Hale 4DK User Manual

4DK Series Pumps

Installation, Operation

and Maintenance

HALE PRODUCTS, INC. ● A Unit of IDEX Corporation

700 Spring Mill Avenue ● Conshohocken, PA 19428 U.S.A.

Telephone: 610-825-6300 ● FAX: 610-825-6440

Manual p/n: 029-0020-79-0-B

NOTICE !

Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale Products 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 REV CHANGED FROM BY DATE APVD

04-115 A RELEASED ERB 05/27/2004 MA L 04-149 B UPDAT ED TO LATEST

DRAWN BY: LwH ISSUE DATE: CHECK ED BY: PRW 06/30/2004

DESIGN

LwH 06/30/2004 MAL

HALE PRODUCTS, INC.

A Unit of IDEX Corporation

Conshohocken, PA 19428 USA

Manual p/n: 029-0020-79-0-B

Printed in U.S.A.

NOT TO BE REPRODUCED OR USED TO

MAKE OTHER DRAWINGS OR MACHINERY

4D Series Pumps

SECTION 1 INTRODUCTION

4DK Series Pumps

OVERVIEW

Hale 4DK Series pumps are designed for handling fuel or demineralized water in the aircraft service industry. Hale 4DK series pumps are self-priming and driven primarily by a split-shaft 4DK series gearbox.

Models of 4DK pumps are as follows:

4DK: The 4DK pump has a 4” (102 mm) Victaulic suction connection and one or two 4” (102 mm) Victaulic discharge connections, facing either the front or rear. This pump is available with a 1:2.96 or 1:3.40 gearbox ratio for capacities of 600 GPM (2,271 LPM).

The 4DK-30 model pump is built to strict military standards, and is equipped with a pneumatic shift indicator switch.

4D6K: The 4D6K model pump is built for highperformance commercial applications. The design of the 4D6K allows for quick field maintenance and serviceability. The pump has a 6” (152 mm) Victaulic suction connection and a front-facing 4” (102 mm) Victaulic discharge connection. This pump offers 1:2.96 and 1:3.40 gearbox ratios for peak performance in capacities of approximately 750 to 800 GPM (2,839to 3,028 LPM).

Both models are available with an optional mechanical 10:1 tachometer drive mounted on the pump shaft.

For an illustrated pump overview, see heading 4DK Series Overview, beginning on page 38.

PRINCIPLES OF OPERATION

This section reviews the principles of operation of Hale 4DK series pumps and provides a description of the pump component parts.

Centrifugal Force

Hale 4DK series pumps are self-priming centrifugal pumps that operate on the principle of centrifugal force created by a rapidly spinning disk. Figure 1 below shows that an amount of fluid has been placed at the center of a disk.

Figure 1: Centrifugal Force

The disk is rotated at some speed, and the fluid is thrown from the center toward the outer circumference of the disk. The velocity at which the fluid travels from the center directly relates to the diameter of the disk and the speed of rotation.

When a fluid is confined in a closed container (such as the pump body), the velocity is converted to pressure and pressure rises to a level that depends on the speed of rotation. There are three interrelated factors that regulate the performance of a centrifugal pump:

❑ SPEED (RPM) If the speed of rotation

increases with flow held constant, fluid pressure increases.

❑ PRESSURE Pressure is usually

measured in Pounds Per Square Inch (PSI or BAR).

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4DK Series Pumps

If pressure changes with speed held constant, the flow, measured in gallons per minute (GPM) or liters per minute (LPM), changes inversely; that is, if pressure increases, flow decreases.

❑ FLOW Flow is usually measured in the

number of gallons of fluid per minute (GPM or LPM) that a pump can deliver when supplied from draft. If the pressure is held constant, the flow increases with an increase in the speed of rotation.

A centrifugal pump is preferred due to its 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 (8.3 BAR), and the inlet pressure is 45 PSI (3.1 BAR), the pump must only produce the difference in pressure or 75 PSI (5.2 BAR). This contributes to low engine and pump speeds with reduced maintenance. Decreased maintenance is aided by the fact a centrifugal pump has few moving parts; such as the impeller, shaft and seal.

Note: 4DK Series pumps are single stage pumps, meaning there is a single impeller on a common shaft.

As fluid is evacuated from the suction passage atmospheric pressure pushes the fluid through the suction passage.

Generally, the pump consists of the following major components:

❑ Pump body ❑ Impeller and Shaft Components ❑ Gearbox

Self-Priming

The 4DK pumps can only self-prime if the pump body is full of fluid. A recirculation chamber and passage keeps the impeller eye wet. This allows fluid to circulate inside the pump providing the self-priming action.

CAUTION !

THE PUMP CANNOT SELF-PRIME AND WILL BE DAMAGED IF RUN DRY FOR EXTENDED PERIODS OF TIME.

Pump Operation

As the impeller rotates the fluid moving outward in the impeller creates a vacuum in the suction eye allowing the pump to lift the fluid into the volute (or body).

DISCHARGE

INTAKE

CUT WATER

VANES

EYE

DIFFUSER

Figure 2: Impeller Operation

To develop the required volume and pressure, the Hale 4DK series pump utilizes an impeller with a single suction channel where fluid enters.

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4DK Series Pumps

The impeller develops discharge pressure and directs the fluid to a single cut water and then to the discharge opening.

The cut water is wedge-shaped and divides the fluid between the volute and the pump discharge. Figure 2: "Impeller Operation" on page 8 shows the flow of fluid through the Hale 4DK series pump.

Cavitation

Cavitation occurs when a centrifugal pump is attempting to discharge more fluid than it is receiving. When cavitation occurs, bubbles are created under the vacuum, near the eye of the impeller. Cavitation is often referred to as “the pump running away from the fluid supply.”

This means that the operator is trying to pump more fluid 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.

The vacuum gauge is usually tapped into the intake chamber several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The most common way to eliminate cavitation is to decrease the amount of fluid being discharged. This is accomplished by decreasing engine speed or closing discharge valves.

This will allow pressure to increase, however this will result in a reduction of flow.

Cavitation can also be eliminated be increasing the pressure on the pump inlet. This is accomplished with reduced vertical lift, reduced inlet losses, or running from positive pressure supplies.

Refueler pumps are generally gravity fed from the tank, therefore cavitation is less of an issue unless design limits are exceeded. Reduced performance can be expected when defueling aircraft due to the inlet restrictions involved.

PUMP COMPONENTS

To eliminate cavitation, the operator must be aware of the warning signs and immediately correct the situation or serious damage to the pump and impeller will occur. The most reliable indication that a pump is approaching cavitation is when an increase in engine RPM does not cause an increase in pump discharge pressure. A low barometer, high elevation, or elevated fluid temperature will also contribute to cavitation.

Pumps are rated at standard temperatures and barometric pressures. When conditions vary from standard, the maximum capacity of the pump from draft can be affected.

The operator must not depend entirely on the vacuum gauge (if one is installed in the application) to indicate when a pump is nearing cavitation.

The basic parts of a Hale 4DK series centrifugal pump are briefly described as follows:

Pump Body

The pump body and related parts are constructed from aluminum.

The Hale 4DK series pump body is a single piece. Service of the impeller, clearance rings, and mechanical seal is accomplished by removing the pump body. This can often be accomplished without removing the entire pump and gearbox assembly from the apparatus. Additionally, a minimum of piping need be removed since the connections use Victaulic type couplings.

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4DK Series Pumps

The pump has a suction inlet on the front. The incoming fluid is directed to the impeller through the suction piping.

Impeller

A hard anodized aluminum impeller provides velocity to the fluid. This part is mounted on a shaft that is rotated by the gearbox. The fluid enters the rotating impeller at the intake (or eye), and is confined by the shrouds and the impeller vanes to build pressure. The vanes guide the fluid from the inlet to the discharge. Vanes curve away from the direction of rotation so the fluid moves toward the outer edge. The shrouds form the sides of the impeller and keep the fluid confined to centrifugal acceleration.

Figure 2 (on page 8) traces a drop of fluid from the intake of the impeller to the discharge outlet. The impeller is mount-ed so that the discharging tube is widest at the pump outlet. The volute collects the fluid.

A further increase in pressure and a decrease in velocity take place in the diffuser which is cast into the pump body.

Stationary

Seat

Wear is due to foreign material found in most fluids. Clearance rings are designed for replacement as the clearance increases from usage and wear.

If a pump is operated without fluid for extended periods or without discharging fluid, it may overheat. This may damage the pump and the drive mechanism. Fluid should be circulated to prevent overheating.

Bearings

Bearings support and align the impeller shaft for smooth operation.

Mechanical Seal

A mechanical seal is standard on 4DK series pumps. As shown in Figure 3, a stationary seat is in constant contact with a rotating carbon seal ring face to prevent leakage.

O-Ring

Carbon

Seal Ring

Retainer

Diaphragm

Spring

Clearance Rings

Pump Shaft

Clearance rings seal the impeller, preventing pressurized fluid from

Towards

Pump Head

leaving the pump volute and returning to the intake of the impeller. Centrifugal pumps have clearance rings at the impeller

Figure 3: Mechanical Seal Parts

intake to prevent leakage. This is accomplished by limiting the radial clearance between the spinning impeller and the stationary clearance ring.

The sealing boot is made of a rubber elastomer that is specifically designed for high temperature operations.

A clearance ring usually has a radial clearance of about 0.0075” (0.2mm) or a 0.015”

PUMP DRIVES

(0.4mm) diametral clearance. However, the clearance increases over time as the pump is operated.

4DK Series pumps are operated from the truck chassis drive shaft through a split-shaft gearbox.

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Impeller

Side

4DK Series Pumps

The split shaft gearbox has a sliding collar that selectively directs the engine power to the pump or the apparatus drive axle.

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 17,000 pound-feet (23.05 kN-m).

The 4DK series of pump gear boxes utilize tapered roller bearings to support the shaft loads. Special care must be taken to properly set the clearances on these bearings.

Bearings must be replaced as matched sets with shims. See Section 5 "Maintenance and Repair," beginning on page 21.

Shifting

The split-shaft gearbox is equipped with a power shift system. An in-cab control valve is provided for mode selection.

This control locks in place for pump operation. An indicator switch is provided to alert the operator when the gearbox has fully shifted from ROAD to PUMP position.

Additionally, provisions are provided for manual shift due to failure of the power shift system. Different pump models utilize different indicating switches. Some indicator switches are pneumatic while others are electric dependent on which pump model is selected and/or your operation requirements.

SECTION 2 OPERATING PROCEDURES

OVERVIEW

This section provides information and procedures for the operation of Hale 4DK series pumps.

OPERATING PROCEDURES

NOTICE !

THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES AND POLICIES ESTABLISHED BY YOUR COMPANY, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED BY THE APPARATUS MANUFACTURER'S MANUAL.

REFER TO COMPANY PROCEDURES ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES.

ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.

General Operation

1. Position the truck for the best hookup

NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRUCK TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS ZERO “0” BEFORE MAKING PUMP TRANSMISSION SHIFT. (SEE FIGURE 4: "IN-CAB PUMP SHIFT CONTROL," ON PAGE 12.)

NOTICE ! - continued

layout.

CAUTION !

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4DK Series Pumps

Indicator Light

Road Position

Control Handle

Neutral Position

Panel Placard

Figure 4: In-Cab Pump Shift Control

Neutral Position

Pump Position

2. Bring the truck to a complete stop before attempting to shift from ROAD to PUMP.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRAL position.

5. Move the in-cab pump shift control valve from the ROAD position to the PUMP position. Within a few seconds the shift warning indicator lights, indicating a complete shift.

Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or has an electric switch, follow the instructions supplied with that valve.

6. After pump shift has completed, place the truck transmission in the proper pump operating range or gear.

Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck’s chassis manual for details.

WARNING !

DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ON.

8. 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.

WARNING !

DO NOT OPEN THROTTLE UNLESS ALL GREEN PUMP INDICATOR LIGHTS ARE ON.

9. Verify that the pump panel shift indicator green “OK TO PUMP” light is on.

10. If necessary, open the suction valve to allow fluid to flow into the pump.

11. If necessary to eliminate air pockets, open appropriate valve to expel air or prime the pump, if so equipped.

12. Note the discharge pressures and intake pressures as applicable, then open the engine throttle gradually until the master discharge gauge indicates the desired pressure.

For most operation conditions, this will be direct drive (1:1) ratio. In addition, the speedometer should read 5MPH to 15 MPH (8 -15 KMH) after the shift has been completed.

7. If the shift does not complete, shift truck transmission to “N” and repeat the entire procedure.

13. Set the automatic relief valve or governor control system according to your company policy, if so equipped.

If the master intake gauge shows a high vacuum before the desired discharge pressure or flow is reached, it indicates that you are getting all the fluid the suction piping will supply.

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4DK Series Pumps

To increase the pressure when this occurs, reduce the pump flow.

As the throttle is opened, the pressure gauge reading increases with engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. In this case, 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 trying to pump more capacity than is available from the supply. Also check the inlet strainers for possible debris restricting the flow.

14. Open the discharge valve(s).

15. After completion of pumping, gradually reduce the pump pressure until the engine is at an idle speed.

2. Apply the truck parking brake and chock the wheels.

3. Shift the truck transmission to the NEUTRAL position.

4. For PUMP or ROAD position, put the incab shift control in the NEUTRAL position. (Neutral position is exactly in the middle, between the road and pump positions.)

5. Shut down the engine.

WARNING !

DO NOT ATTEMPT EMERGENCY SHIFT PROCEDURES WHILE THE ENGINE IS RUNNING.

6. Employ the manual override procedure at the shift cylinder on the pump gearbox as follows:

16. Verify that the operator’s hand throttle or governor control has returned to idle position.

17. Shift the truck transmission into the NEUTRAL position, and wait about four seconds. Check to make sure the speedometer reads “0.”

18. Move pump shift control valve lever to the ROAD position. The in-cab and panel pump indicator lights should go out when the pump transmission starts to shift into the ROAD position.

Emergency Pump Shift Procedures

Before implementing manual override shift procedures, repeat recommended procedures as described in the previous section. If the shift fails to take place, follow these procedures.

1. Bring the truck to a complete stop.

Note: The shift stroke is approximately 1” (25 mm). Make sure the gearbox is fully shifted and shift indicators show proper mode.

7. An eyebolt is provided in the shift shaft to accept a drift punch or screwdriver. By inserting this tool into the hole provided, you are able to pull or push the shaft manually.

8. Pull the shift shaft OUT for PUMP position (after in-cab control valve selection), or push shift shaft IN for ROAD position (after in-cab control valve selection).

If the shift stroke cannot be completed manually, turn the drive shaft slightly by hand to realign the internal gears and repeat the manual shift effort.

9. Some units may be equipped with a manual shift device attached to the eye bolt. Refer to the manufacturer’s instructions when manual shift devices are installed.

Manual p/n: 029-0020-79-0 13

4DK Series Pumps

Post Operation Procedures

1. Fill out the pump run log, indicating total pumping time, per your company guidelines.

2. Report all pump, vehicle equipment malfunctions, and irregularities to the proper authority.

NOTES

________________________________________________________________________

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SECTION 3 PREVENTIVE MAINTENANCE

4DK Series Pumps

AFTER EACH USE

❑ Check seals for leaks. ❑ Check piping for leaks. ❑ Close all valves and caps.

WEEKLY

❑ Verify operation of pump shift indicator. ❑ Check drive lines.

MONTHLY

Check drive lines and flange bolts to ensure:

❑ No bolts are missing. ❑ All bolts are tight. ❑ Bolts used are “Grade 8” strength.

Check pump mounting bolts to ensure

❑ No bolts missing. ❑ All bolts are tight.

4DK AMBIENT TEMPERATURE OIL SELECTION

DEXRON III SYNTHETIC COGNIS 2803

EMGARD SAE 50 SYNTHETIC COGNIS 294/ 2833

-40 -30 -20 -10 0-510 20 30 40 60 80 100 120

Note: Use above specified lubricants or equal. Consult factory for additional recommendations.

5

Figure 5: Recommended Oils

For climates with ambient temperatures below freezing (32°F/0°C), use Dextron III synthetic oil (Cognis 2803 or equal).

An oil level sight gauge is provided on the side of the gear box. (See Figure 6: "Sight Level Gauge/Lubrication.") The gear box requires five (5) quarts (4.7liters) of oil to bring the level to the halfway point on the sight level gauge (minimum FULL level). Adding oil in excess of the halfway point may cause the unit to run in excess of higher than recommended operating temperature.

°F

ANNUALLY

Gear Box – Oil Change

Oil Level Sight Gauge

Oil Fill Plug

Minimum FULL Level

Replace gearbox oil with recommended type. See Figure 5: "Recommended Oils Chart" and in the next column.

For climates with ambient temperatures above -5°F (-15°C) replace then gearbox oil with Emgard SAE 50 synthetic oil (Cognis 2924/2833 or equal).

Figure 6: Sight Level Gauge/ Lubrication

Manual p/n: 029-0020-79-0 15

Speed Counter Grease

Fitting

4DK Series Pumps

Speed Counter – Lubrication

See Figure 6: "Sight Level Gauge/Lubrication" on page 15.

Lubricate the speed counter grease fitting annually using Mobil Grease 28 or equal – Hale p/n: 029-0670-00-0.

Pump Shift Warning Indicator Lights

WARNING !

BE SURE THAT THE PARKING BRAKE IS SET AND EVERYONE IS CLEAR OF THE TRUCK BEFORE SHIFTING TO THE PUMP ON POSITION. THE WHEELS MUST BE BLOCKED TO PREVENT ANY MOVEMENT OF THE TRUCK.

1. Follow the operating procedures in Section 2, beginning on page 11, to engage the pump.

2. Verify that the warning indicators in the cab and on the pump control panel are ON.

3. Switch to non-pumping operation and verify the warning indicators are OFF.

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Hale 4DK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

NOTICE !

Contents

SECTION 1 INTRODUCTION

OVERVIEW

PRINCIPLES OF OPERATION

Centrifugal Force

Figure 1: Centrifugal Force

Self-Priming

Pump Operation

Figure 2: Impeller Operation

Cavitation

PUMP COMPONENTS

Pump Body

Impeller

Bearings

Mechanical Seal

Clearance Rings

Figure 3: Mechanical Seal Parts

PUMP DRIVES

Shifting

SECTION 2 OPERATING PROCEDURES

OVERVIEW

OPERATING PROCEDURES

General Operation

Figure 4: In-Cab Pump Shift Control

Emergency Pump Shift Procedures

Post Operation Procedures

SECTION 3 PREVENTIVE MAINTENANCE

AFTER EACH USE

WEEKLY

MONTHLY

Figure 5: Recommended Oils

ANNUALLY

Figure 6: Sight Level Gauge/ Lubrication

Pump Shift Warning Indicator Lights