temperature" on page 195.
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Barometric pressures below 29" Hg. can also limit lift when drafting. High elevations and storm conditions can affect maximum flow available from any pump. Also see Table G-3: "Lift Loss from Barometric Reading" on page 196.
Pumping From Draft
1. Position the apparatus as close to the water source as practical. The pump can draw 100% of its rated capacity with a 10 ft (3 m) vertical lift and 20 feet (6 meters) of suction hose.
2. As the vertical lift increases to above 10 ft (3 m), pump capacity is reduced. Also see Table G-1: "Lift Loss from Elevation" on page 195.
3. Bring the truck to a complete stop, apply the truck parking brake, shift the truck transmission to the NEUTRAL position. See WARNING! note on page 53.
4. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP. Also see heading "Pump-To-Road Shift Procedures" on page 65.
5. Engage the PTO (power take-off) per the PTO manufacturer's instructions (move the in-cab pump shift control valve to the PUMP position). The GREEN shift warning lights illuminate, indicating a complete shift. (See Figure 4-1: "Driver's Compartment Indicator Lights" on page 55.)
Note: If the truck manufacturer uses another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
CAUTION!
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB ARE ON.
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (SEE FIGURE 4-2: "PUMP OPERATOR'S PANEL" ON PAGE 56.)
6. Exit the driving compartment only after all the above steps are completed and you are sure that the appropriate lights in the cab and panel are ON.
7. Verify that the pump panel GREEN shift indicator OK TO PUMP light illuminates and that all hose connections are complete. For "Split-Shaft" operation Place the truck transmission in the proper pump operating range or gear. 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.
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Some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not register after shifting to the pump position. See the chassis manual for details.
8. Activate the priming pump - pull the control handle, or press the push button. 9. Your departmental manual for pumping should specify the correct RPM for prim-
ing. However, in general, priming should be operated at IDLE. 10. Running the engine at speeds higher than 1,200 RPM during priming is not rec-
ommended. It does not improve the priming operation but can cause damage to the pump.
CAUTION!
IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO (0), OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND WITHIN 30 TO 45 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
STOP THE PUMP AND CHECK FOR AIR LEAKS OR POSSIBLE PROBLEMS. SEE SECTION 6 "TROUBLESHOOTING," ON PAGE 93.
11. Monitor the intake and discharge master gauges. When the pump is primed, the intake reading falls below zero (0), and the discharge pressure starts to increase. You may also hear water splashing on the ground, indicating the pump is primed.
12. Gradually open the discharge valve until water emerges in a steady stream. Then open the other discharge valves to the desired setting.
13. Gradually open the engine throttle until the desired pressure or flow is achieved.
CAUTION!
DO NOT CAUSE A WHIRLPOOL AT THE STRAINER. THIS ALLOWS AIR INTO THE PUMP, CAUSING ROUGH OPERATION AND PULSATION. REPOSITION THE STRAINER OR REDUCE FLOW.
14. As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating.
15. If the pump is cavitating, warn personnel that the flow is being REDUCED. Close the throttle slowly until you operate without cavitation. The following can also lead to cavitation: Large nozzle tips - Use a smaller nozzle to reduce flow.
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Air enters with the water - Air leaks can cause rough operation and an increase in engine speed without an increase in pressure or flow. If an air leak is suspected, discontinue pumping. See heading "Troubleshooting" on page 93.
Hot water - See heading "Lift Loss from Temperature" on page 195. Low barometer - See heading "Lift Loss from Barometric Reading" on page
196. High lift - see Table G-1: "Lift Loss from Elevation" on page 195.
Note: Also see Section Appendix G: "Cavitation" on page 193.
16. If a pump shutdown is desired while pumping from draft, reduce the engine speed to IDLE and close the discharge valves.
17. To resume pumping, open the throttle and discharge valves. If the pump overheats from continued churning without water flow, open the discharge valves periodically to release hot water.
18. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy, see heading "TPM Operation from a Hydrant" on page 57.
19. 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.
20. After completion of pumping procedures, gradually reduce the engine RPM to IDLE speed. See heading "Pump-To-Road Shift Procedures" on page 65. Disengage the PTO per the PTO manufacturer's instructions. Also see heading "Post Operation Procedures" on page 69.
Pumping from On Board Water Tank (Split-Shaft PTO)
1. Position the truck for the best hydrant hookup and discharge hose layout.
2. Bring the truck to a complete stop, apply the truck parking brake, shift the truck transmission to the NEUTRAL position. See WARNING! note on page 53.
3. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP.
4. Move the in-cab pump shift control valve to the PUMP position. The shift warning lights illuminate, indicating a complete shift. (See Figure 4-1: "Driver's Compartment Indicator Lights" on page 55.)
Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
5. Exit the driving compartment only after all the above steps are completed and you are sure that the shift completed lights in the cab and panel are ON.
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6. Verify that the pump panel shift indicator OK TO PUMP green light is ON and that all hose connections are complete.
CAUTION!
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ON.
DO NOT OPEN THROTTLE UNLESS ALL GREEN PUMP INDICATOR LIGHTS ARE ON. (SEE FIGURE 4-2: "PUMP OPERATOR'S PANEL" ON PAGE 56.)
7. Open the tank suction valve. 8. Check the master discharge gauge to see if priming is necessary. Start the prim-
ing pump - pull the control handle or press the prime push button.
CAUTION!
IF DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO, OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND WITHIN 30 TO 45 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
STOP THE PUMP AND CHECK FOR AIR LEAKS OR POSSIBLE PROBLEMS. SEE SECTION 6 "TROUBLESHOOTING," ON PAGE 93.
9. Gradually open the engine throttle until the desired pressure or flow is achieved. 10. As the throttle is opened, the pressure gauge reading increases with the engine
speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. Also see Section Appendix G: "Cavitation" on page 193. 11. If the pump is cavitating, warn personnel.
WARNING!
DO NOT OPEN THROTTLE UNTIL ALL GREEN PUMP LIGHTS ARE ON. (SEE FIGURE 42: "PUMP OPERATOR'S PANEL" ON PAGE 56.)
12. Gradually open the discharge valve until the water emerges as a steady stream. Then open the other discharge valves to the desired setting.
13. Set the automatic relief valve or governor according to your fire department policy (or the separate governor manual).
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If your fire department does not have a policy, see heading "TPM Operation from a Hydrant" on page 57. 14. 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. 15. After completion of pumping procedures, gradually reduce the engine RPM until it is at an IDLE speed. See heading "Pump-To-Road Shift Procedures" on page 65. Disengage the PTO per the PTO manufacturer's instructions. Also see heading "Post Operation Procedures" on page 69.
4.4 PUMPING IN RELAY
Relay pumping is the movement of water through a number of consecutive pumpers, from suction to discharge. Relay operations are necessary when the water source is too far away from the fire to be pumped efficiently by one pumper. The number of pumpers is determined by how far the water source is from the fire.
In some cases, when you are on the receiving end of a relay, it may help to set the suction dump or TPM (if available) very low. This limits the incoming pump pressure by dumping water on the ground before the discharge hose lines are connected and are flowing water.
Then, as the incoming water is used the relief valve control can be increased to the desired operating pressure. This technique also helps to purge air from the incoming hose and the pump before it gets to a dangerously high pressure.
Use this procedure after the hose is positioned, the apparatus are in position, and the pumps are engaged. For setup and engagement instructions for apparatus receiving pressurized water, see heading "Pumping From a Hydrant, General Operation" on page 54.
Relay Procedures
Note: When feeding through a pump, the pump must be in pump gear and the transmission in neutral in order to lubricate the pump and the intermediate gears.
1. Open two discharge gates on all pumps, except on the pump at the source, to expel air from the hose lines and pumps.
2. On each pump, attach the hose lines to one of the discharges and leave the other discharge uncapped.
Note: Uncapping the second discharge gate is not necessary if a relay valve is installed. The valve, connected to the intake side of the pump, automatically opens and dumps water on the ground if too high a pressure is supplied, protecting the pump.
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Note: If no valve is present, you must watch the intake gauge for a high-pressure reading. If necessary, open the gate controlling the uncapped discharge to dump excess water on the ground and reduce pressure.
3. Supply the pump at the water source with water; prime if necessary. 4. The discharge pressure must not exceed 185 PSI (1,276 kPa) for 5" (125 mm)
large diameter hose, or 135 PSI (931 kPa) for 6" (150 mm) hose, per NFPA Standards 1962. See heading "Pumping From a Hydrant, General Operation" on page 54. Also see heading "Pumping From Draft" on page 58.
IMPORTANT!
FOR ADDITIONAL SUPPLY HOSE AND PRESSURE SETTING INFORMATION, SEE NFPA STANDARDS 1962.
5. When the water reaches the second pump, close the uncapped discharge gate. Repeat this step for all pumps until the water reaches the fire ground.
6. Adjust the throttle on the pump at the water source for the required operating pressure. Watch the gauges to avoid cavitation. Also see heading "Cavitation" on
page 193.
7. The pump operator at the fire scene must advise all other pump operators of the amount of water needed at the fire ground.
8. Adjust the discharge pressure or flow at the fire scene to supply the lines being used.
9. Observe the gauges carefully, and adjust the pressure or flow as needed. 10. 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. 11. Follow this procedure for every pump in the relay until the pump at the water source is shut down.
IMPORTANT!
LOCAL TRAINING PROCEDURES MAY VARY SLIGHTLY FROM ABOVE. ALWAYS FOLLOW LOCAL TRAINING PROCEDURES.
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4.5 TANDEM (SERIES) PUMPING
Tandem pumping operations is used when higher pressures are required than a single engine is capable of supplying. This can occur when the pumper is attempting to supply high-rise sprinkler or standpipe systems or long hose layouts.
Note: Two 1,000 GPM (3,785 LPM) pumpers in a series from a hydrant can produce 500 GPM (1,893 LPM) at 500 PSI (3,447 kPa) if the relief valve systems allow 500 PSI (3,447 kPa).
CAUTION!
WHEN SUPPLYING HOSE LINES IN A TANDEM PUMPING OPERATION IT IS POSSIBLE TO SUPPLY GREATER PRESSURE THAN THE HOSE CAN WITHSTAND. PRESSURE SUPPLIED TO THE HOSE SHOULD NOT EXCEED THE PRESSURE AT WHICH THE HOSE IS ANNUALLY TESTED BY THE DEPARTMENT.
CONSULT NFPA 1962, "STANDARD FOR THE CARE, USE AND SERVICE TESTING OF FIRE HOSE INCLUDING COUPLINGS AND NOZZLES," FOR THE TEST PRESSURES RECOMMENDED FOR THE TYPE OF FIRE HOSE USED BY YOUR FIRE DEPARTMENT.
In tandem pumping, the pumper directly attached to the water supply source pumps water through its discharge outlet(s) into the intake(s) of the second engine. This enables the second engine to discharge water at a much higher pressure than a single engine could have supplied. The higher pressure results from the pumps acting in series.
Tandem Procedures
1. Using the large intake hose, connect the first pumper to the hydrant steamer. Open the hydrant until the pump is primed.
2. Position the second pumper "discharge-to-intake" with the first pumper. 3. Open a discharge to flow water. 4. Adjust the throttle on the first pumper until the intake gauge reads approximately
5 PSI (34 kPa). 5. Connect the second pumper to the unused streamer intake of the first pumper,
using a large intake hose (approximately 2-1/2" / 65 mm). 6. Both pumpers pump water to the fire. Also see heading "Pumping From a
Hydrant, General Operation" on page 54.
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IMPORTANT!
LOCAL TRAINING PROCEDURES MAY VARY SLIGHTLY FROM ABOVE. ALWAYS FOLLOW LOCAL TRAINING PROCEDURES.
4.6 PUMP-TO-ROAD SHIFT PROCEDURES
(For Split-Shaft Gearboxes)
1. Verify that the operator's hand throttle or governor control is at IDLE speed. 2. Shift the truck transmission into the NEUTRAL and wait about four (4) seconds.
Check to make sure the speedometer reads ZERO (0). 3. Set the pump to the ROAD position. The in-cab and panel pump indicator lights
go out as the pump transmission shifts into the ROAD position.
IMPORTANT!
REFER TO THE FIRE DEPARTMENT PROCEDURES FOR REMOVING WHEEL CHOCKS, AS WELL AS LAY OUT AND CONNECTION OF SUCTION AND DISCHARGE HOSES.
4.7 PUMP AND ROLL
IMPORTANT!
DURING PUMP AND ROLL OPERATION, IT IS NECESSARY TO SLOW THE FORWARD MOTION OF THE APPARATUS TO THE PTO MANUFACTURER'S RECOMMENDED ENGAGEMENT SPEED.
1. Slow the apparatus to a safe PTO engagement speed as recommended by the PTO manufacturer's recommendations.
Note: Most PTOs must be engaged while the apparatus is stopped. Only a "Hot Shift" PTO can be engaged while the apparatus is rolling.
2. Engage the PTO. 3. Verify the PUMP ENGAGED light is ON. Also see Figure 4-1: "Driver's Compart-
ment Indicator Lights" on page 55. 4. Open the valve between the tank and pump suction. 5. Observe pump discharge pressure and verify that the pump pressure increases.
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6. Prime the pump, if necessary. 7. Open the discharge valves and commence operations.
4.8 RELIEF VALVE PROCEDURES
Be sure to select the correct procedure based on how the truck is equipped. (See Figure 4-3: "TPM / PMD Relief Valve Control" on page 67.) Some trucks may utilize a governor in place of the relief valve.
Standard Relief Valve Procedures
1. Increase the engine RPM to the desired pump operating pressure while reading the discharge pressure gauge.
2. Turn the handwheel slowly counterclockwise until the relief valve opens. The pilot light illuminates and the master pressure gauge drops a few PSI (kPa).
3. Turn the handwheel slowly clockwise until the master pressure gauge rises to the desired pressure and the pilot light goes out.
4. When the pump is not in operation, turn the handwheel clockwise to a position slightly above the normal operating pressure. 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.
TPM Relief Valve Procedures
1. Set the pressure indicator on the PMD control valve to a position slightly above the normal operating pressure (even before water starts to flow).
2. When normal operating pressure is achieved (as indicated on the master pressure gauge while the pump is discharging water), slowly move the adjusting handwheel counterclockwise until the relief valve opens.
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3. The AMBER indicator light illuminates. (See Figure 4-3: "TPM / PMD Relief Valve Control.")
4. Turn the handwheel slowly clockwise until the light goes out.
5. When the pump is not in operation, turn the handwheel clockwise to a position slightly above the normal operating pressure. More complete and detailed information is found in the relief valve manual.
Figure 4-3: TPM / PMD Relief Valve Control
CAUTION!
THE PRESSURE INDICATOR ON THE PANEL IS ONLY A ROUGH INDICATION OF TPM SETTING. ALWAYS USE THE PRECEDING PROCEDURE TO PROPERLY SET THE TPM RELIEF VALVE SYSTEM.
TPM System with Engine Governor
1. Set the pressure indicator on the PMD control valve to a position slightly above the normal operating pressure (even before water starts to flow).
2. Power on the governor control per the manufacturer's manual. 3. Set the discharge pressure using the RPM mode of the pressure governor con-
trol. 4. Move the TPM handwheel counterclockwise until the relief valve opens and the
AMBER pilot light illuminates. 5. 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.
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6. Place the governor control in the PRESSURE GOVERNOR mode. 7. Use the following procedures to change the set pressure while running:
Increasing Pressure Set the TPM to a pressure slightly higher than the desired new pressure. Place the governor control in the RPM mode and increase the speed to the new
pressure. Turn the TPM handwheel counterclockwise until the relief valve opens and the
AMBER pilot light illuminates. (See Figure 4-3: "TPM / PMD Relief Valve Control" on page 67.) 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.
Place the governor control in the pressure governor mode.
Decreasing Pressure Put the governor control in the RPM mode, and reduce the speed to the new pres-
sure. 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.
CAUTION!
THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.
Place the governor control in the PRESSURE GOVERNOR mode.
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4.9 EMERGENCY PUMP SHIFT PROCEDURES
Before implementing manual override shift procedures, repeat the recommended shift procedures. If the shift fails, proceed as follows:
1. Bring the truck to a complete stop. 2. Apply the truck parking brake, and chock the wheels. 3. Shift the truck transmission to the NEUTRAL. 4. For PUMP or ROAD position, place the in-cab shift control in the NEUTRAL (N)
position. 5. Shut down the engine.
WARNING!
DO NOT ATTEMPT EMERGENCY SHIFT PROCEDURES WHILE THE ENGINE IS RUNNING.
6. Employ manual override procedure at the shift cylinder on the pump gearbox as follows: An eyebolt is provided in the shift shaft to accept a drift punch or screwdriver. Insert the tool into the hole provided, then pull or push the shaft manually. Pull the shaft OUT for PUMP position (after in-cab control valve selection), or push shaft IN for ROAD position (after in-cab control valve selection). 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.
7. Once gearbox shift is complete, make sure all personnel are clear of the underside of that apparatus and start the engine to proceed with the desired operation.
4.10 POST OPERATION PROCEDURES
1. Return the engine to IDLE, then slowly close all valves. 2. Place the transmission in NEUTRAL, then slowly shift to ROAD to disengage the
pump. 3. Drain the pump (especially important in freezing weather):
Open the discharge valves, remove suction tube caps, and discharge valve caps.
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Open the pump body drain cocks or Hale multiple drain valve. If a multiple drain valve is used, all pump drain lines should be connected to this valve.
On two-stage pumps, move the transfer valve back and fourth between the VOLUME and PRESSURE positions.
4. If sea water, dirty water, alkaline water or foam solution has been used, FLUSH THE PUMP WITH CLEAN WATER.
5. If installed, drain the gearbox cooler. After the pump is completely drained, replace all caps and close all valves.
6. Remove the wheel chocks only when preparing to leave the scene. 7. Fill out the Pump Run Log, indicating total pumping and out-of-station time. 8. Report all pump, vehicle and equipment malfunctions, and irregularities to the
proper authority. 9. Know and follow all local procedures. See WARNING! note on page 53.
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Truck Manufacturer ______________________________ Pump Model Number _____________________________ Pump Serial Number _____________________________ Year _____________ Unit #________________________
Midship Pump Maintenance Check List
RECOMMENDED "WEEKLY" PROCEDURES
Test relief valve system or governor at 150, 200, 250 PSIG (1000, 1400, 1700 kPa) - see page 80.
Test transfer valve (if applicable) - see page 73.
Test the priming system. Flush the priming system - Also see Chapter 4, heading "Weekly" on page 72.
Lubricate all valves, discharge, suction, hose, drain, and multi-drain - see page 74.
Check pump shift warning indicator lights - see page 74.
Recommended MONTHLY Procedures
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
Complete weekly checks. Lubricate threads on PM relief valve panel control and check lights. Lubricate remote valve controls. Check controlled packing leakage and adjust if necessary (8 to 10 drops per minute).
Perform dry vacuum test. a
Check drive flange bolts for tightness. Lubricate suction tube threads. Clean strainer.
Inspect gaskets. Check oil level in pump gearbox; add oil if necessary.
If necessary, replace oil.
a. *Per NFPA-1911, 22" Hg. minimum vacuum: loss not to exceed 10" Hg vacuum in five (5) minutes.
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Complete all previous checks on all questions.
Check gauge calibration - see page 75.
Check oil level in AutoLube® assembly (SAE-EP 90 or 80W-90); see operation and maintenance manual for details.
Lubricate power transfer cylinder, power shift cylinder, and shift control valve with vacuum cylinder oil, if applicable.
Change pump gearbox oil and refill (SAE-EP 90 oil or 80W-90).
Check individual drain lines from pump to multi-drain to ensure proper drainage and protection from freezing.
Lubricate transfer valve mechanism on two stage pumps. Dry moly spray is preferred.
Disassemble priming pump and clean vanes.
Run yearly standard pump test (per NFPA-1911) to check pump performance levels chart provided below.
Repacking of pump is recommended every two or three years.
Note: The preceding general recommendations are provided for normal use and conditions. Extreme conditions or variables may indicate a need for increased maintenance. Good preventative maintenance lengthens pump life, ensures greater dependability, and minimizes downtime. See "Muscle Pump Service Chart, Part 1 of 3" on page 88.
Annual pump Test Results, in PSIG (kPa)
Category
Capacity at 150 (1000)
Capacity at 200 (1400)
Hose Layout Nozzle Size Nozzle Pressure Gallons (Liters) per Minute Pump Pressure, Current Engine Speed Engine Speed from Original Test Documents Lift and Suction Hose Size and Number.
Capacity at 250 (1700)
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5 Preventive Maintenance
5.1 OVERVIEW
The following procedures are for normal use and conditions. Extreme conditions may indicate a need for increased maintenance. The procedures in this section identify some extreme conditions and the additional measures needed to ensure lengthened pump life and continuing dependability. Always follow local maintenance and test procedures.
5.2 POST OPERATION
1. On two-stage pumps, remove the suction tube strainers and ensure that check valves are free to swing. Verify that no foreign matter is caught between the valve and the seat.
2. Inspect the suction hose rubber washers and washers in the suction tube caps. Remove foreign matter from under these washers. Replace worn, damaged, or dry washers.
3. Verify that all discharge valves, booster line valves, drain valves, and valve cocks are closed.
4. Tighten suction caps. 5. Make sure the gearbox oil reservoir is full to correct level - see heading "Replace
Gearbox Oil" on page 80. Also see Figure 5-5: "Muscle Pump Service Chart, Part 2 of 3" on page 89.
Note: The auto-lube assembly is NOT drained at shipment but must be checked prior to operation. To check auto-lube oil, see Step 18. of Section 7.6 "QMID/QMAX/QTWO AutoLube ® Service" on page 116. Also see Figure 5-4: "Muscle Pump Service Chart, Part 1 of 3" on page 88.
5.3 EXTREME CONDITIONS
Extreme conditions occur when operating in freezing weather or as a result of pumping from a water source that contains material that is harmful if not purged.
During Freezing Weather
In freezing weather, drain the pump as follows:
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1. Open all discharge and suction valves, remove suction tube caps, and discharge valve caps.
2. Open pump body drain cocks and/or Hale multiple drain valve. 3. On two-stage pumps, move the transfer valve back and forth between both the
VOLUME and PRESSURE positions. 4. After the pump is completely drained, replace all caps and close all valves.
Pumping Salt Water, Contaminated Water, or Foam Solution 1. Flush the pump and suction hoses using fresh, clean water. 2. After pumping foam, flush as above until all foam residue is flushed from the sys-
tem. 3. Drain the gearbox cooler, if installed
5.4 WEEKLY
Weekly maintenance consists of the following:
Test the relief valve or governor system - see page 73 Test the priming system - see page 74.
Establish and HOLD prime control for about three (3) to five (5) seconds to flush fresh water through the priming pump.
Note: DO NOT apply lubricant the primer pump vanes or vane slots. Lubricant and cold water produces a gummy residue that renders the unit inoperative.
Test the transfer valve on two stage pumps - see page 73 Test the pump shift warning indicator lights - see page 74 Perform valve maintenance - see page 74 Check and clean the intake strainers - see page 75 Check any auxiliary engines - see page 75 Verify all gauges are in working order - see page 75 Operate pump controls - see page 75 If testing criteria is not met, refer to Section 6 "Troubleshooting" on page 93 for corrective maintenance procedures.
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Relief Valve and TPM Test
When the relief valve is not in operation, maintain a setting above the normal operating pressure. Also see Figure 4-3: "TPM / PMD Relief Valve Control" on page 67.
1. Open the discharge valve, back to the water tank, less than 1/2 way. Also see Section 3.3 "Pressure and Relief Valve Control" on page 39.
2. Increase pump pressure up to 150 PSI (1034 kPa). 3. Turn the relief valve handwheel counterclockwise until the relief valve opens and
the AMBER light illuminates. The master pressure gauge should drop at least 5 to 10 PSI (35 to 69 kPa). 4. Turn the control valve handwheel clockwise then counterclockwise a few times to ensure that the handwheel turns freely. Observe the master pressure gauge and indicator light for proper valve operation. 5. Reset the relief valve to its normal operational setting.
Governor Test
If your apparatus is equipped with an electronic governor, follow the manufacturer's instructions for weekly preventive maintenance.
Transfer Valve Test (Two-Stage Pumps Only)
1. For MANUAL transfer valves: With the engine turned OFF, turn the handwheel between VOLUME and PRESSURE a few times to verify that the valve operates freely. Set the truck for pumping with the transfer valve set to VOLUME. See heading "Relief Valve Procedures" on page 66. Also see heading "TPM Relief Valve Procedures" on page 66. With the engine at IDLE speed, sat the transfer valve to PRESSURE. Verify that the discharge pressure gauge readings have approximately doubled.
2. For POWER transfer valves: With the engine turned OFF, use either a 3/8" socket on the indicator hex nut or insert a rod in the hole in the indicator hex nut and manually transfer the valve back-and-forth to verify that the valve operates freely. Set the truck for pumping with the transfer valve set to VOLUME. Note the discharge gauge readings.
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With the engine at IDLE speed, set the transfer valve to PRESSURE. Verify that the master intake gauge readings have approximately doubled.
Priming System Test
1. Tighten all pump caps, and close all pump valves. 2. Pull the primer control while you watch for a below-zero (0) reading on the master
intake gauge. 3. Continue operation for three (3) to five (5) seconds after the primer starts flushing
water through the pump to clear any possible dirt or slug (gum) buildup. 4. Verify that the master intake gauge readings hold for approximately five (5) min-
utes after you release the primer control. A drop of 10" Hg. in this 5 minute period is anticipated per NFPA 1901. 5. If air leaks are heard or the gauge bounces back to or above zero (0), the pump or valves require service.
Pump Shift Warning Lights
1. Switch to non-pumping operations and verify the warning indicators are OFF. See Section 4 "Basic Operation" on page 53.
2. Verify that the warning indicators in the cab and on the pump control panel function properly.
CAUTION!
MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS BEFORE SHIFTING TO THE PUMP POSITION. VERIFY THE PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT ANY MOVEMENT OF THE APPARATUS.
3. Repair or replace any malfunctioning indicators.
Valve Maintenance
Refer to the separate valve manual for proper valve maintenance procedures.
Lubricate all moving parts of the suction, discharge, hose drain, and multi-drain valves and valve linkage with a good grade of grease. For recommended grease, see "Lube and Sealant Specifications" on page 187.
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Note: The PMD valve should be lubricated every six (6) months.
Intake Strainers
Check and clean any debris from the intake. Flush the pump, if required, using departmental/company procedures. Repair or replace any damaged strainers.
Verify All Gauges are in Working Order
Any gauge that is repeated in the cab or another panel, must agree with the gauge on the operator's panel. Gauges not reading within 10% of the calibrated test gauge must be removed from service and re-calibrated.
Operate Pump Controls
Operate the pump drive controls to verify the pump engages. Verify the indicator lights work properly.
Inspect Water and Foam Tanks
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 Auxiliary Engine
See engine manufacturer's manual for wear and proper operation.
5.5 MONTHLY
Monthly maintenance includes the weekly maintenance procedures plus: Valve lubrication - see page 76 Suction Check Valve testing - see page 76 Gearbox lubrication - see page 76 Dry vacuum testing - see page 78 Checking the pump and drive line bolts - see page 77
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Relief valve system check - see page 81
Valve Lubrication
1. On handwheel-type valves, including PM, PMD, and Transfer Valve Controls, remove old grease and paint, use a dry lubricating spray on gears.
2. Lubricate suction threads with a light coat of grease.
Suction Check Valve Testing, Two-Stage Pumps
On two-stage pumps, remove the suction tube strainers, and reach inside the pump to ensure that the check valves are free to swing. Also verify that no foreign matter is caught between the valve and the seat.
Gearbox Lubrication
Incorrect oil types or amounts of oil result in unnecessary high oil temperature and possible wear or damage. Change the oil every 12 months, depending on pump usage. All lubricants must meet service rating API GL-5 requirements. (See Figure 55: "Muscle Pump Service Chart, Part 2 of 3" on page 89.)
Note: For domestic use, Hale recommends using an SAE EP-90, 80W90 Lubricant or "RoadRanger" Full Synthetic SAE 50 Transmission Lubricant, manufactured by the Eaton® Corporation, or equivalent. For International use, Hale recommends using an ISO68 lubricant, or equivalent.
1. For gearbox capacity - see heading "Lube and Sealant Specifications" on page 187.
2. Remove the gearbox oil fill plug, and check the level of the oil in the gearbox. The oil level should be up to the bottom of the oil fill plug hole. Also see Figure 5-5: "Muscle Pump Service Chart, Part 2 of 3" on page 89.
3. Have clean disposable shop rags and oil dry handy and a suitable container to collect the fluid.
4. If the oil appears white or "milky," a water leak is indicated. Remove the drain plug and drain the oil into a suitable container. Examine the oil for metal flakes or other contamination.
Note: If water leak / contamination is suspected, see Section 5 Troubleshooting, heading 6 "Troubleshooting" on page 93.
5. Either of these conditions indicates maintenance is required to the unit. See Section 9.1 "G Series Gearbox Maintenance" on page 149. Also see Section 9.2 "J Series Gearbox Maintenance" on page 157.
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Packing Gland Adjustment
The packing gland is adjusted for a leakage rate of about 8 to 10 drops per minute at 150 PSI (1034 kPa). This slight leakage lubricates and cools the shaft and packing to prevent burning and scoring.
Check the leakage rate, and adjust the packing gland if necessary. If the leakage rate cannot be adjusted within satisfactory limits, replace packing. See Section 8.1 "Packing Seal Replacement" on page 131 for additional information.
Packing should be replaced every three (3) years.
Adjustment
1. Connect the pump to a fresh water source of about 150 PSI (1034 kPa). If this is not possible, operate the pump at about 150 PSI from draft or from the booster tank discharging through the booster line, another small nozzle, or circulating back to the tank.
2. Count the drops (water leakage) per minute. 3. Shut down engine to make adjustments.
WARNING!
DO NOT RUN THE ENGINE WHILE MAKING PACKING ADJUSTMENTS.
4. Loosen the packing nut lock. The lock is either a spring-loaded pin. The end of the lock fits into a slot in the gland. (See Figure 5-2: "Pump Packing Seal Assembly" on page 86.)
5. To loosen or tighten the packing gland: Insert a screwdriver or rod into one of the slots. Refer to the Hale Service Chart. To loosen the nut, turn it in the direction of engine rotation. To tighten the nut, turn it in the opposite direction to engine rotation.
6. Repeat Steps 1 through 3 and verify that leakage is correct. Tighten to REDUCE leakage, loosen to INCREASE leakage.
Pump, Drive Line and Flange Bolts
Check all pump, drive line and flange bolts to ensure:
1. No bolts are missing.
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2. All bolts are tight. Use a torque wrench and torque bolts to the drive train manufacturer's recommended specifications.
3. Bolts used are "Grade 5" minimum for mounting and "Grade 8" minimum for the driveline.
Priming System Test (Dry Vacuum Test)
(Refer to NFPA 1901 or NFPA 1911)
1. Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if so equipped).
2. Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel.
3. Engage the priming pump until the gauge indicates 22" Hg.
4. Compare the readings of the test gauge and the apparatus gauge. Note any difference.
Figure 5-1: Priming Valve Handle
5. STOP the priming pump and observe the gauge. If the
vacuum falls more then 10" Hg. in five (5) minutes it is an indication of at least
one air leak.
6. Vacuum leaks may often be detected by ear if the engine is turned OFF. Correct leaks immediately before returning the pump to service.
7. Test the suction hose as follows:
Attach the suction hose to the pump.
Place the suction tube cap on the end of the hose in place of a strainer.
Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if so equipped).
Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel.
Engage the priming pump until the gauge indicates at least 22" Hg.
If the vacuum falls more then 10" in 5 minutes, at least one air leak exists.
Verify the test gauge and the apparatus gauge display the same readings. Repair or replace and gauges that do not display the correct pressure.
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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 (TYPICALLY 250 PSI / 17 BAR) INSPECT THE PUMP FOR LEAKS
5.6 ANNUAL
Annual maintenance consists of post-operation, weekly, and monthly maintenance plus the following tasks:
Replacing the pump gearbox oil - see page 80. Relief valve system, check and repair - see page 80. Checking individual drain lines from the pump to the multi-drain to ensure proper
drainage and protection from freezing - see page 81. Disassembly of priming pump to clean vanes - see page 81. (Also see separate
manual provided.)
IMPORTANT!
DO NO USE A LUBRICANT ON THE PUMP VANES AND VANE SLOTS. LUBRICANT AND COLD WATER FORM AN EVENTUAL GUMMY RESIDUE THAT RENDERS THE PRIMING SYSTEM INOPERATIVE. A COMPLETE AND THOROUGH DISASSEMBLY AND CLEANING IS THEN REQUIRED.
MIV Relief Valve Test and Adjustment - see page 81. Relief Valve Test and Adjustment - see page 81. Yearly pump test to check performance levels, including Tank-to-Pump Flow Rate
- see page 82. (Also see NFPA 1911 standard for more details.) Repacking the pump seal at three-year intervals - see page 85 Autolube® assembly oil level check - fill or replace with SAE EP 90 or 80W90
weight oil.
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Lubricating the power transfer cylinder, power shift cylinder, and shift control valve with air cylinder oil.
Replace Gearbox Oil
1. Remove the drain plug (magnetic) and drain the gearbox oil into a suitable container. For container size based on gearbox capacity, see "Lube and Sealant Specifications" on page 187. Also see Figure 5-5: "Muscle Pump Service Chart, Part 2 of 3" on page 89.
2. Have clean disposable shop rags and oil dry handy.
Note: Assembly orientation determines which plugs are used for oil fill, drain and level detection. See installation plate drawings located at the back of this manual.
3. Examine the oil for contamination (e.g., water turns the oil a milky color or settles to the bottom). Also see Section 5 Troubleshooting, heading "Water/Moisture in Pump Gearbox." on page 101.
4. Properly dispose of the used oil. 5. Inspect the magnetic drain plug. If metal filings are present, visually inspect and
clean the internal components. 6. Clean the drain plug (magnetic). 7. Repair or replace gearbox components as necessary. See appropriate Section
for gearbox service. 8. Replace the cooler, if necessary. 9. Remove the oil fill plug and install the drain (magnetic) plug, using suitable thread
sealant. 10. Fill the gearbox with an approved gear oil until oil just begins seeping from the oil
level plug opening. For gearbox capacity, see "Lube and Sealant Specifications" on page 187. Also see Figure 5-5: "Muscle Pump Service Chart, Part 2 of 3" on page 89. 11. Install the oil fill plug using suitable thread sealent.
Relief Valve System Check
1. Place apparatus out of service in accordance with departmental procedures. 2. Test relief valve system in accordance with weekly maintenance check. Also see
heading "Weekly" on page 72. 3. If the relief valve is not working, clean the strainers as follows:
Open pump compartment panel and locate the relief valve system strainer(s).
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On all relief valve systems, the strainer is located in one of the pump pressure ports. On a TPM, an additional strainer is located in one of the pump vacuum ports.
Note: An optional panel-mounted strainer is mounted on some apparatus.
Disconnect tubing then remove strainer from respective tap. Clean any debris from strainer and check strainer for damage. Using a suitable thread sealant (Loctite PST or equivalent) reinstall strainer. Reconnect tubing. 4. Test apparatus and check for leaks around strainer fittings. 5. Place apparatus back in service.
Check Drain Lines to Multi-Drain
Drains are supplied on the pump and piping at the lowest points where water could collect and freeze. Most drain lines are piped together to a multi-drain to allow the entire system to be drained by one valve.
It is necessary to inspect each line of the multi-drain to ensure the entire system is draining when the valve is operated. Inspect each connection and verify the individual lines to the multi-drain are free of debris. Repair and/or replace any lines that are damaged, kinked, or corroded.
Clean Priming Pump
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.)
IMPORTANT!
DO NO USE A LUBRICANT ON THE PUMP VANES AND VANE SLOTS. LUBRICANT AND COLD WATER FORM AN EVENTUAL GUMMY RESIDUE THAT RENDERS THE PRIMING SYSTEM INOPERATIVE. A COMPLETE AND THOROUGH DISASSEMBLY AND CLEANING IS THEN REQUIRED.
MIV Relief Valve Test and Adjustment
See separate manual for additional information.
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Performance Testing Overview
The yearly standard performance test consists of checking the pumper, (according to rating) at three capacities and comparing the results to when the pump was first placed in service. This provides some measure of performance deterioration, if any. (See Table 5-1: "Pump Ratings (GPM / LPM)" on page 82.)
A pump must be able to pump FULL rated capacity at 150 PSI (1000 kPa), 70% capacity at 200 PSI (1400 kPa) and 50% capacity at 250 PSI (1700 kPa).
Table 5-1: Pump Ratings (GPM / LPM)
Capacity
Pressure PSI (kPa)
100% 150 (1000) 100% 165 (1100) 70% 200 (1400) 50% 250 (1700)
500 (2,000)
500 (2,000)
500 (2,000)
350 (1,400)
250 (1,000)
750 (3,000)
750 (3,000)
750 (3,000)
525 (2,100)
375 (1,500)
1,000 (4,000)
1,000 (4,000)
1,000 (4,000)
700 (2,800)
500 (2,000)
Pump Rating in GPM (LPM)
1,250 1,500 1,750 (5,000) (6,000) (7,000)
1,250 (5,000)
1,250 (5,000)
875 (3,500)
1,500 (6,000)
1,500 (6,000)
1,050 (4,200)
1,750 (7,000)
1,750 (7,000)
1,225 (4,900)
625
750
875
(2,500) (3,000) (3,500)
2,000 (8,000)
2,000 (8,000)
2,000 (8,000)
1,400 (5,600)
1,000 (4,000)
2,250 (9,000)
2,250 (9,000)
2,250 (9,000)
1,575 (6,300)
1,125 (4,500)
3,000 (12,000)
3,000 (12,000)
3,000 (12,000)
2,100 (8,400)
1,500 (6,000)
Tank-to-Pump Flow Rate Test
Note: This procedure is provided as a reference only. It does not supersede any local procedures.
1. Fill the water tank until it overflows.
2. Close the tank fill line, bypass the cooling line, and all the pump intakes.
3. Attach sufficient hose lines and nozzles to pump the desired discharge rate.
4. With the pump in gear, open the discharge and begin pumping water.
5. Increase the engine throttle until the maximum consistent pressure is obtained on the discharge gauge.
6. Close the discharge valve without changing the throttle setting. Refill the tank. The bypass valve may be opened to prevent pump overheating.
7. Reopen the discharge valve and check the flow through the nozzle using a Pitot tube or flow meter. Adjust the engine throttle to bring the pressure to the amount previously determined.
8. Compare the flow rate measured to the NFPA minimum or the designated rate of the pump. If the flow rate is lower, a problem may exist in the tank-to-pump line.
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The minimum flow rate should be continuously discharged until 80% of the tank is discharged.
9. The pump should not experience mechanical problems, power loss, or overheat during the test.
Performance Testing Equipment and Materials
Pumpers should be tested from draft at not over a 10' (3 m) lift with 20' (6 m) of suction hose. Pumpers rated at 1,500 GPM (6,000 LPM) and above often require two separate 20-foot (6-meter) lengths of suction hose and a lower lift height.
Use smooth bore test nozzles of accurate size with the Pitot gauge. The volume pumped is then determined by reference to discharge tables for smooth nozzles. Preferably, nozzles will be used on a Siamese deluge gun for greatest 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 (207 and 586 kPa). Also see Appendix F: "Nozzle Size vs. Pressure" on page 191.
The amount of discharge hose required for the service tests is dependent on the flow requirements and capacity test point. Provide adequate hose to discharge the rated capacity with a flow velocity less that 35 ft./sec. Also see Appendix E: "Hose Friction Loss" on page 189.
Since NFPA standards specify both GPM and pressure, it is usually necessary to restrict the flow somewhat to build up the pump pressure. In normal pumping, this restriction would be caused by the friction loss in the lines. It is common practice to gate the discharge valves as required to maintain pressure.
Note:
For 750 GPM (3,000 LPM) test, two 2-1/2" (64 mm) lines should be laid from the pumper to the nozzle
For 1,000 GPM (4,000 LPM) test, three lines are required
For the 1,250 GPM (5,000 LPM) and 1,500 GPM (6,000 LPM) tests, four or more lines are required between the pumper and the nozzle.
For the 1,750 GPM (7,000 LPM), 2,000 GPM (8,000 LPM), and 2,250 GPM tests up to six hose lines into two separate nozzles should be used. Also see Appendix F: "Nozzle Size vs. Pressure" on page 191.
Because deluge guns are not always available, other hose layouts may be used, such as one, 2-1/2" (64 mm) line to a 1-3/8" (35 mm) nozzle for 500 GPM (1,892 LPM). Generally, the
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nozzle used on one, 2-1/2" line should not be larger than 1-1/2" (38 mm) for accuracy in measuring GPM (LPM).
Another alternative when a deluge gun is not available consists of a 1-1/4" (32 mm) nozzle on one and a 1-1/2" (38 mm) nozzle on the other to pass 1,000 GPM (3,785 LPM). The sum of the flow from both nozzles is the GPM (LPM) delivered by the pump. For good pitot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (207 and 586 kPa).
Performance Testing
NFPA standards require a 10% reserve in pressure at the capacity run when the apparatus is delivered. See NFPA 1901 standards for testing procedures.
1. Test the relief valve (per NFPA 1901 standards): Set the relief valve flow rate capacity at 150 PSI (1034 kPa). SLOWLY close the discharge valves. The rise in pressure shall not exceed 30 PSI (207 kPa), or approximately 180 PSI (1241 kPa) operating pressure. SLOWLY open the discharge valves to re-establish the original pressure, 150 PSI (1,000 kPa).
2. Perform Steps 2 and 3 of the post operation maintenance procedures. Also see Section 4.10 "Post Operation Procedures" on page 69.
3. Run the standard pump test in accordance with NFPA standards to check pump performance.
4. Run the engine for 20 to 30 minutes to stabilize the engine temperature. Then run the pump for: Two (2) hours at FULL capacity and at 150 PSI (1000 kPa) Thirty (30) minutes at 70% capacity and at 200 PSI (1400 kPa) Thirty (30) minutes at 50% capacity and at 250 PSI (1700 kPa) Additionally, an engine overload test is required which consists of pumping at FULL capacity and at 165 PSI (1100 kPa) for ten (10) minutes.
5. If the apparatus does not reach performance levels, proceed to Section 6 "Troubleshooting" on page 93.
6. Compare the results of this test to those from when the apparatus was delivered. If the apparatus performance has dropped appreciably compared to its original performance, it needs to be serviced.
Note: Apparatus test results should be on file with the delivery documents. If not, they may be obtained from the apparatus manufacturer or from the original certifying authority).
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Thermal Relief Valve Test
The TRV requires testing every 12 months. Make sure a clear view to the TRV discharge exists. See separate manual for additional information.
Table 5-2: Maximum Pump Run Time
Pressure PSIG (kPa)
Time in Minutes
TRV120 TRV170 TRVM120 TRVM170
200 (1378)
10
20
400 (2758)
4
8
600 (4137)
2
4
CAUTION!
DO NOT RUN THE PUMP FOR LONGER THAN IS SHOWN IN TABLE 5-2: "MAXIMUM PUMP RUN TIME," AS OVERHEATING COULD OCCUR CAUSING SERIOUS DAMAGE TO THE PUMP.
Repacking the Seal
WARNING!
DO NOT ADJUST THE PACKING WITH THE ENGINE RUNNING.
The three rings adjacent to the packing gland are replaced without disassembling the pump. The ring in front of the packing lantern does not need to be replaced. (See Figure 5-2: "Pump Packing Seal Assembly" on page 86.)
Repack the pump as follows:
1. Loosen the packing nut lock. 2. Loosen the packing gland. If necessary, soak the threads with penetrating oil and
work the nut back and fourth to loosen. 3. Loosen the adjusting gland just enough to remove the split glands. If the front
part of the gland is the split type, remove both halves. 4. Remove the old packing rings with a packing hook. The hook can be made from a
bent piece of stiff wire or small pointed rod.
Note: Another type of packing hook is a corkscrew on the end of a flexible shaft. Be sure to remove all shreds of old packing, and clean out the packing housing.
5. Remove all old packing, dirt, and foreign matter from the bearing housing under the gland.
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Figure 5-2: Pump Packing Seal Assembly
6. Repack using the Hale packing kit recommended for your particular pump. For most pumps, the packing is 7/16" (11 mm) square cut to the proper length.
7. Wrap one length of packing around the shaft to form a ring, and push the ring into the housing. Install the second ring the same way, but stagger the joint one-third of the way around from the first joint.
8. Insert a foil separator between each packing ring. The foil separator must be cut to fit.
9. Install the other rings, again staggering the joints. 10. Replace the gland and adjust accordingly. Also see heading "Packing Gland
Adjustment" on page 77. 11. Operate the pump normally for about 15 minutes at 130 PSI (896 kPa), and check
the packing gland. If necessary, adjust the packing nut again - see heading "Packing Gland Adjustment" on page 77.
Worn Clearance Rings and Impeller Hubs
Before assuming that clearance ring wear is at fault, it is advisable to thoroughly check other possible causes of low performance.
Clearance rings limit the internal bypass of water from the discharge side of the pump back to suction. The radial clearance between the impeller hub and the clearance
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rings is only a few thousandths of an inch when new. In clear water, the clearance rings continue to effectively seal for many years of operation. In dirty or sandy water, the impeller hub and clearance rings wear faster. The more wear, the greater the bypass and lower pump performance. It should not be necessary to replace clearance rings until a loss in pump performance is noticed during the annual test see "Performance Testing" on page 84. Often, replacement of the clearance rings reduces the bypass and restores the pump to near original performance. A complete restoration requires that the impeller also be replaced. See Section 7 "Repair and Corrective Maintenance" on page 103 for maintenance and repair information if pump disassembly is required.
Anode Check
(See Figure 5-3: "Hale 1-1/4" NPT Anode" on page 87.) Anodes conform to MIL Spec. A180001. Performance of the anode life varies with water quality and pH. Replace anodes when over 75% of the metal has been consumed. Zinc anodes Inspect every twelve (12) months and replace accordingly. Magnesium anodes Inspect every three (3) months and replace accordingly.
Figure 5-3: Hale 1-1/4" NPT Anode
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Figure 5-4: Muscle Pump Service Chart, Part 1 of 3
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Figure 5-5: Muscle Pump Service Chart, Part 2 of 3
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Figure 5-6: Muscle Pump Service Chart, Part 3 of 3
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6 Troubleshooting
Table 5-2 lists conditions, possible causes and suggested corrective action measures. Before calling Hale Products or a Hale authorized parts service center for assistance, 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. Contact Customer Service at telephone number 800-533-3569.
Pump Model and Serial Numbers see Figure 2-14: "Typical Midship Pump Serial Number Location" on page 36.
Pump Configuration Information Observed Symptoms and under what conditions the symptoms occur.
Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 1 of 9)
Condition
Possible Cause
Suggested Corrective Action
PTO Will Not Engage.
· Consult the PTO Manufacturer's Instructions.
WARNING!
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ILLUMINATED.
Pump Will Not Engage.
Standard transmission with Manual Pump Shift.
Clutch not fully disengaged or malfunction in shift linkage.
· Check clutch disengagement. Drive shaft must come to a complete STOP before attempting pump shift.
Automatic trans- Automatic transmis- · Repeat recommended shift procedures with transmission in NEUmission with Man- sion not in NEUTRAL. TRAL position. Also see heading "Basic Operation" on page 53. ual Pump Shift.
Standard trans- Insufficient air supply
mission with
in shift system.
Power Pump Shift.
Clutch not fully
engaged or malfunc-
tion in shift linkage.
· Repeat recommended shift procedures. · Check system for loss of air supply (leaks). · Check clutch disengagement. Drive shaft must come to a com-
plete STOP before attempting pump shift. · Turn engine OFF and employ shift override procedures as follows:
· Hole is provided in shift shaft to accomplish emergency shifting.
· Complete shift of control in cab to NEUTRAL and proceed to complete shift of lower control manually.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 2 of 9)
Condition
Possible Cause
Suggested Corrective Action
Pump Will Not Engage-continued.
· Repeat recommended shift procedures with transmission in the NEUTRAL position.
· Release brake system momentarily, then reset and repeat recommended shifting procedures.
Automatic transmission with Power Pump Shift
Insufficient air in shift system.
Air leaks in shift system.
· Repeat recommended shift procedures with transmission in the NEUTRAL position.
· Check system for loss of air and possible air leaks. Use manual override procedures, if necessary.
· Also see heading "Standard transmission with Power Pump Shift." on page 93.
· Attempt to locate and repair leak(s). Leakage, if external, may be detected audibly. Internal leakage is more difficult to detect and requires disassembly.
WARNING!
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ILLUMINATED
Pump Loses Prime or Will Not Prime.
Electric priming system.
Note: Weekly priming is recommended to ensure proper operation. See Section 4 Preventive Maintenance, heading "Priming System Test" on page 74.
Inoperative priming system or possible clogged priming pump.
· NO recommended engine speed is required to operate the electric primer. However, 1,000 engine RPM maintains the electrical system while providing enough speed for initial pumping operations. Also see heading "Priming Valves" on page 41.
Note: Using lubricant on the vanes and vane slots during disassembly and cleaning eventually causes a gummy residue to develop, rendering the system inoperative. DO NOT lubricate vanes or vane slots.
· Check the priming system by performing a "Dry Vacuum Test" per NFPA standards. If the pump holds vacuum but primer pulls less than 22" Hg, it could indicate excessive wear in the primmer.
· See Section 4 Preventive Maintenance, heading "Weekly" on page 72. Also see Section 4 Preventive Maintenance, heading "Annual" on page 79.
· Also see heading "Priming Valves" on page 41.
· Repair and/or replace accordingly.
Suction lifts too high. · DO NOT attempt lifts exceeding 22 feet (6.7 meters) except at low elevation.
Blocked suction strainer.
· Remove obstruction from suction hose strainer. · Thoroughly clean strainer screen.
Suction connections.
· Clean and tighten all suction connections.
· Check suction hose and hose gaskets for possible defects - repair and/or replace accordingly.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 3 of 9)
Condition
Possible Cause
Suggested Corrective Action
Pump Loses Prime or Will Not Prime continued.
Note: Weekly priming is recommended to ensure proper operation. See Section 4 Preventive Maintenance, heading "Priming System Test" on page 74.
Air trapped in suction line.
· Avoid placing any part of the suction hose higher than the suction intake.
· Suction hose should be laid out with continuos decline to fluid supply.
· If trap in hose is unavoidable, repeated priming may be needed to eliminate air pockets in suction hose.
Insufficient priming
· Proper priming procedures should be followed.
· Do not release the primer control before assuring a complete prime.
· Open the discharge valve slowly during completion of prime to ensure complete prime.
NOTICE!
DO NOT RUN THE PRIMER OVER FORTY-FIVE (45) SECONDS. IF PRIME IS NOT ACHIEVED WITHIN 45 SECONDS, STOP AND LOOK FOR CAUSES (AIR
LEAKS OR BLOCKED SUCTION HOSES.)
Pump pressure too low when nozzle is opened.
· Prime pump again and maintain higher pump pressure while opening the discharge valve slowly.
Air leaks
· Attempt to located and correct air leaks using the following procedures:
· Perform "Dry Vacuum Test" on pump per NFPA standards with 22" minimum vacuum required with loss not to exceed 10" Hg. in five (5) minutes.
· If a minimum of 22" Hg. cannot be achieved, the priming device or system may be inoperative, or the leak is too big for the primer to overcome (such as an open valve). The loss of vacuum indicates leakage and could prevent priming or cause loss of prime.
· After priming shut OFF the engine. Audible detection of a leak is often possible.
· Connect the suction hose from the hydrant or the discharge of another pumper to pressurize the pump with water. Look for visible leakage and correct. A pressure of 100 PSI (689 kPa) should be sufficient. DO NOT exceed pressure limitations of pump, accessories or piping connections.
· Check pump packing during attempt to locate leakage. If leakage is in excess of recommendations, adjust accordingly. See Section 4 Preventive Maintenance, heading "Repacking the Seal" on page 85.
· The suction side relief valve can leak. Plug the valve outlet connection and retest
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 4 of 9)
Condition
Possible Cause
Suggested Corrective Action
Insufficient Pump Capacity, Single Stage.
Insufficient engine power.
· Engine power check and tune up may be required for peak engine and pump performance.
· Also see heading "Rotation Symptoms." on page 101.
· Recheck pumping procedure for recommended transmission gear or range. Use mechanical speed counter on pump panel to check actual speed against possible clutch or transmission slippage or inaccurate tachometer.
· Check truck manual for proper speed counter ratio.
Relief valve improperly set - if so equipped.
· If relief valve pressure is set too low it allows the valve to open and bypass water.
· Reset the relief valve pressure accordingly.
· See Section 4 Preventive Maintenance, heading "Relief Valve and TPM Test" on page 73.
Suction hose diameter is too small for the volume being discharged
· Use larger sustain hose. · Shorten total length by remove one length at a time. · Reduce volume of discharge.
Restriction in suction line at strainer
· Remove any debris restricting entrance of water at the strainer.
· See Section 4 Preventive Maintenance, heading "Intake Strainers" on page 75.
Air leaks
· See heading "Air leaks" under condition " Pump Loses Prime or WIll Not Prime" on page 95.
Partial collapse of the lining in the suction hose
· Damage to the outer lining may allow air between the outer and inner linings causing a partial collapse.
· Replace hose and retest.
Engine governor set incorrectly.
· If the engine governor is set too LOW (pressure), when on automatic, engine speed decelerates before the desired pressure is achieved.
· Reset governor per manufacturer's procedures.
Truck transmission in wrong gear or clutch is slipping.
· Recheck the pumping procedures for the recommended transmission or gear range. Also see Section 3 Operation, heading "Basic Operation" on page 53.
· Use a mechanical speed counter on the pump panel to check speed against possible clutch or transmission slippage or inaccurate tachometer.
· Check truck manual for proper speed counter ration.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 5 of 9)
Condition
Possible Cause
Suggested Corrective Action
Insufficient Pump Capacity, DualStage.
Insufficient Pressure.
Leak at Pump Packing.
Remote Control Difficult to Operate.
Transfer valve not in proper position for operation, based on capacity rating and pressure.
· Place transfer valve in VOLUME position (parallel) when pumping more than 1/2 rated capacity.
· For pressure above 200 PSI (141379 kPa), pump should be placed in PRESSURE (series) position.
· For operating procedures, review Section 4 "Basic Operation," beginning on page 53.
· For Transfer Valve test, review Section 4, heading "Transfer Valve Test (Two-Stage Pumps Only)," beginning on page 73.
Insufficient engine power.
· See previous heading "Insufficient Pump Capacity, Single Stage." on page 96.
Two-Stage Pump Only -
Transfer valve not in proper position for operation, based on capacity rating and pressure.
· Two-Stage Pump Only -
· Place transfer valve in PRESSURE position (series) when pumping pressures above 200 PSI (1379 kPa).
· For operating procedures, review Section 4 "Basic Operation," beginning on page 53.
· For Transfer Valve test, review Section 4, heading "Transfer Valve Test (Two-Stage Pumps Only)," beginning on page 73.
Packing out of adjustment or worn.
· Readjust packing for 8 to 10 drops per minute leakage at 150 PSI (1000 kPa).
· Packing replacement is recommended every two to three years, depending on usage.
· See Section 4 Preventive Maintenance, heading "Packing Gland Adjustment" on page 77.
Lack of lubrication. · Lubricate the remote control linkages and collar with oil.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 6 of 9)
Condition
Possible Cause
Suggested Corrective Action
Engine Speeds Too HIGH for Required Capacity or Pressure.
Truck transmission in wrong gear or range.
Lift too high, suction hose too small.
Faulty suction hose
Blockage at suction hose entry
Worn pump impeller(s) or clearance rings
Impeller blockage
Pump is approaching "Cavitation"
· Recheck the pumping procedures for the recommended transmission or gear range - review Section 4 "Basic Operation," beginning on page 53.
· Check truck manual for proper speed counter ration.
· Higher than normal lift (10 ft./3.1m)) causes higher engine speeds, high vacuum and rough operation.
· Use larger suction hose. · Move the pump closer to the water source.
· Inner line of suction hose may collapse when drafting and is usually undetectable.
· Try a different suction hose on the same pump. · Test for comparison against original hose.
· Clean suction hose strainer of obstruction. See Section 4 Preventive Maintenance, heading "Intake Strainers" on page 75.
· Follow recommended practices for laying suction hose. · Keep off the bottom of the fluid supply by at least 2 feet (0.6
meters) below the surface of the fluid.
· Repair and/or replace as needed. See Section "Repair and Corrective Maintenance" on page 103.
· A blocked impeller can prevent loss of both capacity and pressure.
· Back flushing the pump from discharge to suction may free the blockage.
· Removing half the pump body may be necessary - this is considered a major repair.
· Gate the discharge valves to allow pressure to increase. This reduces the flow.
· Reduce the throttle opening to the original pressure setting. · Also see "Cavitation" on page 193.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 7 of 9)
Condition
Possible Cause
Suggested Corrective Action
Cavitation
(Pump beginning to cavitate.)
Note: Also see "Cavitation" on page 193.
Discharging more
· Increase the flow into the pump with more and/or larger intake
water than the pump is lines.
taking in
· Gate the discharge valves to reduce flow and maintain pressure.
Air leak
· Verify that the air bleeder on the suction tube is NOT open.
· Locate and eliminate all air leaks during maintenance.
Drafting too high
· Verify lift hose, hose friction, water temperature and other lift limiting factors are reduced or eliminated.
· Locate the pump closer to the water source.
Water temperature too · Reduce volume discharge by lowering the RPM or gating the dis-
high
charge valves.
· Locate a source of cooler water.
Relief Valve Does Not Relieve Pressure When Relief Valves are Closed.
Incorrect setting of control (PM/PMD) Valve.
· Check and repeat proper procedures for setting relief valve system.
· See Section 3 Operation, heading "Relief Valve Procedures" on page 66.
· See Section 3 Operation, heading "TPM Relief Valve Procedures" on page 66.
Relief valve inoperative.
· Possibly in need of lubrication. Remove valve from pump, dismantle, clean and lubricate.
· Refer to relief valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
Relief Valve Does Not Recover and Return to Original Pressure Setting After Opening Valves.
Dirt in system causing · Check and repeat proper procedures for setting the relief valve sticky or slow reaction. system.
· See Section 3 Operation, heading "Relief Valve Procedures" on page 66.
Relief valve inoperative.
· Blocked bleed orifice - clean the bleed orifice with a small wire or straightened paper clip.
· Refer to relief valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
Relief Valve Opens When Control Valves are Locked Out.
Drain hole in housing, piston or sensing valve is blocked.
· Clean the valve drain hole with a small wire or straightened paper clip.
· Refer to relief / sensing valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
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Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 8 of 9)
Condition
Possible Cause
Suggested Corrective Action
Unable to Obtain Proper Setting on Relief Valves.
Discharge Valves Are Difficult to Operate.
Using the wrong procedures. Blocked strainer.
Dirty control valve. "Hunting" condition.
Lack of lubrication.
Valve in need of more clearance for operation.
· Check instructions for setting the relief valve and reset. · See Section 3 Operation, heading "Relief Valve Procedures" on
page 66.
· Check and clean the strainer in the supply line from the pump discharge to the control valve. Check truck manual for the exact location.
· Check and clean tubing lines related to the relief and control valves.
· Remove the control valve and clean.
· Insufficient water supply from the pump to the control valve. · Check the strainer and relief valve system for flow restrictions. · Remove and clean the control valve.
· Recommended weekly lubrication of discharge and suction valve. · Use a good grade petroleum based silicone grease. · Foe Hale Products, SVS Valves, etc., use Never-Seez® White
Food Grade with PTFE. · Refer to separate valve manual for addition information.
· Multi-gasket design allows additional gaskets fro more clearance and free operation. Note: Adding too many gaskets to the valve eventually causes leakage.
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Troubleshooting
Table 6-1: Muscle (Midship) Pump Troubleshooting (Sheet 9 of 9)
Condition
Possible Cause
Suggested Corrective Action
Water/Moisture in Leak coming from Pump Gearbox. above the pump.
· Check all piping connections and tank overflow for possible spillage falling directly onto the pump gearbox.
· Repair accordingly.
Operating or a driving condition that submerges the gearbox in water.
· Visually inspect the unit for external signs of water leakage.
· Was the unit submerged in water? Does your unit include an air vent / breather where water can enter if submerged? If so, change oil. See Section 4 Preventive Maintenance, heading "Replace Gearbox Oil" on page 80.
Normal condensation. · Depending on area / region where unit is operated, normal condensation can develop over time.
· Periodic inspection and possibly more frequent oil changes are needed.
Leaking oil seal or mechanical seal.
· Inspect the oil seals and replace as needed. If the oil seal checks OK, the packing seal or mechanical seal may be leaking.
· There must be NO leaks at the mechanical seal. See Section "Mechanical Seal Replacement" on page 133.
· Packing seals are designed to leak. For requirements, see "Packing Gland Adjustment" on page 77.
· Hydrostatic test the system to determine leakage.
Rotation Symptoms.
Wrong impeller installed.
(Reduced pres-
sure 60100 PSI
[410690 kPa] and reduced flow.) Impellers installed
backwards (two-stage
pump).
· Verify the new impeller vanes are oriented the same as the old impeller before installing, see Figure 2-13: "Pump/Engine Rotation" on page 35.
· Refer to relief / sensing valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
· Verify the impellers are in the correct order - p/n: 016-0280-00-0 is installed closest to the gearbox in an "Engine Rotation" application and CLosest to the front in a "Opposite Engine Rotation" application.
Wrong application attempted.
· The pump was installed on an application for which it was not intended, i.e., front mount vs. rear mount.
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.
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NOTES
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Repair and Corrective Maintenance
7 Repair and Corrective Maintenance
7.1 OVERVIEW
This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Hale pump and gearbox components. 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.
Service should be performed by a trained and qualified service technician, or your authorized Hale Products service representative. Be sure you have sufficient knowledge, experience and the proper tools.
Wherever there is a requirement for new parts, it is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators and to limit "downtime."
7.2 GENERAL REPAIR GUIDELINES
Before You Begin...
IMPORTANT!
READ ALL INSTRUCTIONS THOROUGHLY BEFORE BEGINNING ANY SERVICE REPAIR.
1. Place apparatus out of service in accordance with your departmental procedures. 2. Park the vehicle on a level surface. Set the parking brake and chock the front and
rear wheels in accordance with your departmental procedures. 3. Match mark, tag and/or note, or photograph the orientation of all mechanical and
electrical components and connections to the pump and/or gearbox before disassembly. This aids in proper reassembly. 4. Determine best method for servicing, i.e., servicing while in the apparatus or removal from the top or bottom of the apparatus.
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WARNING!
BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP.
THE PUMP AND GEARBOX ASSEMBLIES CAN BE HEAVY AND BULKY. ADDING ACCESSORIES ALSO 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, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THESE ASSEMBLIES. EXERCISE CARE WHEN USING CHAINS TO PROTECT THE FINISHED SURFACES FROM SCRATCHES.
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING OR INSTALLING FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY.
ALL FASTENERS ON THE PUMP AND GEARBOX 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 ALTERNATIVE POSES A SERIOUS SAFETY RISK.
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC ADHESIVE/ SEALANT, SUCH AS LOCTITE® #246 FOR GEARBOX AND #242 FOR PUMP.
5. Remove necessary body panels and framework to gain access to the pump compartment. Make sure there is sufficient clearance above the apparatus to lift the pump and gearbox assembly out of the apparatus.
6. Remove valve operators, discharge and suction piping and valves that interfere with pump removal.
Have clean disposable shop rags and oil dry handy.
7. Disconnect cooling tubes from the water manifold and pump, air lines, electrical switches and tachometer cable as required.
8. When required, use a Lithium-based grease with 1% to 3% Molybdenum Disulfate. For a listing, see "Lube and Sealant Specifications" on page 187.
9. When replacing fasteners, use the proper nuts, bolts, and other hardware as specified in the manual or drawing. Unless otherwise specified, use minimum Grade 5 SAE fasteners.
10. Also ensure screws/bolts are properly torqued. (See Table 7-1: "Typical Torque Values Chart.")
11. Gearbox - Apply Loctite #246 High Temperature Removable Threadlock (or equivalent) to all bolts on the gearbox.
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Table 7-1: Typical Torque Values Chart
Bolt Size Lock Nut Size
Material
Minimum Torque Ft.-Lb. (N-m)
5/16"-18
Zinc-plated steel
17 (23)
5/16"-18 5/16"-18 3/8"-16
Zinc-plated steel, with 360° nylon lock Silicon bronze Zinc-plated steel
19 (26) 10.3 (14) 30 (41)
3/8"-16 3/8"-16 7/16"-14 7/16"-14 7/16"-14 5/8"-11
Zinc-plated steel, with 360° nylon local 33 (45)
Silicon bronze
18 (24)
Zinc-plated steel
50 (68)
Zinc-plated steel, with 360° nylon local 53 (72)
Silicon bronze
29 (39)
Zinc-plated steel
150 (203)
5/8"-11 3/4"-10 3/4"-10
Silicon bronze Zinc-plated steel, Grade 5 Zinc-plated steel, Grade 8
85 (115) 260 (353) 380 (515)
12. Hale Series Pump - Apply Loctite #242 Medium Strength Threadlock (or equivalent) to all bolts on the Pump.
13. 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.
14. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equivalent) on the rubber seal parts to ease installation.
WARNING!
DO NOT TOUCH THE CARBON SEAL WHILE INSTALLING THE MECHANICAL SEAL. USE OF ANY OTHER LUBRICANT CAN DAMAGE THE MECHANICAL SEAL AND SEAT.
15. Use a pusher or bearing installation tool when installing bearings and seals to avoid cocking them or marking the their faces. Also review heading "Bearings" on page 106.
16. Before placing apparatus into operation, the pump assembly must be tested and checked for leaks.
Remove the Gearbox Assembly
1. Drain oil from the gearbox. Also see Section 4 Preventive Maintenance, heading
"Gearbox Lubrication" on page 76.
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2. Have clean disposable shop rags and oil dry handy and a suitable container to collect the fluid. For gearbox capacity, see "Lube and Sealant Specifications" on page 187.
3. Disconnect drive shafts, air lines, electrical wiring / switches, tachometer cable and cooling lines, as necessary, from the gearbox.
7.3 CLEANING AND INSPECTION GUIDELINES
1. Inspect all components (bearings, seals, gears, etc.) for excessive or abnormal wear, i.e., pitting, scoring / scratches, cracks, splits, etc.
IMPORTANT!
WHEN REASSEMBLING, ALL COMPONENTS MUST BE CLEAN AND FREE OF DEFECTS.
2. Replace O-ring seals and gaskets whenever they are removed to avoid unnecessary downtime later.
3. Clean all gasket material from mating surfaces before installing a new gasket. Be careful not to score the machined surfaces.
4. Install new gaskets and apply a light coat of grease to the gasket to hold it on place. Where applicable, trim gaskets to match the contour of the matching part.
5. Lightly oil or grease the shaft, O-ring seals and lip seals with a coating of generalpurpose grease before reinstalling, especially when pressed-in.
6. For Hale recommended cleaners, see "Lube and Sealant Specifications" on page 187.
7. Replace any hardware that shows signs of excessive wear.
Bearings
Clean bearings and other components using only recommended solvents.
IMPORTANT!
WHEN REPLACING TAPERED BEARINGS, DO NOT INTERCHANGE BEARING MANUFACTURER'S COMPONENTS. THE BEARING RACE AND CONE MUST ALWAYS BE REPLACED IN MATCHING SETS, AS SUPPLIED BY THE MANUFACTURER.
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Tools Required
Lifting gear-lever hoist or chain hoist, and short choker Ball peen hammer Center punch Drift punch Allen wrenches Strap wrench Snap ring pliers Pry bars (2) Ratchets and wrenches for disassembly 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) N-06 or N-07 bearing nut socket or spanner wrench, available from:
Whittet-Higgins at www.whittet-higgins.com or, 35 Higginson Avenue P O Box 8 Central Falls, RI 02863 Phone: (401) 728-0700
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7.4 REMOVING THE PUMP ASSEMBLY
Figure 7-1: Typical Muscle (Midship) Pump Overview
1. First, review preceding Section "Before You Begin..." on page 103. See Section "Drawing Package" on page 203. and review the appropriate Installation Drawing.
2. Install 5/8"-11 UNC eyebolts into the lifting holes on the midship pump body. (See Figure 7-2: "Lifting Eyebolt Attachment Layout," on page 109.)
CAUTION!
ALWAYS USE PROPER LIFTING AND SUPPORT APPARATUS (JACKS, HOISTS, STRAPS, ETC.) WHEN SERVICING THE UNIT. EXERCISE CARE WHEN USING CHAINS TO PROTECT FINISHED SURFACES FROM SCRATCHES. ALSO SEE WARNINGS! NOTE ON PAGE 104.
3. With the pump assembly properly supported and balanced, disconnect the mounting brackets that secure the assembly to the apparatus chassis frame.
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Figure 7-2: Lifting Eyebolt Attachment Layout
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4. Carefully remove the assembly from the apparatus and place on a clean work area. Clamp into a suitable and stable holding device being careful not to damage any machined surfaces.
Installing the Assembly to the Apparatus
Install the pump and gearbox assembly to the apparatus before filling with oil.
1. First, review "Before You Begin...," on page 103 2. Attach proper supporting devices and stabilize the assembly for transport to the
apparatus. (See Figure 7-2: "Lifting Eyebolt Attachment Layout," on page 109.) 3. Place the pump assembly into position within the apparatus. 4. Apply Loctite and secure the midship pump assembly to chassis frame. Torque the
fasteners to proper values in accordance with manufacturer's recommendations. Also see Table 7-1: "Typical Torque Values Chart" on page 105. 5. Remove the lifting device and 5/8"-11 UNC eyebolts. 6. Connect the drive shaft to the gearbox. Apply a coating of Loctite #246 to the fasteners and torque to the manufacturer's specifications. 7. Connect all components to the gearbox. 8. Fill the gearbox to the proper oil level. See "Replace Gearbox Oil," on page 80. 9. Reassemble and connect all components removed to gain access to the pump assembly, paying particular attention to your sketch (photographs) and identification match markings/tags (e.g., valves, suction piping, discharge piping, valve operators, etc.) 10. Reinstall apparatus frame work and body panels previously removed. 11. Test the pump per your departmental requirements. 12. Recheck and top-off oil levels, then return the apparatus to operation.
7.5 REMOVING THE GEARBOX
G Series Gearbox
Review "Before You Begin...," on page 103. Also see Figure 7-3: "Typical G Series Gearbox Removal" on page 111.
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Figure 7-3: Typical G Series Gearbox Removal
Removal - G Series
1. Position a supporting device, such as a jack, under the gearbox.
Note: The number of screws that secure the rear bearing housing to the gearbox depends on the model, e.g., the short gearbox uses seven (7) screws; the long gearbox uses eight (8).
2. Remove the 7/16"-14 screws securing the rear bearing housing to the lower gearbox housing.
3. Remove the gearbox from the apparatus. Move the assembly to a clean work area and clamp into a suitable and stable holding device.
4. Place a temporary cover over the exposed pump assembly to prevent dirt and debris contamination.
5. Inspect bearings and internal parts for signs of excessive wear, pitting or damage. Repair and/or replace accordingly. For gearbox disassembly, see "Disassembly," on page 149.
6. Also see heading "Cleaning and Inspection Guidelines" on page 106.
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Installation - G Series Review preceding sections "Before You Begin...," on page 103.
1. Install a new gasket between the gearbox seating surface of the rear bearing housing.
2. Install a new gasket between the gearbox and gearbox cover. Check the fit and trim the gasket to match the contour of the gearbox, if necessary.
3. Lift the gearbox into place around the rear bearing housing. Apply Loctite #246 and insert two or three 7/16"-14 screws through the rear bearing housing. Tighten screws hand tight.
4. Position the gearbox cover, apply Loctite #246 and insert six 1/2"-13 screws. Tighten screws hand tight.
5. Apply Loctite #246 and insert the remaining 7/16"-14 and 1/2"-13 screws through the rear bearing housing and gearbox cover and gaskets. Tighten all screws in a criss-cross fashion to ensure an EVEN seal, then torque to: 40 ft.-lbs. (54 Nm) for 7/16" 65 ft.-lbs. (88 Nm) for 1/2"
6. Connect drive shafts, cooling lines, air hoses, and electrical connections to the gearbox.
7. Fill the gearbox with oil as shown in "Replace Gearbox Oil," on page 80. 8. Test the pump for proper operation per your departmental requirements. 9. Recheck and top off oil levels before returning the apparatus to operation.
J Series Gearbox
Review preceding sections "Before You Begin...," on page 103.
Removal - J Series 1. Connect or position the gearbox to your supporting device and assure that it is
adequately supported. 2. Remove the 1/2"-13 screws to separate the upper and lower housings and
remove the service spacer plate, if installed. 3. Remove the gearbox from the apparatus. Move the assembly to a clean work
area and clamp into a suitable and stable holding device. 4. Place a temporary cover over the exposed pump assembly to prevent dirt and
debris contamination.
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5. Inspect bearings and internal parts for signs of excessive wear, pitting or damage. Repair and/or replace accordingly. For gearbox disassembly, see "J Series Gearbox Maintenance," on page 157 and "Cleaning and Inspection Guidelines," on page 106.
Figure 7-4: Typical J Series Gearbox Removal
Installation - J Series Review preceding sections "Before You Begin...," on page 103.
1. Make sure the dowel pins are properly seated in the gearbox housing. If they are scored or damage, install new dowel pins.
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2. Install new gaskets onto the seating surface of the lower gearbox housing.
3. Reinstall the spacer plate, and install a new gasket.
4. Lift the gearbox into place aligning the dowel pins with the holes in the upper gearbox housing.
5. Apply Loctite #246 and insert the eight 1/2"-13 cap screws. Tighten the screws in a criss-cross fashion to ensure an even seal and torque screws to 65 ft.-lbs. (88 N-m).
6. Connect the drive shafts, cooling lines, air hoses, and electrical connections to the gearbox.
7. Fill gearbox with oil. See Section 4: Preventive Maintenance, heading "Replace Gearbox Oil" on page 80.
Note: Proper oil level is when oil fills 1/2 to 3/4 of the oil level sight gauge.
8. Test the pump for proper operation per your departmental requirements. Note and repair any leaks.
9. Recheck and top off oil levels before returning the apparatus to operation.
K Series Gearbox
Review preceding sections "Before You Begin...," on page 103.
Removal - K Series
1. Position a supporting device such as a jack under the gearbox.
2. Remove twelve (12) 7/16"-14 x 1-1/2" screws in the rear cover, then remove cover and gasket. (See Figure 7-5: "K Gearbox Removal," on page 115.) Remove the spacer plate if installed.
3. Remove six (6) 5/8"-11 x 2-1/4" screws on the cover of the gearbox. Figure 7-5: "K Gearbox Removal," on page 115.)
(See
4. Remove 7/16"-14 x 1-1/4" screws securing the rear bearing housing to the lower gearbox housing and cover. Remove the gearbox cover.
5. Remove the gearbox from the apparatus. Move the assembly to a clean work area and clamp into a suitable and stable holding device.
6. Place a temporary cover over the exposed pump assembly to prevent dirt and debris contamination.
7. Inspect bearings and internal parts for signs of excessive wear, pitting or damage. Repair and/or replace accordingly. For "K" series gearbox disassembly, see heading "9.3 K Series Gearbox Maintenance," beginning on page 161.
8. Also see heading "Cleaning and Inspection Guidelines" on page 106.
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(12) 7/16"-14 SCREWS
(12) 7/16"-14 SCREWS
(1) FRONT COVER GASKET
(2) GEARBOX COVER GASKET
COOLING LINES
(6) 5/8"-11 SCREWS
REAR VIEW
(1) REAR COVER GASKET
INPUT SHAFT YOKE
FRONT VIEW
Figure 7-5: K Gearbox Removal
Installation - K Series
Review preceding sections "Before You Begin...," on page 103.
1. Install a new gasket between the gearbox seating surface of the rear bearing housing.
2. Install a new gasket between the gearbox and gearbox cover. Check the fit and trim the gasket to match the contour of the gearbox, if necessary.
3. Lift the gearbox into place around the rear bearing housing. Apply Loctite #246 and insert two or three 7/16"-14 screws through the rear bearing housing. Tighten screws hand tight.
4. Position the gearbox cover, apply Loctite #246 and insert six 5/8"-11 screws. Tighten screws hand tight.
5. Apply Loctite #246 and insert the remaining 7/16"-14 and 5/8"-11 screws through the rear bearing housing and gearbox cover and gaskets. Tighten all screws in a criss-cross fashion to ensure an EVEN seal, then torque to: 40 ft.-lbs. (54 Nm) for 7/16"-14 140 ft.-lbs. (190 Nm) for 5/8"-11
6. Install the rear cover using its twelve (12) 7/16"-14 screws.
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7. Connect drive shafts, cooling lines, air hoses, and electrical connections to gearbox.
8. Fill gearbox with oil. See Section 4: Preventive Maintenance, heading "Replace Gearbox Oil" on page 80.
9. Test the pump for proper operation per your departmental requirements. 10. Recheck and top off oil levels before returning the apparatus to operation.
7.6 QMID/QMAX/QTWO AUTOLUBE ® SERVICE
Review preceding sections "Before You Begin...," on page 103.
1. Drain water from the pump. 2. Remove the fill and drain plugs from the AutoLube reservoir and drain oil. (See
Figure 7-6: "AutoLube Assembly Overview," on page 117.) 3. Have clean disposable shop rags and oil dry handy and a suitable container to
collect the fluid - approximately one (1) quart (0.9 liters). 4. Use a center punch to mark the AutoLube front bearing housing cover and the
front bearing cover housing for proper alignment during re-assembly. 5. Remove the 1/2"-13 UNC screws attaching the AutoLube to the pump body. At
the "notches" in the front bearing housing, gently and evenly pry the AutoLube assembly from the pump body and impeller shaft.
CAUTION!
THE AUTOLUBE IS MANUFACTURED FROM CAST METAL. DO NOT USE A CHISEL TO SEPARATE THE AUTOLUBE HOUSING FROM THE PUMP BODY.
THE MATING SURFACES COULD BE SCRATCHED OR GOUGED, WHICH COULD CAUSE A LEAK. ALWAYS PRY BETWEEN THE "NOTCHES" IN THE AUTOLUBE HOUSING AND THE PUMP BODY TO SEPARATE THE ASSEMBLY FROM THE PUMP HOUSING.
6. Place the AutoLube face down on a work bench and remove the two 3/8"-16 UNC allen-head screws from the impeller side.
7. Remove the diaphragm. 8. Remove the oil seal retaining ring, then remove and discard the oil seal. 9. Check the impeller shaft front sleeve bearing for wear - replace accordingly.
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Figure 7-6: AutoLube Assembly Overview
CAUTION!
THE FRONT SLEEVE BEARING / BUSHING SEATS AGAINST A SHOULDER IN THE AUTOLUBE BEARING HOUSING AND CAN ONLY BE REMOVED AND INSTALLED AS DIRECTED OR SERIOUS DAMAGED COULD RESULT.
10. To replace the front sleeve bearing, a press must be used. Also see Figure 7-6: "AutoLube Assembly Overview."
11. Clean the inner and outer halves of the AutoLube. 12. Check for restrictions in the water passages in the bearing housing, leading to the
area between the front bearing cover and the front diaphragm. Clean as required. 13. Install a new oil seal, then install the seal retaining ring. (See Figure 7-6: "AutoL-
ube Assembly Overview," on page 117.) 14. Align and install the diaphragm.
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15. Line up the center-punch marks and install the housing cover. Apply Loctite #242 to the two (2) 3/8-16 UNC screws. Tighten and torque to 26 ft.-lbs. (35 N-m).
16. Install a new gasket onto the bearing housing. 17. Slide the AutoLube assembly onto the pump shaft. Apply Loctite #242 and
secure the assembly with 1/2"-13 UNC screws. Tighten the screws in a crisscross fashion ensuring an EVEN seal, then torque to 64 ft.-lbs (87 N-m).
CAUTION!
DO NOT DAMAGE THE OIL SEAL. A DAMAGED OIL SEAL COULD RESULT IN DAMAGE TO THE AUTOLUBE ASSEMBLY, AS WELL AS THE PUMP.
18. To eliminate air pockets and false readings, fill the AutoLube with 90W oil, if possible, by pumping new oil in from the bottom plug opening until the oil spills from the top plug opening.
CAUTION!
PURGE THE AIR FROM THE AUTOLUBE WHILE FILLING WITH OIL OR A "FALSE-FILL" SITUATION COULD DEVELOP, WHICH COULD CAUSE DAMAGE TO THE AUTOLUBE AND OTHER INTERNAL COMPONENTS.
19. Add water to the pump. 20. Operate the fire pump and check the AutoLube for water or oil leaks per your
departmental requirements. 21. Recheck and top off oil levels before returning the apparatus to operation.
7.7 IMPELLER ASSEMBLY
Review preceding section "Before You Begin...," on page 103.
QMID/QMAX/QTWO Removing Impeller and Clearance Rings
1. Drain the water from the pump, then remove the gearbox. For G Series Gearbox, see heading "Removal - G Series" on page 111 For K Series Gearbox, see heading "Removal - K Series" on page 114
2. Remove the drain lines from the lower pump body.
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WARNING!
THE LOWER PUMP BODY WEIGHS APPROXIMATELY 100 LBS (46 KGS). (SEE FIGURE 7-7: "QMAX / QTWO ASSEMBLY OVERVIEW," ON PAGE 120.) SUPPORT THE LOWER PUMP BODY AND IMPELLER ASSEMBLY WITH THE PROPER LIFTING DEVICE. FAILURE TO DO SO COULD RESULT IN THE LOWER PUMP BODY AND IMPELLER ASSEMBLY FALLING, WHICH COULD RESULT IN SERIOUS PERSONAL INJURY, OR PROPERTY DAMAGE.
3. Match mark the lower pump body, Autolube housing, and rear bearing housing for easy and accurate reassembly. (See Figure 7-6: "AutoLube Assembly Overview," on page 117.)
4. Drain the oil from the AutoLube - see heading "QMID/QMAX/QTWO AutoLube ® Service" on page 116
5. Remove the: 1/2"-13 UNC x 2" screws from the "top half" of the AutoLube bearing housing and the pump body. (See Figure 7-7: "Qmax / Qtwo Assembly Overview," on page 120.) 1/2"-13 UNC x 1-3/4" screws from the upper half of the rear bearing housing and pump body. 1/2"-13 UNC x 1-1/4" screws, from the lower pump body.
WARNING!
DO NOT REMOVE THE FOUR CAP SCREWS, ONE IN EACH CORNER OF THE LOWER PUMP BODY, UNTIL THE LIFTING DEVICE IS IN POSITION. FAILURE TO DO SO COULD RESULT IN THE LOWER PUMP BODY AND IMPELLER ASSEMBLY FALLING, WHICH COULD RESULT IN SERIOUS PERSONNEL INJURY OR PROPERTY DAMAGE.
6. Position the lifting device to support the lower pump body, then remove the 5/8"11 UNC x 5" screws in each of the four corners of the lower pump body. (See Figure 7-7: "Qmax / Qtwo Assembly Overview," on page 120.)
7. Lower the lower pump body and impeller assembly being careful that it does not tip from the lifting device.
Move the assembly to a clean work area and clamp into a suitable and stable holding device. 8. Remove the remaining screws from the lower half of the AutoLube, the rear bearing housing, and the lower pump body.
9. Lift the impeller assembly from the lower pump housing and set aside.
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Figure 7-7: Qmax / Qtwo Assembly Overview
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WARNING!
THE IMPELLER ASSEMBLY IS HEAVY. DO NOT ATTEMPT TO LIFT THE ASSEMBLY WITHOUT THE AID OF PROPER LIFTING APPARATUS CAPABLY OF HANDLING THE LOAD. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR PROPERTY DAMAGE.
10. See heading "Cleaning and Inspection Guidelines" on page 106. Clean the gasket sealing surfaces of the upper and lower pump bodies, as well as those on the AutoLube and the rear bearing housing face. Whenever gaskets are removed, they must be replaced. Clean the clearance ring and clearance ring seats in both the upper and lower pump body halves to so that the new clearance rings seat properly.
Note: Pitting of the clearance rings may occur from the build-up of material and the effects of corrosion. Once the seats are cleaned, any pitting on the clearance rings is considered normal.
Disassembly - QMAX/QMID Single-Stage Pump
1. Place the impeller shaft assembly on a suitable workbench, capable of handling the load.
2. Carefully remove the AutoLube assembly from pump shaft end. Also see heading "QMID/QMAX/QTWO AutoLube ® Service" on page 116.
3. Remove the outer retaining ring and clearance ring. (See Figure 7-7: "Qmax / Qtwo Assembly Overview," on page 120.) Before removing the impeller, note the orientation of the vanes for proper reassembly. The vanes turn in a clockwise manner when viewed from the front.
4. Using an acetylene torch, carefully heat the "eye" and hub of the impeller EVENLY for approximately two minutes. When heated properly, the impeller is removed from the pump shaft using a gear puller. If the impeller moves but does not slide freely, do not immediately reheat. Allow the assembly to cool to room temperature, then reheat again and continue removing the impeller.
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WARNING!
WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHILE HEATING THE IMPELLER TO REMOVE OR INSTALL IT ONTO THE IMPELLER SHAFT. HEATED METAL CAN CAUSE SERIOUS INJURY TO YOUR HANDS.
DO NOT OVER HEAT THE IMPELLER. THE IMPELLER IS CONSTRUCTED OF BRONZE. IF THE IMPELLER IS OVERHEATED (AND TURNS RED OR BLUE DURING REMOVAL FROM THE SHAFT), IT HAS BEEN WEAKENED AND MUST BE REPLACED.
ALLOW ALL COMPONENTS TO COOL TO ROOM TEMPERATURE BEFORE CONTINUING.
5. Remove the inner clearance ring, then remove the impeller key.
Assembly - QMAX/QMID Single-Stage Pump
Also see Figure 7-7: "Qmax / Qtwo Assembly Overview" on page 120.
1. Clean the impeller shaft and the keyway. Also see heading "Cleaning and Inspection Guidelines" on page 106. See WARNING! note on page 122.
2. Check the water way in the seal housing for restrictions - clean as needed. 3. Install the inner retaining ring. 4. Install a new gasket on the seal housing face. (See Figure 7-7: "Qmax / Qtwo
Assembly Overview," on page 120.) 5. Verify the key is free to slide in the impeller keyway, then install the key.
CAUTION!
IF THE IMPELLER OR CLEARANCE RINGS ARE DROPPED, DAMAGED OR DEFORMED, THEY MUST BE REPLACED.
6. Install the inner clearance ring over the impeller shaft checking for proper orientation.
7. Using the torch, heat the "eye" and hub of the new impeller in an EVEN fashion for approximately two minutes. Then, slide the impeller onto the shaft making sure the vanes are in the proper orientation.
Note: The vanes turn in the clockwise direction when viewed from the front of the impeller assembly. If the impeller does not fully slide onto the shaft allow the assembly to cool to room temperature before re-heating.
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8. Install the outer retaining ring and the outer clearance ring ensuring proper orientation.
9. Slide the AutoLube assembly over pump shaft. Also see heading "QMID/QMAX/ QTWO AutoLube ® Service" on page 116.
10. Install the impeller shaft assembly to the pump.
Disassembly - QTWO Two-Stage Pump
Also see Figure 7-7: "Qmax / Qtwo Assembly Overview" on page 120.
1. Place the impeller shaft assembly on a suitable workbench, capable of handling the load.
2. Remove the AutoLube assembly from pump shaft end. Also see heading "QMID/ QMAX/QTWO AutoLube ® Service" on page 116.
IMPORTANT!
MARK THE PRIMARY OR SECONDARY IMPELLERS IN RELATION TO THE AUTOLUBE. IMPROPER OR BACKWARD INSTALLATION OF THE IMPELLERS AFFECTS PUMP PERFORMANCE.
3. Remove impeller retaining rings. 4. With an acetylene torch EVENLY heat the "eye" and hub of the first impeller for
approximately two minutes. 5. When heated properly the impeller is removed from the pump shaft using a gear
puller. If the impeller moves but does not slide freely, do not immediately reheat. Allow the complete assembly to cool to room temperature, then reheat again and continue removing the impeller. 6. Allow the components to cool to room temperature before continuing. 7. Remove the center support bearing. Then rotate the impeller shaft assembly end for end and heat and remove the second impeller. 8. Remove the impeller key.
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Assembly - QTWO Two-Stage Pump
Also see Figure 7-7: "Qmax / Qtwo Assembly Overview" on page 120.
1. Clean the impeller shaft, the keyway, and the seal housing and face. Also see heading "Cleaning and Inspection Guidelines" on page 106. See WARNING! note on page 122.
2. Check the waterway in the seal housing for restrictions - clean as needed. 3. Install a new gasket on the seal housing face. 4. Install the key into the keyway.
CAUTION!
IF THE IMPELLER OR CLEARANCE RINGS ARE DROPPED, DAMAGED OR WARPED, THEY MUST BE REPLACED.
5. Install the inner clearance ring over the impeller shaft checking for proper orientation.
6. With an acetylene torch EVENLY heat the "eye" and hub of each impeller for approximately two minutes.
7. Slide the individual impellers onto the shaft making sure they are in the correct orientation. Make sure the center support bearing is installed between impellers.
Note: The vanes turn in a clockwise direction when viewed from the front of the impeller assembly. If the impeller does not fully slide onto the shaft allow the assembly to cool to
room temperature before re-heating and continue installing the impeller. 8. Allow the components to cool to room temperature before continuing. 9. Install the outer retaining ring and the outer clearance ring ensuring proper orien-
tation. 10. Slide the AutoLube assembly over pump shaft. Also see heading "QMID/QMAX/
QTWO AutoLube ® Service" on page 116. 11. Install the impeller shaft assembly to the pump.
Inspection Clearance Rings
(See Figure 7-8: "Clearance Ring and Impeller ID / OD Measurement.")
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Figure 7-8: Clearance Ring and Impeller ID / OD Measurement
Inspect the front and back of both clearance ring IDs and ODs in several places for signs of wear. Using a caliper, measure the inside diameter of each ring in several places.
When new, the radial clearance between the impeller hub and the clearance rings is between 0.005" to 0.007" (0.127-0.177mm) per side. Maximum acceptable radial clearance on used pumps is between 0.015" to 0.020" (0.381-0.508mm) per side.
If the gap between the impeller and the clearance ring is greater than 0.020" (0.508 mm) you must measure the impeller hub diameter. (See Figure 7-8: "Clearance Ring and Impeller ID / OD Measurement.") If the impeller diameter is greater than 8.480" (215 mm), the clearance ring must be replaced.
If the impeller diameter is less than 8.480" (215 mm) but more than 8.437"
(214 mm), the impeller hub diameter can be cut (turned down) and "undersized" clearance rings can be ordered to compensate for the new impeller diameter. Contact Cus-tomer Service at Hale Products at 800-533-3569.
CAUTION!
WHEN TURNING IMPELLERS TO FIT UNDERSIZED RINGS, CAUTION MUST BE EXERCISED TO ENSURE THAT THE CLEARANCE RING SURFACE RUNS TRUE WITH THE BORE TO WITHIN 0.002" (0.051 MM).
If the impeller diameter is less than 8.437" (214 mm) and you are not meeting pump performance, you may need to replace both the clearance rings and the impeller.
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Installing the Impeller and Clearance Rings
Also see Figure 7-7: "Qmax / Qtwo Assembly Overview" on page 120.
1. Install the pump body gaskets to the lower pump body, trimming as necessary. 2. Install the impeller assembly into the lower pump housing, carefully aligning the
clearance ring lock notches with the clearance ring lock tabs in the lower pump body. Rotate the clearance rings to one side to align the lock notches with the lock tabs in the upper pump body.
CAUTION!
FAILURE TO LINE UP THE CLEARANCE RING LOCK NOTCHES WITH THE PUMP BODY TABS MAY RESULT IN PUMP DAMAGE AND PUMP FAILURE.
3. Install the 1/2"-13 UNC x 1-3/4" screws through the rear bearing housing and the seal housing. Do not tighten at this time.
4. Install the 1/2"-13 UNC x 2" screws into the AutoLube housing and lower pump body.
5. Make sure the dowel pins are in the upper pump body to assist with alignment to the lower pump body.
6. Using proper lifting device, slowly raise the lower pump body and the impeller assembly into place. Align the lower pump body aligns with the dowel pins and the clearance ring notches with the clearance ring lock tabs in upper pump body. (See Figure 7-7: "Qmax / Qtwo Assembly Overview," on page 120.)
7. Rotate the impeller shaft and check for free movement when the lower pump body and the impeller assembly is in place.
8. Apply Loctite and install the four 5/8"-11 UNC x 5" screws (one in each corner of the lower pump body). Tighten snugly but do not fully torque.
9. Apply Loctite and install the remaining 1/2"-13 UNC x 1-3/4" screws in the rear bearing housing and mechanical seal housing, and the 1/2"-13 UNC x 2" screws into the AutoLube. Tighten to 53 ft.-lbs. (72 N-m).
10. Remove the lifting device. 11. Torque the 5/8"-11 UNC x 5" screws to 150 ft.-lbs. (203 N-m), then, starting from
the center and moving outward, tighten and torque the lower pump body screws to 65 ft.-lbs. (88 N-m). 12. Install the gearbox. For G Series Gearbox, see heading "Installation - G Series" on page 112
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For K Series Gearbox, see heading "Installation - K Series" on page 115 Also see WARNINGS! note on page 104. 13. Test the pump for proper operation per your departmental requirements. Note and repair any leaks. Recheck and top off oil levels before returning the apparatus to operation.
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NOTES
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8 Packing and Mechanical Seal Maintenance
8.1 PACKING SEAL REPLACEMENT
When the packing adjustment has reached its limit, a single ring of packing can be added. However, it is usually more efficient to repack the pump. (See Figure 8-1: "Pump Packing Seal Overview.") Also see Figure 8-2: "Packing / Mechanical Seal Assembly Overview" on page 132.
Figure 8-1: Pump Packing Seal Overview
Review preceding sections "Before You Begin...," on page 103 and "Cleaning and Inspection Guidelines," on page 106.
The three rings adjacent to the packing gland can be replaced without disassembling the pump. The ring in front of the lantern does not need to be replaced. (See Figure 81: "Pump Packing Seal Overview.")
WARNING!
DO NOT RUN THE ENGINE WHILE PERFORMING ANY SERVICING TO THE PACKING, I.E., PACKING SEAL ADJUSTMENT OR REPLACEMENT.
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(See Figure 8-1: "Pump Packing Seal Overview"
on page 131.)
Figure 8-2: Packing / Mechanical Seal Assembly Overview
1. Loosen the slotted packing nut. (See Figure 8-1: "Pump Packing Seal Overview" on page 131.)
2. Release the packing gland locking lever and set the lever roll pin on the housing pin stop.
3. Loosen the split packing nut just enough to remove the split glands. If necessary, soak the threads with penetrating oil and work the nut back and fourth to loosen. If the front part of the gland is the split type, remove both halves.
4. Remove the old packing rings with a packing hook. The hook can be made from a bent piece of stiff wire or small pointed rod. Another type of packing hook consists of a corkscrew on the end of a flexible shaft.
5. Be sure to remove all shreds of old packing, and clean out the packing housing as best as possible.
Note: Forced air can also be used to remove the packing. Use appropriate safety measures if forced air is being used.
6. Remove all old packing, dirt and foreign matter from the bearing housing, especially under the packing gland.
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7. Repack using the Hale packing kit recommended for your particular pump. For most pumps, the packing is 7/16" (11 mm) square cut to the proper length.
8. Wrap one length of packing around the shaft to form a ring, and push the ring into the packing housing. Install the second ring the same way, but stagger the joint one-third of the way around from the first joint. (See 8.1 "Packing Seal Replacement" on page 131.)
9. Insert foil separators between each packing ring. The foil separators must be cut to fit the shaft.
10. Install the other rings, again staggering the joints. 11. Replace the gland and adjust accordingly. See Section 4: Preventive Mainte-
nance, heading "Packing Gland Adjustment" on page 77. 12. Operate the pump normally for about 15 minutes, and check the packing gland. If
necessary, re-adjust the packing nut accordingly.
8.2 MECHANICAL SEAL REPLACEMENT
Note: Before starting disassembly, use a center punch to match-mark the rear bearing housing, mechanical seal housing, and pump body. This assists with proper alignment during reassembly. If the mechanical seal requires replacement, order Hale Mechanical Seal Replacement Parts Kit, p/n: 296-5210-50-0.
CAUTION!
MECHANICAL SEALS ARE PRECISION-ENGINEERED DEVICES. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO ALL MATING FACES. ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION. SOLID FACES MUST BE CLEANED WITH AN APPROPRIATE DEGREASER AND A SOFT CLOTH.
Qmax and Qtwo Pumps with G Series Gearbox
Review preceding sections "Before You Begin...," on page 103 and "Cleaning and Inspection Guidelines," on page 106.
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Also see Figure 8-4: "Mechanical Seal Overview / Replace-
ment" on page 135.
Figure 8-3: Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview
Removing the Seal (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview.") Also see Figure 8-4: "Mechanical Seal Overview / Replacement" on page 135.
IMPORTANT!
IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS NOTICED, THE MECHANICAL SEAL MUST BE INSPECTED.
1. Remove the gearbox - see heading "G Series Gearbox" on page 110. 2. Remove the 5/8"-11 screw and bearing retainer washer from the end of the
impeller shaft. 3. Remove twelve 1/2"-13 screws securing the rear bearing housing to the pump
body.
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Figure 8-4: Mechanical Seal Overview / Replacement
4. Install two 1/2"-13 x 2-1/2" cap screws into the 1/2"-13 UNC threaded holes on the rear bearing housing to use as jacking screws.
5. Install a 1/2"-13 x 2-1/2" screw into one of the holes on the rear bearing housing into the pump body to keep the mechanical seal housing from rotating while removing the rear bearing housing.
Note: It may be necessary to use pry bars to loosen the back bearing and gear before attempting to remove the rear bearing housing.
6. Evenly turn the jacking screws clockwise to separate the rear bearing housing away from the pump body.
7. Remove the gear and gear key from the impeller shaft.
IMPORTANT!
DO NOT ALLOW THE WEIGHT OF THE REAR BEARING HOUSING TO REST ON THE OIL SEAL AS DAMAGE MAY RESULT RENDERING THE SEAL INOPERATIVE.
8. Remove the rear bearing housing being careful not to damage the oil seal. 9. Remove the slinger from the impeller shaft. 10. Match-mark the mechanical seal cover and mechanical seal housing. Remove four
7/16"-14 screws securing the mechanical seal cover.
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11. If necessary, use pry bars in the slots provided to loosen the mechanical seal cover from the mechanical seal housing. (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.)
12. Remove the old mechanical seal from the housing and impeller shaft. Two small hooks aid in the removal. (See Figure 8-4: "Mechanical Seal Overview / Replacement" on page 135.)
Note: Removing the mechanical seal renders it inoperative; it must be replaced.
13. Inspect bearings and other internal parts for excessive wear, pitting or damage. Repair and/or replace accordingly.
Installing the Seal
1. See CAUTION! warning on page 133.
2. Clean the bore of the pump head using alcohol swabs supplied with the Hale repair kit (p/n: 296-5210-50-0). Also clean solid running faces with alcohol wipes.
3. Ensure that the pump body, mechanical seal housing, impeller bores and all mating surfaces of the mechanical seal assembly are absolutely clean throughout the entire installation process.
4. Make sure the impeller shaft is smooth and free of burrs at the gear key slot and bearing journals.
5. Clean the pump shaft with alcohol swabs.
6. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equivalent) to the mechanical seal bellows, the pump shaft and seal.
WARNING!
OIL AND GREASE WILL DAMAGE THE MECHANICAL SEAL FACE. DO NOT TOUCH THE FACE OF THE MECHANICAL SEAL.
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUAL) ON THE RUBBER MECHANICAL SEAL TO EASE INSTALLATION. USING AN OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT. MAKE SURE ALL SHAFT SURFACES AND THE INSIDE OF THE SEALING BOOT ARE WELL LUBRICATED.
7. Without touching the carbon seal, slide the new mechanical seal bellows end over the impeller shaft making sure the spring is oriented towards the impeller. (See Figure 8-4: "Mechanical Seal Overview / Replacement" on page 135.)
8. Using a soft pusher tube (2" / 51 mm PVC pipe) and keeping fingers away from carbon seal ring, push the mechanical seal assembly into the mechanical seal housing. If binding occurs apply more lubricant to the impeller shaft and bellows. Verify the stationary seat is firmly seated in the housing.
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9. Without touching the face of the seat, install the cup and seat into the mechanical seal cover. Lubricate the cup and mechanical seal cover with Pac-Ease Rubber Lubricant Emulsion. Also apply a generous coating of the lubricant to the seal diaphragm.
10. Replace the seal rings in the mechanical seal cover. Apply a light coat of grease to the rings being careful not to get grease on the impeller shaft.
11. Slide the mechanical seal cover over the impeller shaft making sure the seal remains seated in the bore of the cover. Make sure there is no oil or grease on the faces of the mechanical seal. (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.)
12. If binding occurs, apply additional PAC-EASE lubricant.
13. Screw a 7/16"-14 UNC stud into one of the holes in the mechanical seal housing to aid in bolt hole alignment.
14. Insert the mechanical seal cover in the mechanical seal housing making sure to line up your center punch marks.
15. Apply Loctite and install four 7/16-14" screws. Tighten the screws evenly in a staggering (or criss-cross) fashion. Torque screws to 40 ft.-lbs. (54 N-m).
Note: If the screws are being replaced, they must be replaced with Grade 5, zinc plated steel, nylon locking type screws.
16. Slide the slinger onto the impeller shaft.
17. Install new oil seal.
18. Place a new gasket over the mating surface of the mechanical seal housing and rear bearing housing.
19. Install two 1/2"-13 UNC studs into the mechanical seal housing. Slide the rear bearing housing over the impeller shaft making sure the oil seal aligns properly. Align the bolt holes and your center punch marks.
IMPORTANT!
DO NOT ALLOW THE WEIGHT OF THE REAR BEARING HOUSING TO REST ON THE OIL SEAL AS DAMAGE MAY RESULT RENDERING THE SEAL INOPERATIVE.
20. Apply Loctite and insert twelve 1/2"-13 screws to secure the rear bearing housing to the seal housing. Evenly tighten the screws in a staggering (or criss-cross) fashion and torque to 65 ft.-lbs. (88 N-m). (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.)
21. Install the 250-0310-00-0 (310S) bearing onto the impeller shaft and properly seat into the bearing housing.
22. Insert the gear key into the slot on the impeller shaft, then install the gear.
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23. Install #409 bearing and properly seat in the bearing housing. 24. Install the bearing retainer washer on impeller shaft end and secure using 5/8-11
(16 mm) screw. Tighten the screw and torque to 135 ft.-lbs. (183 N-m). 25. Re-install the gearbox - see heading "Installation - G Series" on page 112. 26. Operate the pump for about 15 minutes, and check the seal for leakage.
Qmax and Qtwo Pumps with K Series Gearbox
Review preceding sections "Before You Begin...," on page 103 and "Cleaning and Inspection Guidelines," on page 106.
Removing the Seal (See Figure 8-5: "QmaxK and QtwoK Mechanical Seal Assembly Overview.") Also see Figure 8-6: "Mechanical Seal Overview / Replacement" on page 139.
IMPORTANT!
IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS NOTICED, THE MECHANICAL SEAL MUST BE INSPECTED.
1. Remove the gearbox - see heading "K Series Gearbox" on page 114. 2. Remove bearing lock nut, lock washer, and support washer from impeller shaft.
(See Figure 8-5: "QmaxK and QtwoK Mechanical Seal Assembly Overview" on page 139.) 3. Remove ¼"-20 x 1-1/2" socket head screw on thick leg of rear bearing housing. 4. Remove the smaller portion of the rear bearing housing (facing gearbox).It may be necessary to remove the four ¼" x ¾" screws, bearing plate and bearing before removing the smaller portion of the rear bearing housing. 5. Remove the larger spacer. 6. Remove gear and gear key. 7. Remove the smaller spacer. 8. Remove twelve 1/2"-13 screws securing the rear bearing housing to the pump body. 9. Install two 1/2"-13 x 2-1/2" cap screws into the 1/2"-13 UNC threaded holes on the rear bearing housing to use as jacking screws.
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(12) 1/2"-13 x 1-3/4" UNC Screws Teflon Seal Ring
Seal Ring Mechanical Seal
Pump Gear Oil Seal
Slinger
1/4"-20 x 1-1/2" Socket Head Screw
(4) 1/4" x 3/4" UNC Screws
Support Washer Lock Washer Bearing Lock Nut
Key
Pump Shaft
(4) 7/16"-14 UNC Screws
Rear Cover
Bearing
Mechanical Seal Housing
Rear Bearing Housing
Mechanical Seal Cover
(Smaller) Spacer Roller Bearing
Bearing Plate (Larger) Spacer
Also see Figure 8-6: "Mechanical Seal Overview / Replacement" on page 139.
Figure 8-5: QmaxK and QtwoK Mechanical Seal Assembly Overview
Figure 8-6: Mechanical Seal Overview / Replacement
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10. Install a 1/2"-13 x 2-1/2" screw into one of the holes on the rear bearing housing into the pump body to keep the mechanical seal housing from rotating while removing the rear bearing housing.
Note: It may be necessary to use pry bars to loosen the roller bearing before attempting to remove the rear bearing housing.
11. Evenly turn the jacking screws clockwise to separate the rear bearing housing away from the pump body.
IMPORTANT!
DO NOT ALLOW THE WEIGHT OF THE REAR BEARING HOUSING TO REST ON THE OIL SEAL AS DAMAGE MAY RESULT RENDERING THE SEAL INOPERATIVE.
12. Remove the rear bearing housing being careful not to damage the oil seal. 13. Remove the slinger from the impeller shaft. 14. Match-mark the mechanical seal cover and mechanical seal housing. Remove four
7/16"-14 screws securing the mechanical seal cover. 15. If necessary, use pry bars in the slots provided to loosen the mechanical seal
cover from the mechanical seal housing. (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.) 16. Remove the old mechanical seal from the housing and impeller shaft. Two small hooks aid in the removal. (See Figure 8-6: "Mechanical Seal Overview / Replacement" on page 139.)
Note: Removing the mechanical seal renders it inoperative; it must be replaced.
17. Inspect bearings and other internal parts for excessive wear, pitting or damage. Repair and/or replace accordingly.
Installing the Seal
1. See CAUTION! warning on page 133. 2. Clean the bore of the pump head using alcohol swabs supplied with the Hale
repair kit (p/n: 296-5210-50-0). Also clean solid running faces with alcohol wipes. 3. Ensure that the pump body, mechanical seal housing, impeller bores and all mat-
ing surfaces of the mechanical seal assembly are absolutely clean throughout the entire installation process. 4. Make sure the impeller shaft is smooth and free of burrs at the gear key slot and bearing journals. 5. Clean the pump shaft with alcohol swabs.
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6. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equivalent) to the mechanical seal bellows, the pump shaft and seal.
WARNING!
OIL AND GREASE WILL DAMAGE THE MECHANICAL SEAL FACE. DO NOT TOUCH THE FACE OF THE MECHANICAL SEAL.
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUAL) ON THE RUBBER MECHANICAL SEAL TO EASE INSTALLATION. USING AN OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT. MAKE SURE ALL SHAFT SURFACES AND THE INSIDE OF THE SEALING BOOT ARE WELL LUBRICATED.
7. Without touching the carbon seal, slide the new mechanical seal bellows end over the impeller shaft making sure the spring is oriented towards the impeller. (See Figure 8-4: "Mechanical Seal Overview / Replacement" on page 135.)
8. Using a soft pusher tube (2" / 51 mm PVC pipe) and keeping fingers away from carbon seal ring, push the mechanical seal assembly into the mechanical seal housing. If binding occurs apply more lubricant to the impeller shaft and bellows. Verify the stationary seat is firmly seated in the housing.
9. Without touching the face of the seat, install the cup and seat into the mechanical seal cover. Lubricate the cup and mechanical seal cover with Pac-Ease Rubber Lubricant Emulsion. Also apply a generous coating of the lubricant to the seal diaphragm.
10. Replace the seal rings in the mechanical seal cover. Apply a light coat of grease to the rings being careful not to get grease on the impeller shaft.
11. Slide the mechanical seal cover over the impeller shaft making sure the seal remains seated in the bore of the cover. Make sure there is no oil or grease on the faces of the mechanical seal. (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.)
12. If binding occurs, apply additional PAC-EASE lubricant.
13. Screw a 7/16"-14 UNC stud into one of the holes in the mechanical seal housing to aid in bolt hole alignment.
14. Insert the mechanical seal cover in the mechanical seal housing making sure to line up your center punch marks.
15. Apply Loctite and install four 7/16-14" screws. Tighten the screws evenly in a staggering (or criss-cross) fashion. Torque screws to 40 ft.-lbs. (54 N-m).
Note: If the screws are being replaced, they must be replaced with Grade 5, zinc plated steel screws.
16. Slide the slinger onto the impeller shaft.
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17. Install new oil seal in rear bearing housing. 18. Place a new gasket over the mating surface of the mechanical seal housing and
rear bearing housing. 19. Properly seat 250-8240-00-0 roller bearing into rear bearing housing. Do not
install roller bearing race yet. 20. Install two 1/2"-13 UNC studs into the mechanical seal housing. Slide the rear
bearing housing over the impeller shaft making sure the oil seal aligns properly. Align the bolt holes and your center punch marks.
IMPORTANT!
DO NOT ALLOW THE WEIGHT OF THE REAR BEARING HOUSING TO REST ON THE OIL SEAL AS DAMAGE MAY RESULT RENDERING THE SEAL INOPERATIVE.
21. Apply Loctite and insert twelve 1/2"-13 screws to secure the rear bearing housing to the seal housing. Evenly tighten the screws in a staggering (or criss-cross) fashion and torque to 65 ft.-lbs. (88 N-m). (See Figure 8-3: "Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview" on page 134.)
22. Install race of the 250-8240-00-0 roller bearing onto the impeller shaft between shaft and bearing.
23. Insert small spacer against race. 24. Insert the gear key into the slot on the impeller shaft, then install the gear. 25. Insert large spacer on shaft. 26. Install the 250-8340-00-0 bearing and properly seat in the bearing housing. 27. Secure bearing plate to rear bearing housing with four 1/4" x 3/4" screws. 28. Place support washer on shaft and insert lock washer with outer teeth pointing
toward gearbox and inner tooth in small groove of shaft. 29. Apply Loctite to shaft threads and tighten lock nut on impeller shaft. Torque nut to
135 ft.-lbs. (183 N-m). Using a punch, bend one tooth on lock washer into one groove on lock nut. 30. Re-install the gearbox - see heading "Installation - G Series" on page 112. 31. Operate the pump for about 15 minutes, and check the seal for leakage.
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Impeller Assembly and Mechanical Seal Qflo, Qflo-Plus and Qpak Pump
Review preceding sections "Before You Begin...," on page 103 and "Cleaning and Inspection Guidelines," on page 106. Also see Figure 8-7: "Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview" on page 144.
Removing the Mechanical Seal
IMPORTANT!
IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED.
1. Remove the gearbox - see heading "G Series Gearbox" on page 110. For J Series Gearbox, see heading "J Series Gearbox" on page 112.
2. Remove the twelve 7/16-14 UNC screws and remove the bearing housing from the pump body. (See Figure 8-7: "Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview" on page 144.)
3. Install 7/16"-14 UNC screws into the threaded holes on bearing housing to use as jacking screws.
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Figure 8-7: Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview
4. EVENLY turn the jacking screws clockwise to back the bearing housing out of the pump body. Make sure the assembly is properly supported.
5. Remove the gearbox and impeller assembly to a suitable work area. 6. Be careful NOT to damage the brass clearance rings or impeller as you separate
the gearbox assembly from the pump head. 7. Remove cotter pin and nut from impeller shaft.
Note: On Qpak pumps an inducer is installed directly in front of the impeller. First remove the inducer, then the impeller.
8. Using a suitable puller, remove the impeller and impeller key from the shaft and set safely aside.
9. Use hooks that fit around the shaft and seal, then remove the mechanical seal assembly. (See Figure 8-8: "Mechanical Seal Overview / Replacement" on page 144.)
10. Remove the cup and seat from the bearing housing.
Figure 8-8: Mechanical Seal Overview / Replacement
11. Clean the impeller shaft and all components - proceed to Section 6, heading 7.3 "Cleaning and Inspection Guidelines" on page 106.
12. Measure the impeller wear surfaces and the clearance rings for excessive wear see heading "Inspection Clearance Rings" on page 124.
13. If necessary, remove and replace the clearance rings in the pump body and rear bearing housing.
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Note: Removing the clearance ring renders it inoperative. It must be replaced. A usual good practice, if one ring requires replacement, the other should be replaced as well. Also verify the impeller clearance.
14. Inspect the rear clearance ring for wear and replace accordingly. 15. Removing the impeller may disturb the mechanical seal. A new seal must be
installed. 16. Inspect the oil seal in the rear bearing housing and replace if necessary.
Installing the Seal
1. See CAUTION! warning on page 133. 2. Clean the bore of the pump head using alcohol swabs. Solid running faces must
be cleaned with alcohol wipes, supplied with the Hale repair kit (p/n: 296-521050-0). 3. Ensure that the pump body, mechanical seal housing, impeller bores and all mating surfaces of the mechanical seal assembly are absolutely clean throughout the entire installation process. 4. Make sure the impeller shaft is smooth and free of burrs at the gear key slot and bearing journals. 5. Clean the pump shaft with alcohol swabs. 6. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) to the mechanical seal bellows and the pump shaft and seal areas.
WARNING!
OIL AND GREASE WILL DAMAGE THE MECHANICAL SEAL FACE. DO NOT TOUCH THE FACE OF THE MECHANICAL SEAL.
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUAL) ON THE RUBBER MECHANICAL SEAL PARTS TO EASE INSTALLATION. USING AN OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT. MAKE SURE ALL SHAFT SURFACES AND THE INSIDE OF THE SEALING BOOT ARE WELL LUBRICATED.
7. Lubricate the carbon seal, cup and seat assembly with Pac-Ease Rubber Lubricant Emulsion. Without touching the carbon seal, slide the cup and seat assembly over the impeller shaft. (See Figure 8-4: "Mechanical Seal Overview / Replacement" on page 135.)
8. Using a soft pusher tube (2" / 51 mm PVC pipe) and keeping fingers away from carbon seal ring, carefully push the cup and seat assembly in until they are
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seated squarely in the rear bearing housing. If binding occurs apply more lubricant.
9. Orient the carbon seal ring towards the seal and slide the bellows and spring over the impeller shaft. Use the pusher tube to make sure the assembly is pushed all the way in. If binding occurs apply more lubricant to the impeller shaft and bellows.
10. Insert impeller key in the impeller shaft and install the impeller on the shaft. Also insert the inducer. See heading "Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview" on page 144.
11. Install impeller nut - tighten and torque to 135 ft.-lbs. (183 N-m). Lock the impeller nut in place using a cotter pin.
12. Apply a light coating of grease to the seal ring groove and install a new seal ring on the rear bearing housing.
13. Install a new gasket on the rear bearing housing, holding it in place with a light coating of grease.
14. Thread two 7/16"-14 UNC studs in the pump body to help guide the rear bearing housing onto the pump body.
15. Using proper lifting device lift gearbox and impeller assembly into place. Use studs to guide the rear bearing housing into the pump body.
16. Insert the 7/16"14 UNC cap screws into the rear bearing housing. Tighten and torque screws to 40 ft.-lbs. (58 N-m).
17. Reconnect drive shafts, electrical, and air lines to gearbox.
18. Fill the gearbox with oil. See Section 4: Preventive Maintenance, heading "Replace Gearbox Oil" on page 80.
19. Operate the pump for about 15 minutes, and check the seal for leakage.
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NOTES
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9 Gearbox Maintenance
9.1 G SERIES GEARBOX MAINTENANCE
Review heading "Before You Begin..." on page 103. Also review heading "Cleaning and Inspection Guidelines" on page 106.
Disassembly
Intermediate and Sliding Gear Shaft Assemblies Remove and disassemble the intermediate shaft assembly. (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox.")
Figure 9-1: Intermediate Shaft and Sliding Gear, Typical G Series Gearbox
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1. Set the gear shift to the PUMP position to center the sliding gear under the intermediate gear.
2. Remove the 7/16"-14 UNC x 1" screw and washer holding the intermediate shaft in place. (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
3. Press the intermediate gear shaft out of the gearbox housing from the rear of the unit towards the front.
4. Remove the intermediate gear assembly, including the bearing assemblies and split spacer.
5. Remove the bearings from each side of the intermediate gear, then remove both the seal rings.
6. Clean and inspect all parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly.
Tail Shaft Assembly
Figure 9-2: Tail Shaft Assembly
Note: If the tail shaft and sliding gear shaft require service it is not necessary to remove the gearbox from the apparatus. If only the tail shaft assembly needs to be removed, engage the sliding gear (PUMP position).
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1. Remove and disassemble the tail shaft assembly - four 7/16"-14 hex screws. (See Figure 9-2: "Tail Shaft Assembly" on page 150.)
2. Remove in the following order: Rear bearing cap gasket. Outer bearing retaining ring Outer bearing Inner bearing retaining rings (2) Inner bearing Tail shaft from the rear bearing cap Drive shaft oil seal
3. Clean and inspect all parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly.
Power Gearshift Assembly (See Figure 9-3: "Power Gearshift Assembly" on page 152.)
1. Set the gear shift to the PUMP position. 2. Remove the 1/2"-20 nylon set screw, spring and ball. 3. Loosen the 3/8"-16 rod end nut. Remove the gearshift rod end and hex nut. 4. Remove the two 5/16" hex nuts and 5/16"-18 screws and remove the gear shift
cover and gasket. 5. Unthread the gearshift rod extension, then remove the piston. 6. Remove the shaft bearing, then the inner retaining ring. 7. Remove two 7/16"-14 screws and remove the cylinder body and gasket.
Note: The gearshift fork cannot be removed from the sliding gear shaft until the sliding gear is removed. See heading "Sliding Gear and Fork" on page 152.
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Figure 9-3: Power Gearshift Assembly
8. Clean and inspect all parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly.
Sliding Gear and Fork
(See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
Note: If your assembly includes the PTO drive option, first remove the PTO drive to enable disassembly the sliding gear and fork. See heading "PTO Drive Option, Qflo / Qflo Plus / Qpak Series Pump" on page 153.
1. If the tail shaft has not been removed, set the gear shift to the ROAD position to place the sliding gear on the tail shaft. If the tail shaft has been removed, leave the gearshift in the PUMP position.
2. If the optional speed counter is included, disconnect the electrical connector and unscrew the sensor from the front bearing cap.
3. Remove the front bearing cap and gasket - four 7/16"-14 screws. 4. Remove the sliding gear assembly from the housing. 5. If the tail shaft is not removed, remove the front sliding gear assembly from the
gearbox housing. Reach in and slide the sliding gear from the tail shaft.
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6. Make a note of the location of the fork in relation to the gearshift shaft before removing the fork. (See Figure 9-3: "Power Gearshift Assembly" on page 152.)
7. While holding the fork, loosen the 7/16"-14 screw and pull the shaft out of the fork and gearbox housing.
8. From the sliding gear assembly, remove in the following order: Sliding gear bearing retaining ring - see Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149. Sliding gear shaft from the front bearing cap Drive shaft oil seal and slinger from the front bearing cap Electrical switches from the gearshift cap - see Figure 9-3: "Power Gearshift Assembly" on page 152.
9. Inspect the cooling tube for damage and leaks. 10. Clean and inspect all parts for excessive wear, chips, scoring or other damage.
Repair and/or replace accordingly.
PTO Drive Option, Qflo / Qflo Plus / Qpak Series Pump (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.) Also see Figure 9-4: "PTO Drive Option" on page 154.
1. Remove the rear bearing cap, bearing and gasket - the four (4) 7/16"-14 screws. 2. Examine the rear bearing cover bearing and if required, remove the retaining ring
to separate the bearing from the cover. Replace accordingly. 3. Remove the retaining ring holding the input gear in place. 4. To remove the sliding gear shaft, gear and fork, see heading "Sliding Gear and
Fork" on page 152. 5. Clean and inspect all parts for excessive wear, chips, scoring or other damage.
Repair and/or replace accordingly.
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Figure 9-4: PTO Drive Option
Assembly
Gearshift Cap (See Figure 9-3: "Power Gearshift Assembly" on page 152.)
1. Install new switch seal rings, then thread gearshift switch into the gear shift shaft cap.
2. Install a new gearshift cap gasket. 3. Install the gearshift shaft cap - two 7/16"-14 screws.
Sliding Gear Assembly (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
1. Hold the gearshift fork in place and slide the gearshift shaft through the opening in front of the housing and the gearshift fork. Be sure the fork is in the proper position.
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2. Apply Loctite #242 to the 018-8340-00-0 screw that attaches the fork to the shaft. Tighten and torque to 65 ft.-lbs. (88 N-m).
3. Place the sliding gear into the shift fork. Make sure the shift fork groove on the sliding gear is oriented towards the front of the gearbox. (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
4. Install a new drive shaft oil seal in the front bearing cap.
5. Using a brass drift or bearing installation tool, install the sliding gear bearing. (See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
6. Install the slinger onto the sliding gear shaft.
7. Insert the sliding gear shaft into the front bearing cap by sliding it from the front to the rear. Do not damaging the oil seal.
8. Install the bearing retaining ring.
9. Apply Loctite #242 to the four 7/16"-14 screws. Install the sliding gear shaft and front bearing cap and gasket. Tighten and torque screws, in a criss-cross pattern, to 40 ft.-lbs. (54 N-m).
10. The sliding gear shaft must mesh with the sliding gear. Insure the gearshift fork is in its proper position.
Tail Shaft and Gear Shift Assemblies
(See Figure 9-2: "Tail Shaft Assembly" on page 150.)
1. Using a brass drift or bearing installation tool, install the inner tail shaft bearing.
2. Install a new shaft oil seal, Hale p/n: 296-2540-00-0.
3. Insert the tail shaft into the rear bearing housing. Do not damage the oil seal.
4. Install both retaining rings.
5. Using a brass drift or bearing installation tool, install the outer tail shaft bearing.
6. Install a retaining ring to secure the outer bearing in place.
7. Install the sliding gear shaft needle bearing to the front end of the tail shaft.
8. Install the tail shaft and rear bearing cap and gasket. Ensure the needle bearing slides over the male end of the sliding gear shaft.
9. Install the rear bearing cap - four 7/16"-14 screws. (See Figure 9-2: "Tail Shaft Assembly" on page 150.) EVENLY tighten and torque the screws, in a criss-cross pattern, to 40 ft.-lbs. (54 N-m).
10. Install a new shifting cylinder gasket. (See Figure 9-3: "Power Gearshift Assembly" on page 152.)
11. Install a new shaft seal O-ring in the shifting cylinder.
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12. Install the shifting cylinder assembly by sliding it over the gearshift shaft. Apply Loctite #242 to the two 7/16"-14 nylon locking screws and tighten.
13. Install the inner piston retaining ring, then install a new piston inner seal ring.
Note: Install piston retaining rings with flat side (square corners) facing away from piston.
14. Install a new piston outer seal ring. (See Figure 9-3: "Power Gearshift Assembly" on page 152.)
15. Install the cylinder piston with the flat side of the piston facing the interior of the cylinder.
16. Install the outer piston retaining ring, then install a new gearshift shaft seal on the cylinder cover.
17. Install cylinder cover - two 5/16"-18 hex screws and 5/16"-18 studs and tighten. 18. Install the gearshift rod end. Tighten the 3/8"-16 hex nut.
PTO Drive Option
(See Figure 9-4: "PTO Drive Option" on page 154.)
1. Slide the rear bearing cover and gasket, with bearing (and retaining ring) onto the sliding gear stem.
2. Install, tighten and torque accordingly - four (4) 7/16"-14 hex screws. (See Table 7-1: "Typical Torque Values Chart" on page 105.).
Intermediate Shaft Assembly
(See Figure 9-1: "Intermediate Shaft and Sliding Gear, Typical G Series Gearbox" on page 149.)
1. Press a new intermediate gear bearing assembly (two bearings with split spacer) into the intermediate gear.
2. Install new seal O-rings. 3. Set the gearshift in the PUMP position. 4. Place the intermediate gear in position towards the front of housing, centered
over the sliding gear.
Note: On "XG" series gearboxes, hold the intermediate gear spacer in position towards the rear of the gearbox housing. Install the intermediate shaft (front cutout facing down) through the front opening in the gearbox housing.
5. Press the intermediate shaft through the intermediate gear (and the intermediate gear spacer) until the cut out on the front of the shaft is flush with the outer surface of the gearbox housing.
6. Install the shaft washer and tighten the screw - 7/16-14 screw.
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7. Rotate the sliding gear shaft and manually shift the gearshift to check for proper operation.
8. Remove the gearbox from the holding fixture and install - see heading "Installation - G Series" on page 112.
9.2 J SERIES GEARBOX MAINTENANCE
(See Figure 9-5: "Typical J Series Gearbox Assembly" on page 158.)
Review heading "Before You Begin..." on page 103. Also review heading "Cleaning and Inspection Guidelines" on page 106. Also review WARNINGS! note found on page 104.
Disassembly
Idler Shaft Disassembly 1. With the gearbox secured in a holding fixture, remove and disassemble the idler
shaft assembly. (See Figure 9-5: "Typical J Series Gearbox Assembly" on page 158.) 2. Remove the 1/2-13 screw and washer from the idler shaft. 3. Press the idler gear shaft out of the gearbox housing from the front of the unit towards the rear. 4. Through the top of the gearbox, remove the idler gear assembly, which includes two tapered roller bearings. Remove the bearings from each side of the idler gear. 5. Remove the idler shaft seal ring from the shaft. 6. Clean and inspect each component of the intermediate shaft assembly. Inspect bearings for wear, pitting, and damage. Inspect the gear tooth surface for wear damage and pitting.
Note: During reassembly, apply a thin coat of grease the seal rings to limit resistance as the seals pass through the housing and bearings.
7. Replace all components that are worn, damaged, or pitted.
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158
Figure 9-5: Typical J Series Gearbox Assembly
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Screw A (4) Screw B (4)
Upper Housing
Gasket Breather Vent
End Cap Hex Head Capscrew
(1/2" -13 UNC x 1-1/4")
Gear Spacer
Idler Shaft O-Ring Tapered Roller Bearing
Dowel Pin (2)
Idler Gear
(57 Teeth)
Retaining Ring Tapered Roller Bearing
Washer Hex Head Capscrew
(1/2" -13 UNC x 2")
Spacer Gasket (2)
Drive Gear
(54 Teeth)
Plug
(1/2" NPT)
Hex Head Capscrew
(5/8" -11 UNC x 1-1/2")
Washer Flange Oil Seal
Retaining Ring
Spherical Bearing
Spacer Spherical Bearing Retaining Ring Oil Seal
Input Shaft
Lower Gearbox Housing
View Gauge
(1/2" NPT)
Magnetic Plug
(1/2" NPT)
Key Input Gear Key
Gearbox Maintenance
Input Shaft Disassembly (See Figure 9-5: "Typical J Series Gearbox Assembly" on page 158.)
1. Remove the 1/2"-13 screw and washer. 2. Using an appropriate puller, remove the companion flange from the input shaft. 3. Remove the companion flange 0.375" x 1.563" (10 x 40 mm) key from the shaft. 4. Remove the oil seal from the companion flange end of the drive shaft, then
remove the bearing retaining ring. 5. Remove oil seal from other side of gearbox and remove the bearing retainer ring. 6. Using proper press, carefully press the input shaft from gearbox housing. 7. Remove the bearings and the input shaft 0.750" x 1.75" (19 x 44 mm) square key
from input shaft. 8. Note the orientation of gear, then through top of gearbox housing remove the
input gear from gearbox housing. 9. Using bearing puller, remove bearings from gearbox housing if necessary.
Assembly and Installation
(See Figure 9-5: "Typical J Series Gearbox Assembly" on page 158.)
Input Shaft Assembly 1. On the "non-drive" side of the gearbox housing, install the following (in order):
A new spherical bearing. A new retaining ring.
2. On the "drive" side of the gearbox housing, install the following (in order): Input gear into gearbox housing in proper orientation. (See Figure 9-5: "Typical J Series Gearbox Assembly" on page 158.) 3/4" x 1-3/4" (19 x 44 mm) square key in the input shaft. Holding the input gear in place, insert input shaft while aligning the shaft key to the slot in the gear. Also, make sure the shaft aligns with the bearing. A new spherical roller bearing over the input shaft. Align the shaft and bearing with the housing and carefully press bearing into place. A new retaining ring into gearbox housing.
3. Press new oil seals into both sides of gearbox housing.
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4. Install the 0.375" x 1.563" (10 x 40 mm) key on input shaft, then install the companion flange.
5. Apply Loctite #242 to 1/2"-13 UNC screws, then install the washer and screw. Tighten and torque accordingly.
Idler Shaft Assembly 1. Press new tapered roller bearings into the idler gear. (See Figure 9-5: "Typical J
Series Gearbox Assembly" on page 158.) 2. Install new shaft seal ring on the end of the idler shaft. 3. Through the top of the gearbox housing, insert the idler gear in position towards
the front of the gearbox housing. Ensure the teeth of the idler gear align to the teeth of the input gear. 4. Press the idler shaft through the idler gear until the shaft is seated in the gearbox housing. 5. Apply Loctite #242 to the 1/2-13 screw. Install the washer and screw. Tighten the 1/2-13 screw. 6. Rotate the input gear shaft to check for proper operation. 7. Using an appropriate lifting device, remove the gearbox from the holding fixture. 8. Install the gearbox - see heading "J Series Gearbox" on page 112.
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9.3 K SERIES GEARBOX MAINTENANCE
Oil seals (Input/Tail Shafts)
Figure 9-6: Oil Seal Replacement
Input shaft and tail shaft oil seals are replaced by disconnecting the yoke from the pump and can be accomplished with the unit installed.
1. Remove the 3/4-10 x 1-3/4" screw and washer and carefully slide the yoke from the shaft.
2. Remove the defective oil seal being careful not to score the shaft. 3. Carefully insert a new oil seal into the housing. 4. Carefully slide the yoke onto the shaft and secure using the 3/4-10 x 1-3/4" screw
and washer. Torque screw to 260 ft.-lb. (352 N-m). DO NOT overtighten the yoke must spin freely.
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Tail Shaft Assembly
IMPORTANT!
THE MOST EFFICIENT METHOD FOR INTERNAL SERVICING OF THE GEARBOX IS TO REMOVE IT AND THE PUMP ASSEMBLY AS A COMPLETE UNIT FROM THE APPARATUS.
Figure 9-7: Tail Shaft Assembly
Removal And Disassembly
1. Review preceding sections "Before You Begin...," on page 103. 2. Remove eight 7/16-14 x 1-1/2" screws securing bearing carrier to the gearbox
housing. 3. Slide the complete bearing carrier assembly out of the gearbox housing. 4. Begin taking apart the bearing carrier assembly by unscrewing the 3/4-10 x
1-3/4" screw and washer from yoke. Remove the yoke from the tail shaft. 5. Drive tail shaft through bearing carrier. Use a dead blow hammer or similar to
avoid marring the shaft.
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6. Press the bearing cone off the tail shaft. 7. If necessary, remove the roller bearing inner race. 8. Remove the oil seal. It will be damaged during this process and must be
replaced. Replacements are ordered using Hale p/n: 296-2680-00-0. 9. Remove the bearing cone from the bearing carrier. Gently tap out the bearing cups and remove the bearing spacers. 10. Using retaining ring pliers, remove the retaining ring from the bearing carrier. 11. Remove the O-ring seal from the bearing carrier.
Inspection 1. Clean bearings and other components using parts cleaner. 2. Carefully inspect bearings and seals for signs of excessive wear. The bearings,
shims, and spacers are a matched set and must be replaced as a unit. Order using Hale p/n: 250-8140-53-0. 3. Obtain new components from Hale Products as appropriate.
Reassembly and Installation See Figure 9-7, "Tail Shaft Assembly," on page 162
1. Using retaining ring pliers, install retaining ring into bearing carrier. 2. Insert, on top of the retaining ring, the outer bearing spacer, then press in the
bearing cup.
Note: Be careful not to mix bearing components with those from other bearing sets. Should the outer spacer be confused with that from the bearing carrier, the one used for the tail shaft assembly is noticeably thinner than the bearing carrier spacer.
3. To the tail shaft, press on the roller bearing inner race (see Figure 9-7: above). 4. Slide the matching inner bearing cone and spacer onto the tail shaft. Both are a
tight fit. 5. Insert tail shaft into gearbox housing, aligning inner race of roller bearing with
outer race on the mating input shaft. Also see Figure 9-8: "Shaft End Gap".
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Figure 9-8: Shaft End Gap
6. Carefully slide bearing carrier over the tail shaft.
7. Temporarily secure bearing cover using eight 7/16-14 x 1-1/2" screws. Torque screws to 50 ft.-lb. (68 N-m).
8. Using a feeler gauge, measure the gap between the input and tail shafts, as shown in Figure 5-3 above.
9. Remove the bearing carrier and install correct amount of spacers to produce a 0.060" ± 0.010" (1.524 mm ± 0.254 mm) gap.
Note: Under normal circumstances, replacing bearings, seals, cones, etc. will have little effect on the gap setting. Reinstalling all existing shims maintains the required gap (0.060" ± 0.010" [1.524mm ± 0.254mm]). However, if either shaft is replaced or the housing is changed, the gap must be checked and set.
10. Repeat Steps 5 through 8. Also repeat Step 9, if necessary.
11. When the gap is properly shimmed and you are ready to install the bearing carrier to the gear box, install a new gasket.
Use a light coating of general purpose grease to hold the gasket in place. 12. Place the inner spacer onto the tail shaft. Insert the remaining bearing cone onto
the tail shaft. Both are a tight fit.
13. Carefully press a new oil seal into the bearing carrier.
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14. Place the yoke onto the end of the tail shaft and secure using the 3/4-10 x 1-3/4" screw and washer. Torque screw to 260 ft.-lb. (352 N-m). Rotate the yoke to ensure free spin. If too tight, back-off slightly on the 3/4-10 bolt.
15. Secure the bearing carrier using eight 7/16-14 x 1-1/2" Grade 8 screws. Apply Loctite 246 (or equal) to the threads prior to installation. Torque screws to 50 ft.-lb (68 N-m).
16. Replace the fluid and install the gearbox cover.
Input Shaft
Figure 9-9: Input Shaft Assembly
Removal and Disassembly
1. Remove gearbox cover and tail shaft assembly as previously described. 2. Unscrew the 3/4-10 x 1-3/4" bolt and washer securing the input yoke.
Slide the yoke off the input shaft. 3. Carefully drive the input shaft into the gearbox using a dead blow hammer, or
similar, to avoid marring the shaft. 4. Pull the input shaft through the bearing carrier bore and out of the gearbox hous-
ing.
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Note: The shift collar, input gear, bearing cone, inner spacer, shims, needle bearing, and bearing cup may drop into the gearbox housing. Remove these components from the gearbox housing.
5. If necessary, remove the roller bearing outer race from the input shaft. 6. Remove the oil seal. It will be damaged during this process and must be
replaced. A replacement oil seal can be ordered using Hale p/n: 296-2860-01-0. 7. Remove the remaining bearing cone out of the housing. See Figure 9-9, "Input
Shaft Assembly," on page 165. 8. Tap out bearing cups and remove outer spacer. 9. Using retaining ring pliers, remove the retaining ring from the gearbox housing.
Inspection
1. Clean bearings and other components using parts cleaner. 2. Carefully inspect bearings and seals for signs of excessive wear.
The tapered roller bearings, shims and spacers are a matched set and must be replaced as a unit. Order a new set using Hale p/n: 250-8140-52-0. 3. Obtain new components from Hale Products as appropriate.
Reassembly and Installation
See Figure 9-9, "Input Shaft Assembly," on page 165.
1. Using retaining ring pliers, install the retaining ring into the gearbox housing. 2. Insert the outer bearing spacer and press the outer bearing cup into place.
Note: Should the outer bearing spacer be confused with that of the tail shaft assembly, the one used in the bearing carrier assembly is noticeably thicker.
3. Tap the inner bearing cup into place. Tap evenly around circumference to prevent an uneven fit.
4. Press the roller bearing outer race into the input shaft. Using retaining ring pliers, insert the retaining ring into the input shaft.
5. Insert the input shaft partially through the bearing cover bore and install the needle bearings, shifting collar, input gear, and bearing cone onto the shaft.
6. Insert the input shaft into the housing until the bearing cone contacts the bearing cup.
7. Install the inner bearing spacer and shims onto the input shaft and press the remaining bearing cone onto the input shaft.
8. Carefully press the oil seal into the housing.
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9. Secure the input yoke onto the input shaft using the washer and 3/4-10 x 1-3/4" screw. Torque to 260 ft.-lb (350 N-m).
10. Install the tail shaft and gearbox cover.
KPS Power Shift Assembly
Figure 9-10: KPS Shift Cylinder Assembly
Removal 1. Pull the shift rod into PUMP position (out). Loosen 3/8-16 nut and remove rod end
and nut from end of shift shaft. 2. Unscrew four 5/16-18 x 1" screws holding down KPS cover. 3. Remove cylinder cap and seal O-ring. 4. Using a seal pick, remove scraper and seal ring from the KPS cap. 5. Unscrew KPS extension shaft. 6. Remove KPS piston from shaft then remove seal rings. 7. Unscrew two 7/16-14 x 1" screws then remove KPS cylinder and gasket. 8. Remove seal ring from shift cylinder.
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Gearbox Maintenance
9. Remove and check bushing for wear. Replace accordingly with Hale p/n: 2509550-00-0.
Installation 1. Install new seal ring in cylinder groove. 2. Using a light coating of general-purpose grease to hold it in place, install gasket
on gearbox. 3. Align KPS cylinder and secure using two 7/16-14 x 1" screws. 4. Apply a light coating of general-purpose grease to seal rings before installation.
Install a new seal ring on the piston then install piston on shaft. Make sure the flat side of the piston is towards the inside of the cylinder. 5. Thread extension shaft onto shift rod. Prior to installation, coat threads with Loctite 246 (or equal). 6. Make sure the piston and shaft move freely in the shift cylinder. 7. Apply a light coating of general-purpose grease then install the scraper and seal rings in the KPS cover. 8. Install KPS cover with scraper and seal rings over the shaft. 9. Apply Loctite 246 (or equal) then install four 5/16-18 x 1" screws. 10. Install rod end and 3/8-16 nut on end of shift shaft. Lock the rod end with the nut.
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KPS Shift CAP and Switch
Gearbox Maintenance
Figure 9-11: KPS Shift Cap Assembly
Removal 1. Disconnect control connection. 2. Unscrew the 1/2-20 x 1/2" setscrew, then remove detent spring and ball. 3. Unscrew the switches and remove them from the cap. See Figure 9-11: "KPS
Shift Cap Assembly". 4. Remove two 7/16-14 x 1" cap screws and the gearshift shaft cap (not shown). 5. Remove the gasket from the mating surface of the gearbox.
Installation 1. Apply a light coating of general-purpose grease to hold gasket in place, then
place gasket on gearbox.
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Gearbox Maintenance
2. Align the gearshift shaft cap. Apply Loctite 246 (or equal) and install two 7/16-14 x 1" screws.
3. Install the detent ball and spring. Secure using 1/2-20 x 1/2" setscrew. 4. Place detent ball into gearshift cap. Install the switches onto the cap by threading
them in. Prior to installation, coat threads with Loctite 246 (or equal). 5. Reconnect the electrical control connection.
Gear Shift Fork
Removal 1. Remove gearbox cover, tail shaft assembly, input shaft assembly, KPS cylinder,
and KPS shift switch. 2. Release the gearshift fork by unscrewing the shift fork screw. 3. Pull the shift-shaft from the gearbox and remove gearshift fork from inside the
gearbox. 4. Drive shift shaft bushings out of gearbox housing, if necessary.
Installation 1. If necessary, press shift shaft bushings into gearbox housing. 2. While holding the shift fork in place, insert shift shaft into gearbox housing by slid-
ing shaft through the shift fork. 3. Install shift fork screw. This is a specialty screw that cannot be substituted with
standard hardware. Contact Hale for replacement part, Part Number 018-835000-0. 4. Install KPS shift switch, KPS cylinder, tail shaft assembly, input shaft assembly, and gearbox cover.
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Idler Shaft
Gearbox Maintenance
Figure 9-12: Idler Shaft Assembly
Removal
1. Remove the gearbox cover, tail shaft, KPS, and input shaft. 2. Remove 1/2-13 x 1-1/2" screw and brass washer. 3. Insert a brass drift or similar into the 1/2-13 tapped hole and tap the idler shaft out
of the gearbox housing. 4. Remove idler gear assembly and spacer from gearbox housing. 5. Begin disassembling the idler gear assembly by removing the bearing cups,
shims, and inner spacer. 6. Next, tap the bearing cones from the idler gear. Take care not to damage the
gear. 7. Using retaining ring pliers, remove the two retaining rings from the idler gear. 8. Remove O-ring from idler shaft.
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Gearbox Maintenance
Inspection 1. Clean bearings and other components using parts cleaner. 2. Carefully inspect bearings and seals for signs of excessive wear.
The bearings, shims, and spacers are a matched set and must be replaced as a unit. Order a new set using Hale p/n: 250-8310-00-0. 3. Obtain new components from Hale Products as appropriate.
Installation 1. Assemble the idler gear assembly by first installing the two retaining rings into the
idler gear using retaining ring pliers. 2. Next press the bearing cups into the idler gear. 3. Finish the assembly by installing the bearing spacer, shims, and cones. 4. Install the O-ring on the idler shaft. 5. With the gearbox housing horizontal, partially insert the idler shaft into the hous-
ing, and slide the idler gear assembly and spacer onto the shaft. 6. Apply Loctite 246 (or equal) to the 1/2-13 x 1-1/2" screw and brass washer.
Tighten screw to 75 ft.-lb. (102 N-m). This will pull the shaft into the housing. 7. Install the input shaft, KPS, tail shaft, and gearbox cover.
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Installation
10 Installation
10.1 OVERVIEW
This section provides guidelines and recommendations for installing the midship muscle pump assembly into your truck chassis.
10.2 MOUNTING
Also see Section "Installation and Parts Drawings," located at the back of this manual. Plate # 923A ........ Qpak Installation Plate # 887A ........ Qmax Installation Plate # 884A ........ Qflo Installation Plate # 889A ........ Qtwo Installation Plate # 1159 ........ Qmax K Plate # 1173 ........ Qtwo K
IMPORTANT!
TO FULLY SUPPORT THE MIDSHIP MUSCLE PUMP ASSEMBLY, USE ALL MOUNTING BOLT HOLES PROVIDED IN THE MIDSHIP PUMP HOUSING. ALSO SEE FIGURE 7-1: "LIFTING EYEBOLT ATTACHMENT LAYOUT" ON PAGE 174.
WARNING!
THE MIDSHIP 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, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE MIDSHIP PUMP AND GEARBOX ASSEMBLIES.
Mounting Holes
Two 1/2-13 tapped holes mounting holes are provided for 1/2-13 UNC eyebolts. (See Figure 7-1: "Lifting Eyebolt Attachment Layout," on page 174.)
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Installation
174
Figure 7-1: Lifting Eyebolt Attachment Layout
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Installation
10.3 DRIVELINE ISSUES
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.
CAUTION!
ALL FASTENERS ON THE HALE PUMP AND GEARBOX ASSEMBLY HAVE BEEN SELECTED FOR THEIR APPLICATION. HALE DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTERNATIVE POSES A SERIOUS SAFETY RISK.
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC 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 equipment and its operators and to reduce unnecessary "downtime."
Issues
It is critical to use computer driveline analysis software, such as Dana's "The Expert," during driveline layout. Dana's software is available free on the World Wide Web at:
http://www2.dana.com/expert
When performing calculations, strive to achieve the lowest driveline torsional and inertial vibrations, making sure to avoid severe driveline angles. Be conservative and always err on the side of SAFETY. Always measure the drive shaft after construction to make sure it matches the computer design.
Remember the following points while designing a driveline:
Problems can occur with or without noticeable vibration. Do not use a bubble protractor to measure driveline angles. Use a digital inclinom-
eter. Remember to zero the inclinometer on the truck frame, not the ground. Center the sliders.
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Installation
Long drivelines can lead to component vibration or failure. As the driveline approaches half critical speed, a vibration will occur that can damage driveline components.
Table 10-1: Maximum Recommended Driveline Lengths below lists the maximum driveline length using a safety factor of 42% of critical speed.
Table 10-1: Maximum Recommended Driveline Lengths
Shaft RPM
2,400 2,600 2,800 3,000 3,200 3,400 3,600 3,800 4,000
2.0 (51) 47 (1,194) 45 (1,143) 44 (1,118) 42 (1,067) 41 (1,-41) 39 (991) 38 (965) 37 (940) 36 (914)
Tube Diameter, Inches (Millimeters)
2.5 (64)
3.0 (76)
3.5 (89) 4.0 (102)
53 (1,346) 51 (1,295) 49 (1,245) 47 (1,194) 46 (1,168) 44 (1,118) 43 (1,092) 42 (1,067) 41 (1,041)
58 (1,473) 55 (1,397) 53 (1,346) 52 (1,321) 50 (1,270) 48 (1,219) 47 (1,194) 46 (1,168) 45 (1,143)
63 (1,600) 60 (1,524) 58 (1,473) 56 (1,422) 54 (1,372) 53 (1,346) 51 (1,295) 50 (1,270) 48 (1,219)
67 (1,702) 64 (1,626) 62 (1,575) 60 (1,524) 58 (1,473) 56 (1,422) 55 (1,397) 53 (1,346) 52 (1,321)
4.5 (114) 71 (1,803) 68 (1,727) 65 (1,651) 63 (1,600) 61 (1,549) 59 (1,499) 58 (1,473) 56 (1,422) 55 (1,397)
This table is based on a 0.134" (3.4mm) wall thickness. Although wall thickness does not have a significant effect on drive shaft length for this calculation, it does have some effect.
Extremely short drive lengths can also cause problems from excessive operating angles. Use caution and conservative design values when utilizing air ride suspension and short rear drivelines.
More information on fire apparatus drivelines can be found in Hale OEM Technical Bulletin # 957. For application assistance and approval, contact a driveline equipment manufacturer, such as Spicer/Dana or Merritor.
Note: Hale assumes no liability for any information provided under this heading "Driveline Issues." Driveline design and truck system integration is the responsibility of the apparatus manufacturer. Failure to comply with the driveline parameters set forth can result in termination of Hale's warranty on driveline related issues.
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Installation
10.4 PLUMBING CONNECTIONS
Also see Section "Installation and Parts Drawings," located at the back of this manual for more detail.
Plate # 923 .......... Qpak Installation Plate # 887 .......... Qmax Installation Plate # 1052 ........ Qflo Plus Installation Plate # 889 .......... Qtwo Installation The midship muscle pumps offer a variety of suction and discharge arrangements to suite most applications and is dependent on model purchased. Review the above plate drawings for your model for additional information.
Other flanges and manifolds are available. Contact Hale Products at 800-533-3569.
10.5 PANEL MOUNTED ACCESSORIES
Hale panel mounted accessories are designed with consideration given for proper drainage to prevent freezing. Due to the symmetry of the design, it is possible to install some accessories incorrectly - upside down. To insure proper installation, review the following:
Panel mounted accessory devices must be installed above the level of the pump or a drain must be installed at the low point in the line. (Do not connect to the master drain.)
All tubing connectors should be on the bottom of the device or pointed down to avoid traps and to provide natural drainage.Tubing should be installed with the shortest, most direct route and should not be "teed" for another purpose. No loops or bends that could create water traps should be allowed as an ice filled low spot could result in a safety device malfunction.
All devices are designed to operate with the available water through 3/8" (9.5mm) ID tubing. If plastic or nylon tubing is being used that has a smaller ID, caution should be exercised since it could adversely affect the reaction time of the device.
10.6 FLUID LEVELS
To meet various shipping regulations, ALL fluids within the pump and gearbox assemblies (excluding the Auto-Lube) are drained prior to shipping from the factory.
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Installation
IMPORTANT!
AT INSTALLATION AND BEFORE OPERATING FOR THE FIRST TIME, OIL MUST BE ADDED TO THE GEARBOX RESERVOIR TO THE APPROPRIATE LEVELS. FOR THE
PROPER OIL TO USE AND QUANTITY REQUIRED, SEE HEADING "REPLACE GEARBOX OIL" ON PAGE 80. ALSO SEE FIGURE 5-5: "MUSCLE PUMP SERVICE CHART, PART 2 OF 3" ON PAGE 89.
The auto-lube assembly is NOT drained at shipment but must be checked prior to operation. To check the auto-lube for oil, see Step 18. of Section 7.6 "QMID/QMAX/ QTWO AutoLube ® Service" on page 116. Also see Figure 5-4: "Muscle Pump Service Chart, Part 1 of 3" on page 88.
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Glossary
Appendix A: Glossary
Atmospheric .......Pressure caused by the elevation of air above the earth. Atmospheric pressure is 14
Pressure .............pounds per square inch at sea level. Pressure increases below sea level and decreases
above sea level. The weather also effects atmospheric pressure. Atmospheric pressure
effects a pumps ability to pump from draft. Higher pressures increase a pumps
performance, while lower pressures can cause a noticeable decrease in lift.
Auxiliary..............Permits water from a pump to cool the radiator water through a heat exchange.
Cooling Valve
Capacity ..............Pump flow rating.
Cavitation ...........Occurs when the pump attempts to deliver more fluid than is being supplied. This causes
the formation of bubbles in the pump. When the bubbles collapse, the liquid, under
pressure, rushes in to fill the empty space. This damages the pump and must be
corrected immediately.
Centrifugal .........Force that tends to make rotating bodies move away from the center of rotation.
Force
Centrifugal .........A pump that uses a rapidly spinning disk or impeller to create the pressure for fluid
Pump
movement.
Certification ........Pumper test in accordance with NFPA standards to determine if a pump can deliver its
rated volume and pressure.
Check Valve........A one-way valve or non-return valve that allows flow in one direction, but shifts to prevent
flow in the reverse direction.
In two stage pumps, there are two swing check or flap valves in the suction passage
of the second stage. They are located in each side of the pump between the suction
tube and the pump body. These valves swing open when pumping in parallel for volume.
They are closed by first stage pressure when pumping in series for pressure.
Clearance ...........Prevents discharge fluid from returning to the eye of the impeller.
Ring
Compound .........A compound gauge is graduated to read pressure in "pounds per square inch" and
Gauge
"vacuum in inches of mercury."
Cut Water ............Cut water is a wedge-shaped point between the volute (pump body) and the pump
discharge where the volume of fluid is directed to the discharge connection.
Dead Heading .....Operating a pump without any discharge. The lack of flow causes temperatures to rise
inside the pump.
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Glossary
WARNING!
IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. THIS COULD DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.
Double Suction ..Fluid enters on both sides of the impeller. Impeller Dry Prime Test ...Provides information on the ability of a priming pump to evacuate air from the main
pump. If the vacuum does not hold, it is an indication there is a leak in the system. Flow Meter ..........Measures the volume of fluid that is flowing. Friction Loss ......Loss of pressure in hose, fittings, standpipes, and other appliances because of the
resistance between the fluid molecules and the inside surfaces of the hoses, fittings, standpipes, piping, and other appliances. Front-Mount .......Pump mounted ahead of the vehicle's engine usually on the front of the radiator. Pump Gauge .................Pressure read from a gauge (PSIG). Pressure Governor.............Minimizes pressure changes by controlling engine speed to maintain pump discharge pressure. Horsepower ........A measure of mechanical work. Impeller ...............The working part of a centrifugal pump that, when rotating, imparts energy to fluid. Essentially, an impeller consists of two disks separated by vanes. The vanes force the fluid to move outward between the disks so that it is thrown outward at high velocity by centrifugal force. The water from the impeller discharges into a diverging passage known as a volute, converting the high velocity energy of the water into pressure. Impeller Eye........Point where fluid enters the impeller. Net Pump ............The difference in pressure between discharge and suction pressure. Pressure Packing ...............Material that maintains an airtight seal at the point where the impeller shaft enters and exits the pump body. Parallel ................Capacity position in which each impeller on a two-stage pump works independently into the discharge often termed "Volume Mode." 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 Positive ..............Pressure above atmospheric. Pressure Power Valve........A valve that uses hydraulic pressure to transfer two-stage pump operation from volume
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Glossary
mode to pressure mode, and vice versa.
Pressure .............Force per unit area.
Pressure ............The pressure gauge is usually graduated in pounds per square inch (PSI) only. It
Gauge
is connected to the pump discharge manifold, thus indicating pump discharge ressure.
Priming ...............Priming evacuates the air from the main pump and suction hose, thus creating a vacuum.
This allows atmospheric pressure on the source of the fluid to push the fluid up into the
suction hose and pump.
Priming Pump ....An auxiliary positive displacement pump which pumps air out of the pump body that
creates a vacuum to prime the main pump. The priming pump is a rotary vane type,
electric motor driven. Once the main pump is primed and pumping, the priming pump
is shut off.
Priming Pump ...A valve located in the priming line between the priming pump and the main pump.
Valve
It remains closed at all times except when priming. The control is normally located on
the pump panel.
Pump Shift ..........A midship pump is usually mounted with a split gearbox installed in the drive shaft.The
pump shift moves a sliding gear in the gearbox that transmits power either to the pump
or the rear axle. In ROAD position, power is shifted to the rear axle for driving; in PUMP
position, the rear axle is disconnected, and power is shifted to the pump shaft.
Relay ...................Movement of water from an apparatus at a water source to additional apparatus until
water reaches the fire ground.
Relief Valve.........An automatic valve which, when activated by the relief valve control, holds pump
pressure steady when discharge valves or shut-off nozzles are closed. The valve
maintains its given pressure by dumping the pump discharge flow into the pump suction.
Relief Valve ........A handwheel adjustment valve which controls and/or adjusts the relief valve to
Control (PM) maintain the working pressure (i.e., set to control the desired pressure).
Series ..................Pressure position in which the first impeller's discharge is fed to the eye of the second
impeller in a two-stage pump which then discharges the fluid from the pump (often
termed "Pressure Mode").
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.
Stages .................The number of impellers in a pump that are used in series; that is, one following another
in terms of flow. Each impeller develops part of the total pump pressure.
Tachometer ........Indicates the speed of the engine crankshaft in revolutions per minute.
Torque.................The force that acts to produce rotation.
Transfer Valve ...A two-position valve in a pump that changes the operation from parallel (volume) to
series (pressure) operation and vice versa (not used on single stage pumps).
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Glossary
Vanes ..................Guides inside an impeller that direct fluid to the volute (pump body). Volute..................A gradually increasing discharge waterway. Its function is to collect the water from the
impeller and, depending on its design, it either increases pressure and decreases velocity or increases velocity and decreases pressure. Water...................Amount of energy in the water stream. Horsepower Wear Rings .........See Clearance rings.
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Measurements and Conversions
Appendix B: Measurements and Conversions
Water Horsepower ........................................................................................................ (GPM x PSI)/1,714 One Gallon of Water Weighs .................................................................................................. 8.33 Pounds One Gallon...................................................................................................................... 231 Cubic Inches One Cubic Foot....................................................................................................................... 7.48 Gallons One Pound per Square Inch of Head ........................................................................... 2.31 Feet of Water One Inch of Mercury ................................................................................................... 1.132 Feet of Water One Pound per Square Inch ...............................................................................2.0178 Inches of Mercury
equals 27.68 inches of Water One Cubic Meter...................................................................................................................... 1,000 Liters One Imperial Gallon .................................................................................................................. 1.2 Gallons
To Convert
BAR Feet of Head FT-LB (Torque) Gallons HP (Horsepower) One Pound per Square Inch (PSI) One Pound per Square Inch (PSI) Pounds per Square Inch (PSI)
Table B-1: Conversion Chart
To
PSI Pounds Pressure N-m Liters KW (Kilowatts) One BAR KPA Feet of Head
Multiply By
14.504 0.4331 1.3558 3.785 0.7457 0.0690 6.895 2.31
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Measurements and Conversions
NOTES
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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 .
Table C-1: Alternate Lubricant Manufacturers (Sheet 1 of 2)
Oil / Lubricant
Manufacturer
Alternate STANDARD-Temperature Lubricant (Cognis 2923/2833) See Service Manual for additional information.
Brad Penn Full Synthetic Transmission Lube SAE-50
American Refining Group 77 N Kendall Avenue Bradford, PA 16701
Bulldog Synthetic Transmission Lube SAE-50 Trans.
D-A SynSure Synthetic Lube SAE-50 Trans.
Mack Truck Company 2100 Mack Boulevard Allentown, PA 18105
D.A. Lubricant Company, Incorporated 1340 West 29th Street Indianapolis, IN 46208
Dyna-Plex 21C Synzol SAE-50 Trans.
Universal Lubricants P O Box 2920 2824 North Ohio Wichita, KS 67219
Emgard SAE-50 Synthetic Transmission Lubricant
Cognis Corporation 5051 Estecreek Drive Cincinnati, OH 45232
Fleetrite Synthetic SAE-50 Transmission Oil Trans.
Hi-Tek Synthetic SAE-50 Trans.
International Truck & Engine Corporation 5 Westbrook Corporate Center Westchester, IL 60154
Industrial Oils Unlimited P O Box 3066 Tulsa, OK 74101
Kenworth SAE-50 Original Factory Fill Fluid Trans.
Paccar Parts 750 Houser Way N Renton WA 98055
Maxtro MT SAE-50 Trans.
Country Energy LLC 5500 Cenex Drive Inver Grove Heights, MN 55077
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Alternate Lubricant Manufacturers
Table C-1: Alternate Lubricant Manufacturers (Sheet 2 of 2)
Oil / Lubricant
Manufacturer
Alternate STANDARD-Temperature Lubricant (Cognis 2923/2833) See Service Manual for additional information.
Monarch Syntran Plus SAE-50 Trans.
Royal Manufacturing Company, Inc. P O Box 3308 516 South 25th West Avenue Tulsa, OK 75127
Mystik Synguard SX-7000 SAE-50 Trans.
Cato Oil and Grease Company P O Box 26868 1808 NE 9th Street Oklahoma City, OK 73126
Peterbilt SAE-50 Original Factory Fill Fluid, Trans.
Paccar Parts 750 Houser Way N Renton, WA 98055
SYN-CD Gear Lubricant SAE-50 Trans.
Valvoline HD Synthetic Trans. Oil SAE-50 Trans.
Black Bear Company, Incorporated 27-10 Hunters Point Avenue Long Island City, NY 11101
Valvoline, Incorporated A Subsidiary of Ashland Oil, Inc. 3499 Blazer Parkway Lexington, KY 40512
Alternate LOW-Temperature Lubricant (Cognis 2803) See Service Manual for additional information.
CAUTION! USE ONLY FOR EXTREME LOW TERPERTAURES, BELOW FREEZING (32° F / 0° C)
Motorcraft Synthetic ATF
Local Ford Dealership
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Lube and Sealant Specifications
Appendix D: Lube and Sealant Specifications
Table D-1: Oil Capacity and Recommendation
Pump
Gearbox or Approximate Capacity
Pedestal
Quarts
Liters
Recommended Oil
4DK
5
4.7
APS
B
2
1.9
APSM
(Vertical)
MBP MBPM 4DB SBP
B
1.5
1.4
(Horizontal)
B
1.75
1.7
(Inverted)
QTWO / QMAX
G
4
3.8
QPAK / QFLO
X, L and R
QFLO PLUS
Series
DSD / SMD
SMM / QSMG / QG 8FGF G
3
2.8
/ 8FGR / RGA / QMID / S Series
LGA
QPAK-J
J
2
1.9
RSD-M / RSD PSM / SMR-A
SMR-A / SMR-U SMR-AC
50FB-U / 50FB-U-U 8FC-U
QFLO-A QPAK-A HFM / CSD / PSD
PSD (Inverted)
HG *
1.4
1.3
Pedestal - Long 0.75
0.71
/ Short
(1.5 pints)
Pedestal
A
1
0.95
2.5
2.4
HP Portables P
1.5
1.4
4
3.8
A
4
3.8
APM / AP (Inverted)
APMG MG
1.25
1.2
MGA
3
2.8
(Horizontal or
Vertical)
I (Special)
4
3.8
CBP4 / CBP5 2CBP4 / 2CBP5
APM / AP CBP / 2CBP CBP2 / CBP3 2CBP2 / 2CBP3
20FS 30FS
50FBG / 80FBG
G
60FBG
1
0.95
1.75
1.7
1.75
1.7
3
2.8
SAE 50 - above 0° F (above -18° C); Dextron III or Cognis 2803 between -40°F to 0°F (-40° to -18°C) SAE 50 80W-90; 75W-80 Synthetic SAE 50 80W-90; 75W-80 Synthetic SAE 50 80W-90; 75W-80 Synthetic SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.) Full Synthetic 75W-140
SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.) 75W-80 Synthetic SAE EP 90 80W-90 (Lubricants must meet service rating API GL-5.) ISO 68 Grade; SAE 50W 80W-90; 75W-80 Synthetic (Lubricants must meet service rating API GL-5.) 10W-40 to 15W-40 Multi-Grade Engine Oil (Lubricants must meet service rating API GL-5.) SAE EP90; 80W-90; 75W-80 Synthetic (Lubricants must meet service rating API GL-5.) SAE 20W Non-Detergent Oil SAE 30W
SAE 20W Non-Detergent Oil SAE 30W SAE 30W SAE EP 90 80W-90 (Lubricants must meet service rating API GL-5.) SAE EP 90 80W-90 (Lubricants must meet service rating API GL-5.) SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.) SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.)
SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.) SAE EP90; 80W-90 (Lubricants must meet service rating API GL5.) SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.)
SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.) SAE EP90 80W-90 (Lubricants must meet service rating API GL-5.)
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Lube and Sealant Specifications
Note: * For domestic use, Hale recommends using an SAE EP-90, 80W-90 Lubricant or "Roadrunner" Full Synthetic SAE 50 Transmission Lubricant, manufactured by the Eaten® Corporation, or equivalent.
Grease
Use a Lithium-based grease with 1% to 3% Molybdenum Dissolved, i.e., Dow Corning BR2-PLUS Lubricate-Fiske #3000 Shell Super Duty Grease Imperial #777 Mobile Grease Special Sunoco Moly #2EP
Note: For Hale SVS Torrent Stainless Valves see separate manual for additional lubrication information.
Green Grease for SVS Valves
Loctite Sealant
#246 High Temperature Removable Threadlock (or equivalent) - primarily for gearbox assembly
#242 Medium Strength Threadlock (or equivalent) - primarily for pump assembly
Oil
See "Alternate Lubricant Manufacturers" on page 185.
Recommended Cleaners
Safety Kleen ® Stoddard Solvent
IMPORTANT!
THE USE AND DISPOSAL OF SOLVENTS / CLEANERS MUST BE IN ACCORDANCE WITH YOUR LOCAL ENVIRONMENTAL REGULATIONS.
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Hose Friction Loss
Appendix E: Hose Friction Loss
Table E-1: Hose Friction Loss (PSI (kPa) / 100 Feet)
GPM (LPM) 3/4" (19mm)
Booster 1.0" (25mm)
Booster 1-1/2" (38mm)
Hose GPM (LPM) 1-3/4" (44mm) Hose with 1-1/2" (38mm) Coupling 2.0" (52) Hose with 1-1/2" (38mm) Coupling 2-1/2" (65mm) Hose 3.0" (75mm) Hose with 2-1/2" (65mm) Coupling 3.0" (75mm) Hose GPM (LPM) 3-1/2" (89mm) Hose 4.0" (100mm) Hose 5.0" (125mm) Hose
10 (38)
20 (76)
30 (114)
40 (151)
50 (189)
60 (227)
70 (265)
80 (303)
95 (360)
125 (473)
150 (568)
13.5 3.5 (93) (24)
44
6
(303) (41)
99
14
(683) (97)
176 24 (1213) (165)
38 (262)
54 (372)
4 (28)
7 (48)
9 (62)
12 (83)
15 (103)
22 (152)
38 (262)
54 (372)
95
14
(360) (97)
125 24 (473) (165)
150 35 (568) (241)
175 47 (662) (324)
200 62 (757) (427)
225 (852)
250 (946)
275 (1,041)
300 (1,136)
325 (1,230)
350 (1,325)
500 (1,893)
750 (2,839)
1,000 (3,785)
8 (55)
13 (90)
18 (124)
25 (172)
32 (221)
6 (41)
8 (65)
10 (69)
13 (90)
15 (103)
18 (124)
22 (151)
25 (172)
5 (34)
8 (55)
20 (138) 45 (310) 80 (552)
4 (28)
8 (55) 17 (117) 36 (248) 68 (469)
500 (1,893)
750 (2,839)
1,000 (3,785)
1,250 (4,732)
1,500 (5,678)
1,750 (6,625)
2,000 (7,571)
9.5 (66)
20 (138)
34 (234)
53 (365)
74 (510)
3 (34)
11
5
(76) (34)
20
8
(138) (55)
31
13
(214) (90)
45
18
(310) (124)
61
25
(402.6) (172)
32 (221)
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Hose Friction Loss
NOTES
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Nozzle Size vs. Pressure
Appendix F: Nozzle Size vs. Pressure
Nozzle Pressure
PSI (kPa) 30 (207) 35 (241) 40 (276) 45 (310) 50 (345) 55 (379) 60 (414) 62 (427) 64 (441) 66 (455) 68 (469) 70 (482) 72 (496) 74 (510) 76 (524) 78 (538) 80 (552) 85 (586) 90 (620) 95 (655) 100 (689) 105 (724) 110 (758) 115 (793) 120 (827)
Table F-1: Nozzle Flow and Pressure Ratings (Part 1)
GPM (LPM) at Various Nozzle Sizes
Nozzle Size in Inches (millimeters)
1/2" (13) 41 (155) 44 (167) 47 (178) 50 (189) 53 (201) 55 (208) 58 (220) 58 (220) 59 (223) 60 (227) 61 (231) 62 (235) 63 (238) 64 (242) 65 (246) 66 (250) 66 (250) 68 (257) 70 (265) 72 (273) 74 (280) 76 (288) 78 (295) 80 (303) 81 (307)
5/8" (16) 64 (242) 69 (261) 73 (296) 78 (295) 82 (310) 86 (326) 90 (341) 91 (345) 93 (352) 94 (356) 96 (363) 97 (367) 99 (375) 100 (379) 101 (382) 103 (390) 104 (394) 107 (405) 110 (416) 113 (428) 116 (439) 119 (451) 122 (462) 125 (473) 127 (481)
3/4" (19) 92 (348) 99 (375) 106 (401) 112 (424) 118 (447) 124 (469) 130 (492) 132 (500) 134 (507) 136 (515) 138 (522) 140 (530) 142 (538) 144 (545) 146 (553) 148 (560) 150 (568) 154 (583) 159 (602) 163 (617) 167 (362) 171 (647) 175 (663) 179 (678) 183 (712)
7/8" (22) 125 (473) 135 (511) 144 (545) 153 (579) 161 (610) 169 (640) 176 (666) 179 (678) 182 (689) 185 (700) 188 (711) 190 (719) 193 (731) 196 (742) 198 (750) 201 (761) 203 (768) 210 (795) 216 (818) 222 (840) 228 (863) 233 (882) 239 (905) 244 (924) 249 (943)
1.0" (25.4) 1-1/8" (29) 1-1/4" (32) 1-3/8" (35) 163 (617) 206 (780) 254 (962) 308 (1,166) 176 (666) 222 (840) 275 (1,041) 332 (1,257) 188 (711) 238 (901) 294 (1,113) 355 (1,334) 199 (753) 252 (954) 311 (1,177) 377 (1,437) 210 (795) 266 (1,007) 328 (1,242) 397 (1,503) 220 (833) 279 (1,056) 344 (1,302) 417 (1,647) 230 (871) 291 (1,102) 360 (1,363) 435 (1,363) 234 (886) 296 (1,121) 366 (1,385) 442 (1,673) 238 (901) 301 (1,139) 371 (1,404) 449 (1,700) 241 (912) 305 (1,155) 377 (1,427) 456 (1,726) 245 (927) 310 (1,174) 383 (1,450) 463 (1,753) 248 (939) 315 (1,192) 388 (1,469) 470 (1,779) 252 (954) 319 (1,208) 394 (1,492) 477 (1,806) 255 (965) 323 (1,223) 399 (1,510) 483 (1,828) 259 (980) 328 (1,242) 405 (1,553) 490 (1,855) 262 (992) 332 (1,257) 410 (1,552) 496 (1,878) 266 (1,007) 336 (1,272) 415 (1,571) 502 (1,900) 274 (1,037) 347 (1,314) 428 (1,620) 518 (1,961) 282 (1,067) 357 (1,351) 440 (1,666) 533 (2,018) 289 (1,094) 366 (1,386) 452 (1,711) 547 (2,071) 297 (1,124) 376 (1,423) 464 (1,756) 562 (2,127) 304 (1,151) 385 (1,457) 476 (1,802) 575 (2,177) 311 (1,117) 394 (1,492) 487 (1,844) 589 (2,230) 319 (1,208) 403 (1,526) 498 (1,885) 602 (2,279) 325 (1,203) 412 (1,560) 509 (1,927) 615 (2,328)
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Nozzle Size vs. Pressure
Table F-2: Nozzle Flow and Pressure Ratings (Part 2)
GPM (LPM) at Various Nozzle Sizes
Nozzle Pressure
Nozzle Size in Inches (millimeters)
PSI (kPa) 1-1/2" (38) 1-5/8" (41) 1-3/4" (44) 1-7/8" (48) 2.0" (51) 2-1/4" (57) 2-1/2" (65) 3.0" (75)
30 (207) 366 (1,386) 430 (1,628) 498 (1,885) 572 (2,065) 651 (2,464) 824 (3,119) 1,017 (3,850) 1,464 (5,542) 35 (241) 395 (1,495) 464 (1,756) 538 (2,037) 618 (2,339) 703 (2,661) 890 (3,369) 1,098 (4,156) 1,581 (5,985) 40 (276) 423 (1,601) 496 (1,878) 575 (2,177) 660 (2,498) 751 (2,843) 951 (3,600) 1,174 (4,444) 1,691 (6,401) 45 (310) 448 (1,696) 525 (1,987) 610 (2,309) 700 (2,650) 797 (3,017) 1,009 (3,820) 1,245 (4,713) 1,793 (6,787) 50 (345) 473 (1,791) 555 (2,101) 643 (2,434) 738 (2,794) 840 (3,180) 1,063 (4,024) 1,313 (4,970) 1,890 (7,154) 55 (379) 496 (1,878) 582 (2,203) 675 (2,555) 774 (2,930) 881 (3,335) 1,115 (4,221) 1,377 (5,213) 1,982 (7,503) 60 (414) 518 (1,961) 608 (2,302) 705 (2,669) 809 (3,062) 920 (3,483) 1,165 (4,410) 1,438 (5,444) 2,071 (7,840) 62 (427) 526 (1,991) 618 (2,339) 716 (2,710) 822 (3,112) 935 (3,540) 1,184 (4,482) 1,462 (5,534) 2,105 (7,968) 64 (441) 535 (2,025) 628 (2,377) 728 (2,756) 835 (3,161) 950 (3,596) 1,203 (4,554) 1,485 (5,621) 2,138 (8,093) 66 (455) 543 (2,055) 637 (2,411) 739 (2,797) 848 (3,210) 965 (3,653) 1,222 (4,626) 1,508 (5,708) 2,172 (8,222) 68 (469) 551 (2,086) 647 (2,449) 750 (2,839) 861 (3,259) 980 (3,710) 1,240 (4,694) 1,531 (5,796) 2,204 (8,343) 70 (482) 559 (2,116) 656 (2,483) 761 (2,886) 874 (3,309) 994 (3,763) 1,258 (4,762) 1,553 (5,879) 2,236 (8,464) 72 (496) 567 (2,146) 666 (2,521) 772 (2,922) 886 (3,354) 1,008 (3,816) 1,276 (4,830) 1,575 (5,962) 2,268 (8,585) 74 (510) 575 (2,177) 675 (2,555) 783 (2,964) 898 (3,390) 1,022 (3,869) 1,293 (4,895) 1,597 (6,045) 2,299 (8,703) 76 (524) 583 (2,207) 684 (2,589) 793 (3,002) 910 (3,445) 1,036 (3,922) 1,311 (4,963) 1,618 (6,125) 2,330 (8,820) 78 (538) 590 (2,233) 693 (2,623) 803 (3,040) 922 (3,490) 1,049 (3,971) 1,328 (5,027) 1,639 (6,204) 2,361 (8,937) 80 (552) 598 (2,264) 707 (2,657) 814 (3,081) 934 (3,536) 1,063 (4,024) 1,345 (5,091) 1,660 (6,284) 2,391 (9,051) 85 (586) 616 (2,332) 723 (2,737) 839 (3,176) 963 (3,645) 1,095 (4,145) 1,386 (5,247) 1,711 (6,477) 2,465 (9,331) 90 (620) 634 (2,400) 744 (2,816) 863 (3,266) 991 (3,751) 1,127 (4,266) 1,427 (5,402) 1,761 (6,666) 2,536 (9,600) 95 (655) 651 (2,464) 765 (2,896) 887 (3,358) 1,018 (3,858) 1,158 (4,384) 1,466 (5,549) 1,809 (6,848) 2,605 (9,861) 100 (689) 668 (2,529) 784 (2,968) 910 (3,445) 1,044 (3,952) 1,188 (4,497) 1,504 (5,693) 1,856 (7,027) 2,673 (10,118) 105 (724) 685 (2,593) 804 (3,044) 932 (3,529) 1,070 (4,050) 1,217 (4,607) 1,541 (5,833) 1,902 (7,200) 2,739 (10,368) 110 (758) 701 (2,654) 823 (3,115) 954 (3,611) 1,095 (4,145) 1,246 (4,717) 1,577 (5,970) 1,947 (7,370) 2,803 (10,611) 115 (793) 717 (2,714) 841 (3,184) 976 (3,695) 1,120 (4,240) 1,274 (4,823) 1,613 (6,106) 1,991 (7,537) 2,867 (10,853) 120 (827) 732 (2,771) 859 (3,252) 997 (3,774) 1,144 (4,331) 1,301 (4,925) 1,647 (6,235) 2,034 (7,700) 2,928 (11,084)
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Cavitation
Appendix G: Cavitation
(See Figure G-1: "Sample, Cavitation Regions.")
Cavitation can occur while pumping from draft, in relay, or from a hydrant (although it is more likely from draft conditions). The operator must be aware of the warning signs and immediately correct the situation.
Cavitation can damage the impeller and other sensitive components, impair pump performance, and reduce flow capacity. The damage done during any one period of cavitation is not great, but the effects are cumulative. Implosions occurring during cavitation break away or erode tiny pieces of metal from the internal parts and the pump casing. When enough metal has been chipped away, the impeller becomes unbalanced causing a strain and vibration on bearings, bushings and shafts.
Figure G-1: Sample, Cavitation Regions
G.1 PROCESS OF CAVITATION
Cavitation occurs when a centrifugal pump attempts to discharge more water than it is receiving. Bubbles are created under the vacuum, formed near the eye of the impeller. Cavitation is often referred to as "the pump running away from the fluid supply." This means you are trying to pump more water out of the pump than is going into the pump.
The formation of bubbles in the low pressure regions of the impeller cause the impeller to "slip" in the water, since the impeller is designed to move liquid not the air in the bubbles. (See Figure G-1: "Sample, Cavitation Regions.")
When increased discharge flow exceeds the intake, bubbles form in the low-pressure region at the eye of the impeller. The pressure of the water in the pump drops as it flows from the suction flange through the suction nozzle and into the impeller.
As flow from the pump increases, the vacuum at the impeller increases. As vacuum increases, water near the impeller eye begins to boil and vaporizes.
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Cavitation
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 subjected to a high positive pressure and condenses back to a liquid.
This sudden change from vapor to liquid generates a shock effect that damages the impeller and pump housing. Usually there are thousands of tiny vapor pockets (or bubbles).
It is the collapsing (or implosion) of these bubbles that causes the characteristic sound of cavitation that has been described as rocks tumbling in the pump.
G.2 WARNING SIGNS OF CAVITATION (DISCHARGE AND GAUGES)
Discharge Pressure
In a properly functioning pump, an increase in RPM increases the discharge pressure and volume. An increase in engine RPM that does not cause an increase in the pump discharge pressure is the most reliable indication that a pump is approaching cavitation.
Vacuum Compound Gauge
Do not depend entirely on the vacuum (compound) gauge to indicate when a pump is nearing cavitation.
The vacuum gauge is usually installed several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The vacuum gauge does not take into account ambient temperature nor atmospheric pressure and is not accurate near zero (0) on the vacuum scale.
G.3 ELIMINATING CAVITATION
To eliminate cavitation, the operator must be aware of the warning signs listed above. Low barometer, high elevation, and elevated water temperature also contribute to cavitation.
The most common way to eliminate cavitation is to decrease the amount of water being discharged by decreasing engine speed or closing discharge valves. However, this also results in a reduction of flow.
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Cavitation
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.
During Operations
Do not increase pump speed beyond the speed at which the pressure ceases to rise. The higher the elevation above sea level, the lower the atmospheric pressure and less lift. Lift loss is in addition to NFPA Baseline of 2.38 ft. (0.73 meters) at 2,000 (610 meters) of elevation - (See Table G-1: "Lift Loss from Elevation.")
Table G-1: Lift Loss from Elevation
Elevation, Feet (Meters)
2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
(610) (914) (1,219) (1,524) (1,829) (2,134) (2,438) (2,743) (3,048)
Lift Loss Feet (Meters)
NFPA Base Line - 2.38 ft. (0.73 m)
1.1
(0.33)
2.2
(0.67)
3.3
(1.00)
4.4
(1.34)
5.5
(1.67)
6.6
(2.01)
7.7
(2.35)
8.8
(2.68)
Open the throttle gradually and watch the pressure gauge and the tachometer, if equipped. An increase in engine RPM without a corresponding increase in pressure indicates cavitation.
Monitor the water temperature. Table G-2: "Lift Loss from Temperature" shows the amount of lift loss as temperatures rise.
Table G-2: Lift Loss from Temperature
Water Temperature
F° (C°)
60° 70° 80° 90° 100° 110°
(16°) (21°) (27°) (32°) (38°) (43°)
Lift Losses Head Ft. (Meters)
NFPA Base Line - 2.38 ft. (0.73 m)
0.3
(0.09)
0.6
(0.18)
1.1
(0.34)
1.7
(0.52)
2.5
(0.76)
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Cavitation
Monitor barometric pressure. NFPA standard sets a baseline of 29.9" Hg. (See Table G-3: "Lift Loss from Barometric Reading.")
Table G-3: Lift Loss from Barometric Reading
Barometric Reading
in. (mb)
Lift Loss, Head Ft. (Meters)
29.9 29.7 29.5 29.3 29.1 28.9 28.7
(1,012.5) NFPA Base Line - 2.38 ft. (0.73 m)
(1,005.8)
0.2
(0.6)
(999)
0.5
(0.15)
(999.2)
0.7
(0.21)
(985.4)
0.9
(0.27)
(987.7)
1.1
(0.33)
(971.9)
1.4
(0.43)
Regularly inspect suction hoses to check for air leaks. Air leaks can also cause cavitation.
Check suction strainer for blockage or effectiveness. See heading "Strainers" on page 197.
Preventive Measures
Consider the size of the suction hose. Table G-4: "Hose Size vs. Pump Rating Capacity" on page 196, 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.
Consider the piping within the truck. Suction losses can result from additional suction piping added to the fire pump during assembly.
Table G-4: Hose Size vs. Pump Rating Capacity (Sheet 1 of 2)
Hose Diameter in. (mm)
Flow - gpm (lpm)
250 (1,000) 350 (1,300) 500 (2,000) 750 (3,000) 1,000 (4,000) 1,250 (5,000) 1,500 (6,000) 1,750 (7,000) 2,000 (8,000)
3"
4"
4.5"
5"
6"
Dual Triple
(75) (100) (110) (125) (150) 6" (150) 6" (150)
Lift Loss gpm (lpm)
5.2 (1.6) 2.5 (0.7) 5.0 (1.5) 3.6 (1.5) 11.4 (3.5) 8.0 (3.5) 4.7 (1.4 1.9 (0.6) 14.5 (4.4) 8.4 (2.6) 3.4 (1.0) 13.0 (4.0) 5.2 (1.6) 7.6 (2.3)
1.9 (0.6) 2.6 (0.8) 3.4 (13)
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Cavitation
Table G-4: Hose Size vs. Pump Rating Capacity (Sheet 2 of 2)
Hose Diameter
3"
in. (mm)
(75)
Flow - gpm (lpm)
2,250 (9,000) 2,500 (10,000)
4" (100)
4.5" (110)
5" (125)
6" (150)
Lift Loss gpm (lpm)
Dual Triple 6" (150) 6" (150)
4.3 (1.3) 2.0 (0.6) 5.2 (1.6) 2.3 (0.7)
Follow the maintenance and inspection procedures.
Cavitation can also occur when air enters the pump. The pump could be primed; however, air leaks can cause rough operation and an increase of engine speed without an increase in pressure or flow. If an air leak is suspected, refer to Section 6 "Troubleshooting" on page 93.
Using "soft sleeve" vs. "hard sleeve." The soft sleeve has an advantage as the sleeve collapses under a partial vacuum (visual indication of cavitation), even though the intake gauge might still indicate a positive pressure. With a hard sleeve, the only indicator would be the intake gauge, which is inaccurate at close to the ZERO (0) reading.
Strainers
Clogged strainers or suction strainer selection, restricting flow. Verify the hose strainers and suction strainer are clear (unobstructed) and located deep enough in the water source to insure constant, uninterrupted water flow.
Note: Strainer type, basket vs. barrel, also has an affect on water flow which can contribute to flow restrictions, thus causing cavitation and reduced pump performance, especially during high drafting conditions. 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 operating pressures from the intake source. Carefully monitor and reduce pressures as needed.
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Cavitation
NOTES
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Midship Flow Rates
Appendix H: Midship Flow Rates
Model Qpak 50 Qpak 200M
Qpak 75 Qpak 300M
Qpak 100
Qflo 75 Qflo 300M
Qflo 100 Qflo 400M
Qflo 125
Qflo PLUS 75 Qflo PLUS 300M
Qflo PLUS 100 Qflo PLUS 400M
Qflo PLUS 125 Qflo PLUS 500M
Qmid 100 Qmid 400M
Qmid 125 Qmid 500M
Qmax 100 Qmax 400M
Qmax 125 Qmax 500M
Table F-1: Midship Flow Rates (Sheet 1 of 2)
Type
Capacity
Single-Stage Midship Muscle Pump. 500 GPM at 150 PSI 2,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 750 GPM at 150 PSI 3,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,000 GPM at 150 PSI PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 750 GPM at 150 PSI 3,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1.000 GPM at 150 PSI 4,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,250 GPM at 150 PSI PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 750 GPM at 150 PSI 3,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1.000 GPM at 150 PSI 4,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,250 GPM at 150 PSI 5,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1.000 GPM at 150 PSI 4,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,250 GPM at 150 PSI 5,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1.000 GPM at 150 PSI 4,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,250 GPM at 150 PSI 5,000 LPM at 1,000 kPA PER NFPA 1901 Standard
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
199
Midship Flow Rates
Model Qmax 150 Qmax 600M
Qmax 175 Qmax 700M
Qmax 200 Qmax 800M
Qmax 225
Qtwo 100 Qtwo 400M
Qtwo 125 Qtwo 500M
Qtwo 150 Qtwo 600M
Qtwo 175 Qtwo 700M
Qtwo 200
Table F-1: Midship Flow Rates (Sheet 2 of 2)
Type
Capacity
Single-Stage Midship Muscle Pump. 1,500 GPM at 150 PSI 6,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 1,750 GPM at 150 PSI 7,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 2.000 GPM at 150 PSI 8,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Single-Stage Midship Muscle Pump. 2,250 GPM at 150 PSI PER NFPA 1901 Standard
Two-Stage, Heavy-Duty Midship Muscle Pump.
1.000 GPM at 150 PSI 4,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Two-Stage, Heavy-Duty Midship Muscle Pump.
1,250 GPM at 150 PSI 5,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Two-Stage, Heavy-Duty Midship Muscle Pump.
1,500 GPM at 150 PSI 6,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Two-Stage, Heavy-Duty Midship Muscle Pump.
1,750 GPM at 150 PSI 7,000 LPM at 1,000 kPA PER NFPA 1901 Standard
Two-Stage, Heavy-Duty Midship Muscle Pump.
2,000 GPM at 150 PSI PER NFPA 1901 Standard
Hale Products Inc.
A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone ............. 800.533.3569 Fax........................ 800.520.3473 Web ........www.haleproducts.com
200
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Appendix I
General Gearbox Inspection
The G Series Gearbox is responsible for transmitting power from the chassis drivetrain to the fire pump. The same general maintenance and inspection principles that apply to transfer cases also apply to the G gearbox. With proper operation and care, the G gearbox can last the lifetime of the apparatus.
When changing the oil, note condition and color of the oil as well as particulate matter in the oil and on the drain plug. Milky white oil is an indication of water intrusion and should be addressed as soon as it is detected. Excess particulate in the oil or on the magnetic drain plug can be an indication of a high degree of component wear in the gearbox. Large chips can be an indication of hard shifts. Further inspection may be necessary.
Figure 1 depicts normal appearance of an oil plug at fluid change. Wiping the magnetic surface with a clean shop towel should show only signs of normal metal `fuz' wiith no large chips or particles.
Figure 1: Normal sludge and particulate on magnetic drain plug
201
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Figure 2 shows abnormal levels and size of metalic debris.
Figure 2: Abnormal levels and size of particulate warrants further investigation of gearbox components
Gearbox inspections should be performed during routine recommended maintenance, or at any time there is a question regarding the general condition of the gearbox.
After draining oil, some basic gearbox inspections of internal components can be performed in a minimally invasive fashion with a flexible / articulating borescope inserted through the oil fill hole as shown in Figure 3.
Components that can be examined with the borescope include:
· Input Shaft Bearing · Slider Gear · Idler Gear · Shift Fork
202
Figure 3: Borescope inspection via oil fill port
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Input Shaft Bearing
Bearing performance can be impacted due to improper lubrication, excessive heat, chips, etc. A visual inspection can be performed to look for any signs of concern. Figure 4 shown below gives an example of a borescope picture of the bearing. There is no visible indication of bearing cage damage or discoloration due to corrosion or excess heat which would be cause for concern.
Figure 4: Acceptable bearing
Figure 5 shows a bearing with indications of rust and corrosion on the inner and outer raceways. Any visible rust is an indication that rust and corrosion may have also affected the inner raceway and ball bearing surfaces as well.
203
Figure 5: Bearing with signs of rust and corrosion indicating a replacement bearing may be needed.
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Slider Gear The slider or drive gear transmits power from the input shaft to the pump. When improperly shifted under power or with chassis in motion during shifting, damage to the gear teeth may result. Figure 6 shows wear consistent with a gearcase that had seen "hard shifting" while Figure 4 shows a sliding gear that has been operated properly.
Figure 6: Leading edge tooth chip consistent with "hard shifting"
204
Figure 7: Acceptable slider gear teeth
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Shift Fork
The shift fork is considered a wear item within the gearbox. Over time, the wear seen may require the replacement of the fork. The allowable wear limit on the shift fork is .045". Further teardown may be required to determine the actual amount of wear. Disassembly of the gearbox should be performed by a Hale Products certified technician that adheres to recommended practices as described in the pump manual and any shop procedures as they apply.
Figure 8: Shift Fork with 0.045" of wear
Figure 9: Acceptable Shift Fork
Borescope
When selecting a borescope for use in inspecting the gearbox, a model with an articulating end allows for more complete inspection without dismantling the gearbox. This can make a thorough inspection of the gearbox internals a quick and practical part of gearbox maintenance. Borescope technology has improved while prices have decreased making this a viable option for any maintenance department.
205
MUSCLE (Midship) Pumps Installation, Operation, and Maintenance Manual p/n: 029-0020-63-0
Limited Warranty20
Express Warranty
EXPRESS WARRANTY: Hale Products, Inc. (HALE) hereby warrants to the original Buyer that products 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.
LIMITATIONS: Hale's obligation is expressly conditioned on the Product being:
Subjected to normal use and service. Properly maintained in accordance with Hale's Instruction Manual as to recommended ser-
vices and procedures. Not damaged due to abuse, misuse, negligence, or accidental causes. Not altered, modified, serviced (non-routine) or repaired other than by an Authorized Ser-
vice Facility. Manufactured per design and specifications submitted by the original Buyer.
THE ABOVE EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS WARRANTIES ARE MADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED WARRANTIES INCLUDING, WITHOUT LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; OR PATENT INFRINGEMENT FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER'S DESIGN AND SPECIFICATIONS.
EXCLUSIVE REMEDIES: If Buyer promptly notifies HALE upon discovery of any such defect (within the Warranty Period), the following terms shall apply:
Any notice to HALE must be in writing, identifying the Product (or component) claimed defected and circumstances surrounding its failure.
HALE reserves the right to physically inspect the Product and require Buyer to return same to HALE's plant or other Authorized Service Facility.
In such event, Buyer must notify HALE for a Returned Goods Authorization Number and Buyer must return the product F.O.B. within thirty (30) days thereof.
If determined defective, HALE shall, at its option, repair or replace the Product, or refund the purchase price (less allowance for depreciation).
Absent proper notice within the Warranty Period, HALE shall have no further liability or obligation to Buyer therefore.
THE REMEDIES PROVIDED ARE THE SOLE AND EXCLUSIVE REMEDIES AVAILABLE. IN NO EVENT SHALL HALE BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE INCLUDING, WITHOUT LIMITATION, LOSS OF LIFE; PERSONAL INJURY; DAMAGE TO REAL OR PERSONAL PROPERTY DUE TO WATER OR FIRE; TRADE OR OTHER COMMERCIAL LOSSES ARISING, DIRECTLY OR INDIRECTLY, OUT OF PRODUCT FAILURE.
Express Limited Warranty Hale Products, Inc., 2005
206
Hale Products Inc.
A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone..............800.533.3569 Fax ........................800.520.3473 Web ........ www.haleproducts.com
MUSCLE (Midship) Pumps
("Q" Series)
Drawing Package
Part 2
Hale Products Inc. A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone: 800.533.3569 FAX: 800.520.3473
Web........www.haleproducts.com
Manual p/n: 029-0020-63-0
Contents
8 Drawings.....................................................................................Plate Number
QFLO Series
Qflo Plus Installation................................................................................................................... 1052A Qflo Plus, with "G" Series Gearbox, Installation and Parts Identification.................................... 1053A Qflo A, Installation and Parts Identification................................................................................... 904A Qflo and Qmax Fittings............................................................................................................... 1046A
QPAK Series
Qpak A, with "A" Series Gearbox, Installation and Parts Identification (Sheet 1 of 2).................. 941A Qpak A, with "A" Series Gearbox, Right Drive Unit Option (Sheet 2 of 2).................................... 941A Qpak A, Installation and Parts Identification................................................................................. 942A Qpak, with "J" Series Gearbox, Installation .................................................................................. 924A Qpak, with "G" Series Gearbox, Installation ................................................................................. 923A Qpak Series, Parts Identification (Sheet 1 of 2) ........................................................................... 926A Qpak Series, Parts Identification (Sheet 2 of 2) ........................................................................... 926A Qpak Suction Tube Lengths ......................................................................................................... 925A
QMAX Series
Qmax Installation.......................................................................................................................... 887A Qmax Installation.......................................................................................................................... 913A Qmax, with "G" Series Gearbox, Installation and Parts Identification........................................... 886A Qmax U, Installation and Parts Identification................................................................................ 905A Qmax, with K Series Gearbox, Installation and Parts Identification ........................................... 1156A Qflo and Qmax Fittings............................................................................................................... 1046A
QTWO Series
Qtwo, with "G" Series Gearbox, Installation.................................................................................. 889A Qtwo, with "G" Series Gearbox, Installation and Parts Identification ............................................ 888A Qtwo U, Installation and Parts Identification ................................................................................. 906A Qtwo, with "K" Series Gearbox, Installation and Parts Identification .......................................... 1173A
ECN No
0956
REV
A B C
CHANGE FROM
INITIAL RELEASE
Complete Rewrite
Manual p/n: 029-0020-63-0, Rev. -C Printed in U.S.A.
BY DATE APVD
MAL
LwH 01/01/2006
HALE PRODUCTS, INC. A Unit of IDEX Corporation Conshohocken, PA 19428 USA
WRITTEN BY LwH CHECKED BY TG
ISSUE DATE 01/01/2006
COPYRIGHT ©
NOT TO BE REPRODUCED OR USED TO MAKE OTHER DRAWINGS OR MACHINERY.
© Hale Products, Inc. 2006 All Rights Reserved
Contents - continued
8 Drawings - continued .............................................................. Plate Number
QMID Series
Qmid Installation......................................................................................................................... 1016A
Gearbox and Primer Pump
K Series Gearbox Assembly, Parts Identification ......................................................................... 978A J Series Gearbox Assembly, Parts Identification .......................................................................... 928A Model LG and SG Gearbox Mounting .......................................................................................... 824A G Series Gearbox Assembly, Installation and Parts Identification................................................ 914A LGA Series Gearbox Assembly, Installation and Parts Identification ........................................... 907A ESP-12 Priming Pump, Plumbing and Installation (Sheet 1 of 2)................................................. 821A ESP-12 Priming Pump, Electrical Installation (Sheet 2 of 2) ........................................................ 821A ESP-24 Priming Pump, Plumbing and Installation (Sheet 1 of 2)................................................. 938A ESP-24 Priming Pump, Electrical Installation (Sheet 2 of 2) ........................................................ 938A G Series Gearbox Offsets .......................................................................................................... 1153A K Series Gearbox Offsets........................................................................................................... 1157A
Available Accessories and Options
Anti-Corrosion Anode ................................................................................................................... 869A Booster Pump Mounting, High Pressure ...................................................................................... 705B P Series Relief Valve - Option ...................................................................................................... 547C PVG Priming Valve - Option ......................................................................................................... 480G QLF Transfer Valve, Manual Operation......................................................................................... 472E Shift Indicator Lights, Wiring Schematic, PTO.............................................................................. 825A Shift Indicator Lights, Wiring Schematic, Midship Pump Gearbox ............................................... 746A Seed Counter Assembly - Option ................................................................................................. 910A SPV Priming Valve - Option.......................................................................................................... 828A Suction and Discharge Reference Sheet ..................................................................................... 831A TRV/TRVM Relief Valve System - Option..................................................................................... 729A TPM and TPM/P40 Relief Valve System .......................................................................................742F VPS Power Shift - Option ............................................................................................................. 533D Vehicle Mounted Pump Applications ............................................................................................ 843A
Manual p/n: 029-0020-63-0, Rev. -C Printed in U.S.A.
© Hale Products, Inc. 2006 All Rights Reserved
Notes
_____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
Manual p/n: 029-0020-63-0, Rev. -C Printed in U.S.A.
© Hale Products, Inc. 2006 All Rights Reserved
= PUMP MODEL Ir A-S-TOANPDT-AIRODN-A2-L1/-D2I,PSTC3-IH&NAA-4RLGNEP-TFLSAT[-AANNSGDTA-ERSSDOLH-IODLE-.---------NO-TER-ES.FE-R T-D H-ALE-PU-MP/-ENG-INE-CO-MB-INAT-IO-N L-IST-TD---------200-054-1-CXJ- -----L-I[1(iGTREEsNm-) o._r ------,,------------------r-RG-AE-ATIRO----rG-ETAY-RPBEO--X--r----D-IM x-xE -N -S-IO -VN -S ---z -=;l
Qflo Plus *-2B 2.83 CJ >< B
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
",·-- Qflo Plus *-25 2.55 zo C
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
®
Qflo Plus *-23 2.32 a: aw: D
1-1/4, 2, 2-1/2 & 3 NPT
[AST SOLID
SELECT PROPER RATIO TD MATCH PUMP WITH ENGINE 2 WEIGHT F STANDARD QFL PLUS 1250 G P M PUMP
AS SHOWN LESS PRIMING PUMP= 1100 LBS
°T
1
u"'/"i-'
=:,,
1------- -----
::;;oooo
LIGHTASXEl1El_Y ( GIIEEN )
L____J
Pl.MP OPERATOR'S PANEL
DRIVINCI COMPARTMENT PANEL
Pl.MP SHIFT INDICATOR LIGHTS
0 ID
.J <( <(
14.56 14.75 14.90
5.44
4.06
1.84
E
1-1/4, 2, 2-1/2 & 3 NPT
[AST SOLID
F
1-1/4, 2, 2-1/2 & 3 NPT
[AST SOLID
G
1-1/4, 2, 2-1/2 & 3 NPT
[AST SOLID
H BLANK 2-1/2, 3 & 4 NPT
4
K
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
L
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
M
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
N
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
0
1-1/4, 2, 2-1/2, 3 NPT
MOUNTING HOLES (4) 5/8-11 x 1-1/2 DP USE MINIMUM SAE GRADE 5 SCREWS
N
R
XT X
[LEARAN[E REQUIRE TD
REMOVE REAR BEARING HOUSING TD SERVICE PUMP
FOR WIRt.lG SCHEMATIC SEE PLATE NQ 7-16
(2 l 5/8-11 LIFTING HOLES
PRESSURE [ NNE[TI NS FDR PRESSURE GAGE, HEAT EXCHANGER,
AND GEARBOX [ LING LINES, AN RELIEF VALVE (2) l/4 NPT, (2) 3/8 NPT, (1) l/2 NPT, (1) 3/4 NPT
- Qflo Plus
Qflo Plus
*-21 *-19
2.13 1.96
Iw>-<
CJ -><
15.06 15.25
- Qflo Plus *-23 2.28
12.38
Qflo Plus *-21 2.05 Qflo Plus *-19 1.86 Qflo Plus *-17 1.71
dx
gCJ
2
a:
0
.J
w<(
CJ
12.56 12.75 12.94
4.31
Qflo Plus *-15 1.58
13.13
5.18
2.00
p
1-1/4, 2, 2-1/2, 3 NPT
Q
1-1/4, 2, 2-1/2 & 3 NPT
R
1-1/4, 2, 2-1/2 & 3 NPT
* RATED CAPACITY CGPM) 750, 1000 AND 1250
** THE LONG CL) GEARBOX IS STANDARD AND WILL BE SUPPLIED UNLESS OTHERWISE SPECIFIED
EXAMPLE THE MODEL NUMBER FDR A 1000 A 2 28 GEAR RATIO AND A LONG GEARBOX
GWPOMULDRATBEED QFPLUM PPLWUITSH100-23L
WARNING
s UuT BLANK
TANK SLJ[Tl N
1-1/4, 2, 2-1/2 & 3 NPT
r- /
PVG SEE
PPLRAITMIENGNDV.AL4VBE .STANDARD
EXCEEDING THESE LIMITS DR FAILURE TD FOLLOW THE
RECOMMENDATIONS OUTLINED N THIS DRAWING COULD DAMAGE THE GEARBOX AND RESULT IN PERSONAL INUURY QFL MIDSHIP MAXIMUM PUMP PRESSURE
VT V
BLANK
1-1/4, 2, 2-1/2 & 3 NPT
7
(HYDROSTATIC & HYDRODYNAMIC)= 600 PSI 2HP HIGH PRESSURE PUMP MAXIMUM PUMP PRESSURE
WT
w
BLANK
XXT BLANK
0· BLANK
P* BLANK
1-1/4, 2, 2-1/2 & 3 NPT
p
1-1/4, 2, 2-1/2 & 3 NPT
2-1/2 ,3 AND 4 NPT
4
2-1/2 ,3 AND 4 NPT
4
(2) FRONT AND (2) REAR OPENINGS MACHINE
FDR 115 SERIES FLANGES
STAN AR FRONT AND REAR BLANK
OPTIONAL 1-1/4 NPT, 2 NPT , 2-1/2 NPT or 3 NPT, ALSO TRV, TRV -L or ANODE
4 13 TYP
L, ,, r- _j
\_,) 10 5"-0--- 7j
5 37 7 DD J87 00
4 OD TYP
c-- - - -- 19 75
,___ _ _ _ _ _MD=HLJONLTEISN=G_ 39 50 -- - - - - - - - - - --s
f->- - ----------- -48 DD ________________,
_)L
3/4 NPT PRIMING TAP
ALL PRIMING CDNNECTI NS
TD BE MADE HERE
SUCTION (VACUUM) [ NNE[Tl NS FDR VACUUM GAGE, HEAT EXCHANGER
AND GEARBOX [ LING RETURNS, AND STRAINER FDR TPM RELIEF VALVE (2) l/4 NPT (I) l/2 NPT (I) 3/4 NPT
94
PUMP E
s
TANK SUCTION CDNNE[Tl N
STANDARD BLANK FLANGE
PTI NAL 2-1/2 NPT,
3 NPT or 4 NPT FLANGE, 3" DR 4" SVS VALVE and/or CHECK VALVE
RELIEF VALVE PILOT LIGHT
PM CDNTR L VALVE FDR QD RELIEF VALVE WITH RELIEF VALVE PILOT LIGHT. INSTALL THE CDNTR L VALVE AT A LEVEL HIGHER THAN THE MAIN RELIEF VALVE SD THAT THE CDNTR L VALVE AND c TUBING LINES WILL DRAIN NATURALLY AND MPLETELY. THIS
IS IMPORTANT TD PREVENT DAMAGE FROM FREEZING TPM RELIEF VALVE SYSTEM AVAILABLE. SEE PLATE ND. 742
TPM RELIEF VALVE SYSTEM STANDARD ON 2 GPM PUMP FDR QD RELIEF VALVE SYSTEM SEE PLATE 4 4I
(HYDROSTATIC & HYDRODYNAMIC)= 1000 PSI
MAXIMUN POWER INPUT FDR PUMPING= 450 HP
MAXIMUM TORQUE N PUMP SHAFT= 2300 LBS-FT
MAXIMUM GEARBOX SHAFT TORQUE CRA) = 16,000 LBS-FT
PUMP MODEL
QFL PLUS QFL PLUS QFL PLUS QFL PLUS QFL PLUS
*-23L
*-21L
*-19L
*-17L
*-15L
MAX GEARBOX INPUT RPM
263
2920
3220
3500
3800
PUMP MODEL
QFL PLUS QFLD PLUS QFLD PLUS QFL PLUS QFL PLUS
*-28X
*-25X
*-23X
>+<-21X
*- l 9X
MAX GEARBOX INPUT RPM
212
235
2580
2800
3060
:,'
THROTTLE INDICATOR LIGHT.
SEE PLATE ND. 746 FDR WIRING INSTRUrn NS.
SEE HALE TORQUE LIMIT CHART F-72 FDR ADDITIONAL DATA
THIS PRODUCT AND ITS cMPNENTS ARE PROTECTED BY NE DR MORE
=
r . OPTIONAL SPEED CDUNTER ATTACHMENT Ill RAT! 54" CABLE
F THE FOLLOWING U S PATENTS AND OTHER PATENTS PENDING:
FDR INSTALLATION INSTRU[Tl NS AND PARTS LIST SEE PL91
950,756 3,500,961 3,B59, 703 4,209, 2B2 4,587, 862 3,11 6,694 3,726,30B 3,918,681 4,311,440 4,653,878
PUMP PANEL
PTI NAL 4" OPENING ,__ __ 15 75 _ _ _.., '-3-,-'-1--58--,'-5-5-9 -3--,'-B-O- l,-22-4 -4-,0-8- 9,-34-5 --4---,'-33-7,-8- 30-----------l
STANDARD 3"
7 75 3 59 7 19
PTIDNAL
g so
HP AND 2HP SERIES PUMPS
CSEE PLATE ND'S 704 AND 7 5)
SUCTION TUBES AVAILABLE IN 4-1/2, 5 and 6 NS THREAD
STANDARD LENGTH 6" LONG PTI NAL LENGTH· 9" LONG ALSO AVAILABLE ONLY IN 6 NS THREAD ARE 4" and T' LONG TUBES ( SEE PLATE ND 831 )
STANDARD
SU[Tl N EXTENSl N I78-0063-00-0 (SEE PLATE ND B31)
OPTIONAL MASTER INTAKE VALVE (NOT SHOWN) AVAILABLE FDR MOUNTING BETWEEN THE SUCTION TUBE AND MIV SUCTION
TUBE EXTENSl N N LEFT, RIGHT DR BOTH SIDES ALSO AVAILABLE N
BOTTOM FLANGED OPENING CSEE PLATE ND 814,815,841 & 842)
VT
2 50
l/4 NPT (2) DRAIN TAPS (1 l EA[H SIDE
IL LEVEL
3/4 NPT PLUG SAE EP-90 DR
BOW-90 AP! GL -5 IL
APPROX [APA[ITY
= LONG GEARBOX 4 QTS
w
z
7 DD
6 79
25
DRIVE LINE RECDMMENDATI NS
APPARATUS BUILDER SUPPLIED DRIVELINES
SHALL BE OF APPROPRIATE SIZE TD MAT[H
f"''-1----;-;-
THE CHASSIS AND PUMP REQUIREMENTS WITH
INDIVIDUAL J INT [AN[ELLATI N AND PHASING
BEFORE AND AFTER THE PUMP DRIVE SHAFT
BALANCE (IN[LU ING YOKES l SHALL NOT EXCEED
OPTIONAL PUMP MOUNTED
ESP ELE[TRI[ PRIMER
(SEE PLATE ND 821)
_J
THE RECOMMENDED LIMIT OF EITHER THE DRIVE
SHAFT DR CHASSIS TRANSMISSIDN MANUFACTURER'S
:
11 \
-
--::-:i c:-
. Tl- ----:TJn
8
75
SPE[IFl[ATIDNS DRIVE SHAFT FULL RANGE OPERATING SPEEDS SHALL NOT EXCEED 42% OF ITS CRITICAL SPEED
1D µi_ _/_
J ! ! 16 06
n::r.:
T : _l
l'J..M71,I1J
STANDARD FLANGES
THE HALE [ MBINATl N FLANGES ARE
SIZED FDR SPICER 1600, 1610, 1650, 1700, 1710, 1760, 1800 AND 1810 SERIES FLANGES
, 160 16 10 SERIES 6-5/8 DIA FEMALE PILOT,
OPTIONAL SUCTION EXTENSION PART ND 178-0063-01-0 ( SEE PLATE ND 831)
H-l--'-n---l:l'i----n--,'--' -¼---Ji-l-t- ''
.44 THICK 6 50 PUMP 4.44 RDAD ---.+-+------,
USE ( 8) 3/8 DIA SAE GRADE 8 SCREWS
, 165 1700, 171 SERIES 7-3/4 DIA FEMALE PILOT,
USE ( 8) 3/8 DIA SAE GRADE 8 SCREWS, 1760, 1800, 1810 SERIES 7-3/4 DIA FEMALE PILOT, USE ( 12) 7/16 DIA SAE GRADE 8 SCREWS
WIRING INSTRU[Tl NS
PLATE ND 746
72
11 13
PLATE NO. 1052AB
DRIVE UNIT SHIFT STANDARD MANUAL OPTIONAL VPS POWER SHIFT (SEE PLATE ND 533)
- - - - - -27 DD- - - - - - - -
0 167 B WAS CAST SOLID
04-25 6 A RELEASE FDR PR DUCTI N
Ee ND REV
[HANGED FROM
ERB B-05 -05 MAL
FAS 10-11-04 MAL
BY DATE APV
HALE PRODUCTS, IN[
1§428 SA x
0
t
ohk! p
25
Notes
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
Notes
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
Notes
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Notes
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Notes
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
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Notes
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Notes
________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Notes
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Hale Products, Inc.
A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A.
Telephone ...................800.533.3569 Fax .. ...........................800.520.3473 Web. ............www.haleproducts.com
Acrobat Distiller 9.2.0 (Windows)