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).

Manual p/n: 029-0020-79-0 7

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.

Manual p/n: 029-0020-79-0 9

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.

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

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 !

Manual p/n: 029-0020-79-0 11

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

________________________________________________________________________

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

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.

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

SECTION 4 TROUBLESHOOTING

4DK Series Pumps

Table 4-1 lists the 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.

CAUSE

PUMP WILL NOT ENGAGE

Automatic transmission with power shift system

Insufficient air in shift system

Air leaks in shift system

● Repeat recommended shift procedures with transmission in

● Release brake system momentarily. Then reset and repeat

● Check for leaks in system. Employ manual override proce-

● Attempt to locate and repair leak(s). Leakage, if external, may

If you cannot correct a problem, please have the Model and Serial numbers ready prior to calling the Hale Customer Service Technician Department for assistance – Customer Service telephone number: 610-825-6300.

SUGGESTED CORRECTIVE ACTIONCONDITION POSSIBLE

NEUTRAL position. (See ‘Operating Procedures’ on page 11.)

recommended shifting procedures. (See ‘Operating Procedures’ on page 11.)

dures if necessary. See Emergency Pump Shift Procedures, beginning on page 13.

be detected audibly. Leakage could be internal and not as easily detected.

CAUTION !

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 IN SERVICING. DO NOT LEAVE THE CAB AFTER SHIFTING THE PUMP UNLESS THE SHIFT INDICATOR LIGHT IS ON, OR A SPEEDOMETER READING IS NOTED.

PUMP LOSES PRIME OR WILL NOT PRIME

Chart continued on

Suction lifts too high

Blocked suction strainer

Suction connections

Air trapped in suction line

● DO NOT attempt lifts exceeding 22' (6.7m) except at low

elevation.

● Remove obstruction from suction hose strainer.

● Clean and tighten all suction connections. Check suction

hose and hose gaskets for possible defects. Repair and/or replace.

● Avoid placing any part of the suction hose higher than the

suction intake. Suction hose should be laid with continuous decline to fluid supply.

4DK Series Pumps

SUGGESTED CORRECTIVE ACTIONCONDITION POSSIBLE

CAUSE

PUMP LOSES PRIME OR WILL NOT PRIME continued

INSUFFICIENT PUMP CAPACITY

Air trapped in suction line continued

Pump pressure too low when nozzle is opened

Air leaks

Insufficient engine power

Relief valve improperly set - if so equipped

Engine governor set incorrectly - if so equipped

● If trap in hose is unavoidable, repeated priming may be

necessary to eliminate air pocket in suction hose.

● Prime the pump again and maintain higher pump pressure

while opening the discharge valve slowly.

● Attempt to locate and correct air leaks.

● The suction side relief valve can leak. Plug the valve outlet

connection and retest.

● Engine power check or tune up may be required for peak

engine and pump performance.

● If the relief valve pressure is set too low it allows the valve to

open and bypass fluid.

● Reset the relief valve pressure accordingly.

● If the engine governor is set too low when on automatic, the

engine speed decelerates before the desired pressure is reached.

● Reset the governor per manufacturer's procedures.

INSUFFICIENT PRESSURE

ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE

Chart continued on

Air leaks

Truck transmission in wrong range or gear

● Recheck the pumping procedures for the recommended

transmission or gear range. See truck manual for assistance.

● Use mechanical speed counter on the pump panel to check

speed against possible clutch or transmission slipping or inaccurate tachometer. (Check the truck manual for possible speed counter ratio.)

● See Possible Causes "Air leaks" under PUMP LOSES PRIME

OR WILL NOT PRIME, beginning on page 17.

● See previous section: Insufficient Pump Capacity.

● Check recommended procedures for correct transmission

selection. (See truck manual for assistance.)

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

CAUSE

4DK Series Pumps

SUGGESTED CORRECTIVE ACTIONCONDITION POSSIBLE

ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE continued

Lift too high, suction hose too small

Faulty suction hose

Blockage at suction hose entry

Worn pump impeller(s) or clearance rings

Impeller blockage

● Higher than normal lift (10'/ 3.1m) causes higher engine

speeds, high vacuum and rough operation.

● Use larger suction hose.

● Inner lining of suction hose may collapse when drafting and is

usually undetectable.

● Try a different suction hose on same pump; test for compari-

son against original hose.

● Clean suction hose strainer of obstruction and follow recom-

mended practices for laying suction hose.

● Keep off the bottom of the fluid supply by at least 2' (0.6m)

below the surface of the fluid.

● Repair and/or replace as needed. See heading "Pump Body/

Impeller," beginning on page 32.

● Blockage in the impeller can prevent loss of both capacity and

pressure.

● Back flushing of pumps from discharge to suction may free

blockage. Removing half of the pump body may be required. (This is considered a major repair.)

DISCHARGE VALVES DIFFICULT TO OPERATE

Lack of lubrication

Valve in need of more clearance

● Recommended weekly lubrication of discharge and suction

valve. Use a good grade of petroleum base silicone grease.

● For Hale Products SVS Valves, use Never-Seize

®

White Food

Grade with PTFE.

● Add gasket to the valve cover per the truck manual.

● Multi-gasket design allows additional gaskets for more clear-

ance and free operation.

Note: Adding too many gaskets to the valve eventually causes leakage.

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4DK Series Pumps

NOTES

________________________________________________________________________

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

SECTION 5 MAINTENANCE AND REPAIR

4DK Series Pumps

OVERVIEW

This section describes the removal, inspection, and reinstallation of the 4DK series pump and components as required for maintenance and repair.

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, the proper tools and Hale genuine replacement parts before you attempt any repair maintenance.

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

WARNING !

HALE 4DK SERIES PUMPS ARE DESIGNED TO PUMP AIRCRAFT FUELS IN ADDITION TO DEMINERALIZED WATER (I.E., JP-4, JP-5, OR JP-8, JET-A OR JET-B, KEROSENE, ETC.). PUMPING OF FUELS IS INHERENTLY HAZARDOUS AND CALLS FOR CAREFUL INSPECTION AND MAINTENANCE OF EQUIPMENT. CHECK FOR LEAKS AND HAZARDOUS CONDITIONS. WHEN SERVICING, REMOVE POTENTIAL FIRE AND EXPLOSION HAZARDS FROM THE WORK AREA IN ACCORDANCE WITH YOUR SAFETY REGULATIONS. WHEN HANDLING FLAMMABLE PRODUCTS ALSO FOLLOW ALL INSTRUCTIONS PROVIDED WITH THE APPARATUS.

PROPER GROUNDING AND STATIC CONTROL EQUIPMENT MUST BE INSTALLED, PROPERLY MAINTAINED AND USED IN ACCORDANCE WITH THE APPARATUS MANUFACTURER'S INSTRUCTIONS WHEN PUMPING FUEL.

GENERAL REPAIR GUIDELINES

2. Where grease is called for, use a Lithiumbased grease with 1% to 3% Molybdenum Disulfate. The following examples are approved greases:

❑ Dow Corning BR2-PLUS ❑ Lubriplate-Fiske #3000 ❑ Shell Super Duty Grease ❑ Imperial #777 ❑ Mobil Grease Special ❑ Sunoco Moly #2EP

Also see Figure 5: "Recommended Oils" on page 15.

3. When replacing fasteners, use the proper nuts, bolts, and other hardware.

Many are specifically rated; that is, SAE Grade 5 or higher and must be replaced with the identical type. Apply a coating of Loctite 246 High Temperature Removeable Thread Locker (or equal) before installing.

4. It is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators.

5. When installing the mechanical seal, apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) on the rubber seal parts to ease installation.

WARNING !

THE PUMP AND GEARBOX WEIGH APPROXIMATELY 240 LBS. (109 KG). USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING PUMP AND GEARBOX ASSEMBLY.

1. Match, mark (tag), or note the orientation of components before disconnecting or removing them to aid in proper reassembly.

Manual p/n: 029-0020-79-0 21

4DK Series Pumps

OIL SEALS (Input/Tail Shafts)

See Figure 7 "Oil Seal Replacement."

Screw & Washer

3/4-10 x 1-3/4"

Oil Seal

Figure 7: 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.

Shaft

(Input or Tail)

GEAR BOX and PUMP

Removal

1. Park the vehicle on a level surface with ample clearance around all sides for maintenance availability.

2. Shut down the engine.

3. Set the parking brake and chock the front and rear tires. Obtain access to the pump and gearbox using safe practices in accordance with your regulations.

4. Drain the pump and piping, then disconnect the suction and discharge piping from the pump.

5. Remove the 3/4" NPT drain plug and drain the gearbox oil into a suitable container (approximately 5 quarts/4.7 liters).

6. Disconnect the drive shafts (front and rear) from the gearbox.

7. Disconnect the speed-counter cable, electrical switches, and air lines.

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.

8. ATTACH PROPER LIFTING DEVICE BEFORE LOOSENING OR REMOVING PUMP MOUNTINGS.

9. Disconnect mounting brackets then remove pump and gearbox assembly from apparatus.

3. Carefully insert a new oil seal into the housing.

10. Place pump and gearbox assembly on a stable work bench.

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– yoke must spin freely.

Make sure the oil breather and gearbox cover are in the up direction. Also be certain the shift shaft is in the road (in) position.

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

4DK Series Pumps

Installation

1. Place pump and gearbox assembly on a stable platform. Attach proper lifting device to the pump and gearbox assembly.

2. Lift pump and gearbox assembly into position on the apparatus. Connect mounting brackets and secure using proper fasteners.

3. Correctly align driveline angle for proper operation. Also see Section 6 "Pump Installation" on page 41.

4. Connect the front and rear drive shafts to the gearbox.

5. Connect electrical switches, air lines, and speed-counter cable.

6. Install the 3/4" NPT drain plug. Remove the 3/4" NPT oil fill and level plug located near the KPS cylinder.

7. Fill gearbox to the level plug. See page 15 for recommended oil.

8. Reconnect suction and discharge piping to the pump.

9. Test apparatus and pump for proper operation, observing piping and seals for leaks. Repair any leaks immediately.

GEAR BOX COVER

Installation

1. Apply a light coating of general-purpose grease to the gasket and gearbox mating surfaces.

2. Align gasket and cover on gearbox.

3. Apply Loctite 246 (or equal) then secure the cover using fifteen 3/8-16 x 1" cap screws.

TAIL SHAFT

See Figure 8: "Tail Shaft Assembly" on page 24.

Removal and Disassembly

1. Remove gearbox cover.

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.

6. Press the bearing cone off the tail shaft.

Removal

7. If necessary, remove the roller bearing

1. Remove fifteen 3/8-16 x 1" cap screws, then remove the gearbox cover and gasket.

2. Scrape all remaining gasket material from the gearbox and mating surfaces being careful not to score the machined surfaces.

Manual p/n: 029-0020-79-0 23

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: 296-2680-01-0.

4DK Series Pumps

Retaining Ring

Bearing Cone

Roller Bearing

Inner Race

Tail Shaft

Shims

and Spacer

Bearing Cup

O-Ring

Bearing Carrier

Oil Seal

Yoke

Screw

1/2-13 x 1-3/4"

Washer

Bearing Cup

Figure 8: Tail Shaft Assembly

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: 250-8140-50-0.

Reassembly and Installation

See Figure 8: "Tail Shaft Assembly."

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.

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 8 above).

3. Obtain new components from Hale Products as appropriate.

4. Slide the matching inner bearing cone and spacer onto the tail shaft. Both are a tight fit.

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

Adjust gap between

shafts to 0.060" ± 0.010"

1.52mm ± 0.25mm

4DK Series Pumps

Bearing Carrier

Shim Placement

Figure 9: Shaft End Gap

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: "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 50ft.-lb. (68N-m).

8. Using a feeler gauge, measure the gap between the input and tail shafts, as shown in Figure 9 above.

9. Remove the bearing carrier and install correct amount of spacers to produce a

0.060" ± 0.010" (1.524mm ± 0.254mm) gap.

Note, continued: 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.

Using a light coating of general purpose grease to hold the gasket in place.

12. Place the inner spacer and shims 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.

Note: Under normal circumstances, replacing bearings, seals, cones, etc. will have little effect on the gap setting. Reinstalling all existing shims will maintain the required gap (0.060" ± 0.010" [1.524mm ± 0.254mm]).

Manual p/n: 029-0020-79-0 25

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).

4DK Series Pumps

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" 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

See Figure 10: "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 housing.

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.

Yoke

Screw

3/4-10 x 1-3/4"

Washer

Input Shaft

Retainer Ring

Oil Seal

Figure 10: Input Shaft Assembly

Bearing Cups

Needle Bearing

Shift Fork

Shims

Roller Bearing

Outer Race

Bearing Cones

Input Gear

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

4DK Series Pumps

7. Remove the remaining bearing cone out of the housing. (See Figure 10: "Input Shaft Assembly" on page 26.)

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: 250-8140-51-0.

5. Insert the input shaft partially through the bearing cover bore and install the needle bearings, shift 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.

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 SHIFT CYLINDER

3. Obtain new components from Hale Products as appropriate.

Reassembly and Installation

See Figure 10: "Input Shaft Assembly" on page 26.

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.

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.

See Figure 11: "KPS Shift Cylinder Assembly" on page 28.

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.

4. Press the roller bearing outer race onto the input shaft.

Manual p/n: 029-0020-79-0 27

7. Unscrew two 7/16-14 x 1" screws then remove KPS cylinder and gasket.

4DK Series Pumps

Spacer

Extension Shaft

Lock Nut

Rod End

Cylinder Cap

Screws (4)

5/16-18 x 1"

Piston

Shift Cylinder

Seal Rings (3)

Screws (2), 7/16-14 x 1"

Seal Ring

Bushing

Gasket

Air Inlet Port

1/8" NPT

Figure 11: KPS Shift Cylinder Assembly

8. Remove seal ring from shift cylinder.

9. Remove and check bushing for wear. Replace accordingly with Hale p/n: 2509550-00-0.

Installation

See Figure 11: "KPS Shift Cylinder Assembly."

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.

Align KPS cylinder and secure using two 7/ 16-14 x 1" screws.

3. 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.

4. Thread extension shaft onto shift rod. Prior to installation, coat threads with Loctite 246 (or equal).

5. Make sure the piston and shaft move freely in the shift cylinder.

6. Apply a light coating of general-purpose grease then install the scraper and seal rings in the KPS cover.

7. Install KPS cover with scraper and seal rings over the shaft.

8. Apply Loctite 246 (or equal) then install four 5/16-18 x 1" screws.

9. Install rod end and 3/8-16 nut on end of shift shaft. Lock the rod end with the nut.

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

Shifter Shaft

4DK Series Pumps

Setscrew

1/2-20 x 1/2"

Detent Spring

Detent Ball

Cap

Ball

Bushing

Shift Switch

(See Figure 12

below for details)

Figure 12: KPS Shift Cap Assembly

KPS SHIFT CAP and SWITCH

See Figure 12: "KPS Shift Cap Assembly."

Removal

1. Disconnect control connection.

2. Remove 1/8"NPT air vent.

3. Unscrew the 1/2-20 x 1/2" setscrew, then remove detent spring and ball.

Gasket

Bracket

Screws (2 - not shown)

#10-32 x 1/2"

Installation

See Figure 13: "KPS Shift Cap Assembly."

1. Apply a light coating of general-purpose grease to hold gasket in place, then place gasket on gearbox.

1/8"NPT Port

Output to Air/Electric

Switch

CYL

4. Remove switch by unscrewing two #10-32 x 1/2" screws. Remove switch, gasket, detent ball, and bracket from the cap. (See Figure 13: "Shift Switch Detail.")

5. Remove two 7/16-14 x 1" cap screws and the gearshift shaft cap (not shown).

1/8"NPT Port

Vent

NC NO

1/8"NPT Port

Input from KPS

Power Switch

6. Remove the gasket from the mating surface of the gearbox.

Manual p/n: 029-0020-79-0 29

Figure 13: Shift Switch Detail

4DK Series Pumps

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 gasket, bracket, and switch onto cap using two #10-32 x 1/2" screws. Prior to installation, coat threads with Loctite 246 (or equal).

5. Thread 1/8"NPT air vent into the port labelled NC on shift switch. See Figure 13: "Shift Switch Detail" on page 29.

6. Reconnect electrical control / pneumatic 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

2. While holding the shift fork in place, insert shift shaft into gearbox housing by sliding 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, p/n: 018-8350-00-0.

4. Install KPS shift switch, KPS cylinder, tail shaft assembly, input shaft assembly, and gearbox cover.

IDLER SHAFT

See Figure 14: "Idler Shaft Assembly" on page

31.

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.

1. If necessary, press shift shaft bushings into gearbox housing.

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

7. Using retaining ring pliers, remove the two retaining rings from the idler gear.

8. Remove O-ring from idler shaft.

4DK Series Pumps

Inspection

See Figure 14: "Idler Shaft Assembly."

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: 2508270-50-0.

3. Obtain new components from Hale Products as appropriate.

Installation

See Figure 14: "Idler Shaft Assembly."

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 housing, 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.

1. Assemble the idler gear assembly by first installing the two retaining rings into the idler gear using retaining ring pliers.

Idler Gear

Shims

O-Ring Seal

Idler

Shaft

Bearing Cups

Bearing Cones

Washer

Shims

Nut

1/2-13 x 1-1/2"

Spacer

Retaining Rings (2)

Figure 14: Idler Shaft Assembly

Manual p/n: 029-0020-79-0 31

4DK Series Pumps

PUMP BODY/ IMPELLER

To service the internal parts of the gearbox or pump head (pump shaft, bearings, seals, impeller, etc.) the pump body must first be removed.

See Figure 15: "Pump Body and Impeller Assembly."

Note: The pump body can be removed while the pump and gearbox assembly are mounted on the apparatus.

CAUTION !

BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP BODY.

Pump Body Disassembly

1. Drain the inlet (suction) side of the pump body per your required procedures. Then disconnect the suction and discharge lines.

2. Remove the 1/4" NPT pipe plug from the pump body to drain any remaining fluid. Have a suitable container available to collect access fluid, approximately one to two gallons (3.8-7.6 liters).

3. Remove twelve 7/16-14 x 1-1/4" cap screws and washers that secure the pump body to the pump head.

4. Slide the pump body from the pump head assembly being careful not to damage the pump shaft or mechanical seal assembly.

If you are servicing the mechanical seal, see heading "Mechanical Seal Assembly" on page 34.

See Figure 15: "Pump Body and Impeller Assembly."

Screws/Washers (4)

7/16-14 x 1-1/4"

Screws/ Washers (12)

7/16-14 x 1-1/4"

Mechanical

Seal

5. Scrape all remaining gasket material from the pump head and mating surfaces being careful not to score the machined surfaces.

Pump Housing/Gearbox

Pump Head and

Gasket

Pump Body

Pump Discharge

Impeller

Nut

Spring Pin

Plug

Figure 15: Pump Body and Impeller Assembly

Pump Inlet (Suction)

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

Mechanical

Seal

Pump Head

Seal Spring

Shaft Key

4DK Series Pumps

Pump Shaft

Mechanical

Seal

Clearance

Ring

Impeller

Clearance

Ring

Impeller Nut

Spring Pin

Figure 16: Impeller / Mechanical Seal Assembly

Impeller Disassembly

See Figure 16: "Impeller/Mechanical Seal Assembly."

1. Remove the pump body per preceding section.

2. Tap out the spring pin that locks the impeller nut to the pump shaft.

3. While holding the impeller with a strap wrench, remove the impeller nut.

4. Slide impeller from the pump shaft, then remove the impeller shaft key.

Inspection

See Figure 16: "Impeller/Mechanical Seal Assembly."

Impeller Hub

Inspect the impeller hub(s) for signs of wear per dimensions listed below. Replace impeller if hub is worn or damaged beyond repair.

❑ New impeller hub diameter:

4.752 to 4.754" (120,701-120,752mm)

❑ Wear limits:

4.747 to 4.754" (120,574-120,752mm)

Clearance Ring

See Figure 16: "Impeller/Mechanical Seal Assembly."

Inspect clearance ring for signs of wear. Measure the inside diameter of the clearance ring while it is pressed into the pump head.

❑ New clearance ring diameter (pressed):

4.770" to 4.777" (121.2-121.3 mm)

Manual p/n: 029-0020-79-0 33

4DK Series Pumps

❑ Wear Limits:

4.770" to 4.787" (121.2-121.6mm)

Mechanical Seal Assembly

See Figure 15: "Pump Body and Impeller Assembly" on page 32.

1. Inspect the mechanical seal.

2. If replacing mechanical seal, remove the seal spring and seal bellows from pump shaft.

3. Remove seal stationary seat from pump head.

Installation

See Figure 16: "Impeller/Mechanical Seal Assembly" on page 33.

1. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) to the O-ring on the outside of the stationary seat.

2. Carefully slide the stationary seat over the pump shaft and press it into the pump head. Avoid touching the running face of the seat.

3. Without touching the running face, make sure the stationary seat is seated in the bore of the pump head using a pusher tool as shown in Figure 17: "Mechanical Seal Pusher Tool," in the next column.

4. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) to the pump shaft and seal diaphragm.

5. Without touching the carbon seal ring, push the carbon seal ring, diaphragm, retainer and drive ring onto the shaft.

Figure 17: Mechanical Seal Pusher Tool

Figure 17 should be used to perform this task. Keep the shaft well lubricated and make sure the carbon seal ring seats against the stationary seat.

If binding occurs apply additional lubricant. Slide any springs, cup washers, etc. supplied with the seal onto the shaft. Make sure the spring seats on the drive flange.

Impeller/ Pump Body Installation

See Figure 15: "Pump Body and Impeller Assembly" on page 32.

Before attempting reassembly of the pump body and impeller, the components must be inspected to tolerances. See previous heading "Inspection" on page 33. Replace any component if inspection indicates it is not within tolerances specified.

Impeller Hub Installation

A pusher tool similar to the one shown in

See Figure 16: "Impeller/Mechanical Seal Assembly" on page 33.

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

4DK Series Pumps

1. Install the impeller shaft key into the slot on the pump shaft.

2. Carefully slide impeller over pump shaft aligning keyway with impeller key.

3. While holding the impeller with a strap wrench, tighten impeller nut.

4. Install spring pin to lock the impeller nut to the pump shaft. You may have to apply a little torque to the nut to align the spring pin to the shaft hole.

5. Install pump head. See the following.

Pump Head Installation

See Figure 15: "Pump Body and Impeller Assembly" on page 32.

1. Use a press to install a new oil seal.

2. Apply a generous coating of Pac-Ease Rubber Emulsion (or equal) to the O-ring on the outside of the stationary seat.

Tighten cap screws to 40 ft.-lb. (54.2 N-m).

7. Install impeller and pump body.

Pump Body Installation

See Figure 15: "Pump Body and Impeller Assembly" on page 32.

1. If required, remove worn clearance ring then press a new clearance ring into the pump body.

2. Apply a light coating of grease to the gasket and align on the pump head.

3. Install pump body to the pump head being careful not to damage clearance ring and impeller.

4. Apply a coating of Loctite 246 (or equal) and install the twelve 7/16-14 x 1-1/4" cap screws and washers.

5. Reinstall the 1/4" NPT pipe plug.

3. Press the stationary seat into the pump head. Use the disk from the seal packaging to push the stationary seat in place.

Without touching the running face, make sure the stationary seat is seated in the bore.

4. Apply a coating of general-purpose grease to the gasket and align gasket on the pump head.

5. Install the pump head on the gearbox, being careful not to damage the oil seal, stationary seat and pump shaft.

6. Apply Loctite 246 (or equal) and install the four 7/16-14 x 1-1/4" cap screws and washers to secure the pump head to the gearbox.

PUMP SHAFT

See Figure 18: "Pump Shaft Assembly" on page

36.

To remove the pump shaft and related components, you must first remove the pump body and impeller. See heading "Pump Body/Impeller" on page 32.

Removal

1. Remove pump body, impeller and pump head. See previous heading "Pump Body / Impeller," beginning on page 32.

2. Unscrew speed counter and fitting. Pull spring pin from the pump shaft.

Manual p/n: 029-0020-79-0 35

4DK Series Pumps

Bearing Cover

Screw (4)

7/16-14 x 1-1/2"

Adapter

Cap

Spring

Speed Counter

Shims

Spacer

Shims

Figure 18: Pump Shaft Assembly

Bearing Cup

Pump Shaft

Bearing Cone

Roller Bearing

Pump Gear

Shaft Key

3. Unscrew the four 7/16-14 x 1-1/2" screws allowing removal of the bearing cover and shims. Clean the mating surfaces of all shim material.

4. Using the proper pushing tool, remove the pump shaft and attached components out of the gearbox from the bearing cover side to the pump.

5. Note the orientation of bearing cups and cones for proper reassembly.

6. Remove tapered roller bearing cones from each side of the pump shaft. If necessary, remove the cups from the gearbox bores. If necessary, use a bearing removal tool.

Installation

See Figure 18: "Pump Shaft Assembly."

2. Install bearing cone assembly on impeller side of pump shaft.

3. Carefully slide pump shaft through gearbox from impeller side making sure the bearing cup seats in the gearbox bore.

4. Install bearing cone on opposite side of gearbox.

5. Install pump head.

6. Obtain an assortment of shims before proceeding with installation of the bearing cap.

Install a dial indicator to measure bearing play on the impeller end of the pump shaft.

7. Install bearing cover and shims using the four 7/16-14 x 1" cap screws.

1. Install key, gear, and spacer on pump

Tighten cap screws to 50 ft.-lb. (68 N-m).

shaft. Press bearing cups on pump shaft.

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

4DK Series Pumps

8. Measure the gap under the cover using feeler gauges. Install shims as necessary to obtain 0.002" to 0.004" (0.051-0.101mm) of axial shaft float. Shaft should rotate smoothly and freely.

❑ two pieces – 0.005" (0.13mm) BLUE ❑ two pieces – 0.0075" (0.19mm) CLEAR ❑ two pieces – 0.020" (0.51mm) YELLOW

9. Install impeller and pump body. See heading "Impeller/Pump Body Installation" on page 34.

NOTES

________________________________________________________________________

Manual p/n: 029-0020-79-0 37

4DK Series Pumps

4DK SERIES OVERVIEW

Gear Shift Switch

Detent Spring

Yoke

(Input)

Input Shaft

Assembly

(Also see Figure 20)

Impeller Shaft

Assembly

(Also see Figure 21)

Assembly

and Ball

(Shown in PUMP Position)

Air/ Electric

Switch

Gearbox HousingShift Fork

Input Gear

KPS Shift Cylinder

Assembly

Shift Shaft and

O-Ring Seal

Extension

Rod End

Yoke

(Tail / Output)

Tail/ Output Shaft

Assembly

(See Figure 20)

Idler Gear

Idler Shaft

Assembly

(Also see Figure 21)

4" (102mm)

Victaulic

Suction

Note: Model 4D6K

offers a 6" (152mm)

Victaulic Suction

Volute

(Pump Body)

Speed Counter

Assembly

(Also see Figure 21)

Pump Shaft Cover

(Also see Figure 21)

Gearbox Housing

Pump Gear

4" (102mm) Victaulic

Discharge

Figure 19: 4DK Series Pump Main Overview

(Also see Parts Breakdown at back of this manual.)

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

4DK Series Pumps

Shift Rod Extension

Rod Scraper

(Shift Cylinder)

Seal Ring

Cylinder Cap

Seal Ring

Shift Cylinder

Assembly

Air Inlet Port

(Shift Cylinder)

Shifter Bushing

Shift Rod

Needle Bearings

Gearbox Housing

Shift Fork

O-Ring Seal

Air Vent

Detent Ball

Shift Rod End

Piston

Air Inlet Port

(Shift Cylinder)

Seal Ring

Gasket

Screw and Washer

(Input Shaft Assembly)

Yoke

(Input Shaft Assembly)

Oil Seal

Bearing Cup

Spacer and Shims

Bearing Cone

Shift Collar

Roller Bearing

Outer Race

Roller Bearing Inner Race

Shims

Retaining Ring

Bearing Cup

Oil Seal

Input Shaft

Retaining Ring

Input Gear

Retaining Ring

Spacer and Shims

Bearing

Carrier

Bearing Cone

Gear Shift Switch

Assembly

(Also see Figure 19)

Oil Seal

Yoke

(Tail /Output Shaft Assembly)

Screw and Washer

(Tail /Output Shaft Assembly)

Figure 20: Input and Tail (Output) Shaft Assemblies

(Also see Parts Breakdown at back of this manual.)

Manual p/n: 029-0020-79-0 39

4DK Series Pumps

Pump Shaft Cover

Speed Counter

(10:1)

Idler /

Idler Shaft

O-Ring Seal

Bearing Cone

Bearing Cup

Retaining

Ring

Idler Gear

Idler Spacer

Seal Ring

Pump Head

Gasket

Impeller

Adapter

Bearing Cup

Oil Seal

(Remove to connect Speedometer cable)

Pump Bearing Shim

Bearing Cup

Bearing Cone

Pump Gear

Pump Key

Bearing Cone

Mechanical

Seal Assembly

Cap

Pump Spacer

Pump Shaft

4" (102mm)

Victaulic

Discharge

Impeller

Nut

Plug

Impeller Key

Impeller Nut

4" (102mm)

Victaulic

Suction

Note: Model 4D6K

offers a 6" (152mm)

Victaulic Suction

Figure 21: Pump Shaft Assembly

(Also see Parts Breakdown at back of this manual.)

Clearance Rings

Volute

(Pump Body)

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

SECTION 6 PUMP INSTALLATION

4DK Series Pumps

OVERVIEW

This section provides guidelines and recommendations for installing a Hale 4DK pump and gearbox into a truck chassis.

FRAME MOUNTING

The 4DK gearbox is mounted using four 5/8-11 bolts on either side of the gearbox. See Figure 22: "4DK Series Pump Installation" in the next column. All eight bolt holes are tapped 1" (25mm) deep.

IMPORTANT !

TO FULLY SUPPORT THE GEARBOX AND PUMP, USE ALL EIGHT BOLT HOLES.

3.72"

(95mm)

1.75"

(45mm)

5.75"

(146mm)

4" (102mm) Victaulic

Discharge

3.25" (83mm)

4" (102mm)

Victaulic Suction

1.75"

(45mm)

5.75"

(146mm)

DRIVELINE ISSUES

Due to the increasing sophistication of fire apparatus and truck design, there has been an increase in the number of reported driveline problems. These problems include: drive shaft failure, loosened drive ends on pump gearboxes, broken mounting brackets, driveline joint or slider wear, bearing wear on pumps or rear axles, and vibrations at specific road speeds. While the incidence of these problems is low, they are expensive to fix yet easy to avoid.

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.

While using the software, make sure to perform three separate driveline analyses:

Figure 22: 4DK Series Pump Installation

❑ Rear drive shaft assembly ❑ Total system

This ensures individual shaft cancellation and correct phasing.

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 our without

❑ Front drive shaft assembly

Manual p/n: 029-0020-79-0 41

noticeable vibration.

4DK Series Pumps

❑ Suspension travel and torque wrap-up can

change a marginal driveline into one that is unacceptable.

Always consider the full movement of the driveline.

❑ Center your driveline sliders and ensure they

have sufficient travel to allow for the entire movement of the suspension.

❑ Do not measure driveline angles using a

bubble protractor. Instead, use a digital inclinometer.

Remember to zero the inclinometer on the truck frame, not the ground.

❑ Spilt-shaft drivelines inherently have yoke

phasing that can change with every shift. This is one reason to design the other aspects of the driveline more conserv-atively than a "non-split shaft" truck driveline.

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.

Driveline tube size (diameter) in inches

Shaft 2.0 2.5 3.0 3.5 4.0 4.5 RPM

2400 47 53 58 63 67 71 2600 45 51 55 60 64 68 2800 44 49 53 58 62 65 3000 42 47 52 56 60 63 3200 41 46 50 54 58 61 3400 39 44 48 53 56 69 3600 38 43 47 51 55 58 3800 37 42 46 50 53 56 4000 36 41 45 48 52 55

Figure 23: Maximum Recommended Driveline Lengths

PLUMBING CONNECTIONS

4DK Pump

The 4DK pump is provided with a 4” Victaulic suction connection and a 4” Victaulic oppositesuction-side discharge connection.

Figure 23: "Maximum Recommended Drive Lengths," in the next column, lists the maximum driveline length using a safety factor of 42% of critical speed. 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 between the pump and the rear axle can also cause problems from excessive operating angles when the suspension articulates. 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.

An optional 4” Victaulic suction-side discharge connection is also available.

4DK6 Pump

The 4DK6 pump is provided with a 6” Victaulic suction connection and a 4” Victaulic oppositesuction-side discharge connection.

An optional 4” Victaulic suction-side discharge connection is also available.

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

4DK Series Pumps

APPENDIX A GLOSSARY

Atmospheric ........ Pressure caused by the elevation of air above the earth. Air pressure is 14 pounds

Pressure per square inch at sea level. Pressure increases below sea level and decreases

above sea level. The weather also effects air pressure. Atmospheric pressure effects a pumps ability to pump from draft. Higher pressures increases 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.

Rings

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 victaulic discharge connection.

Dead Heading ..... Operating a pump without any discharge. The lack of flow causes temperatures to

rise inside the pump. See WARNING ! on next page (1-16).

Manual p/n: 029-0020-79-0 43

4DK Series Pumps

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.

Eye, Impeller ....... Point where fluid enters the impeller.

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.

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

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

4DK Series Pumps

Positive................ Pressure above atmospheric.

Pressure

Power Valve ........A valve that uses hydraulic pressure to transfer two-stage pump operation from

volume 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 is

Gauge connected to the pump discharge manifold, thus indicating pump discharge

pressure.

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 booster pump

that creating 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, will hold 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.

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.

Manual p/n: 029-0020-79-0 45

4DK Series Pumps

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).

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.

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

4DK Series Pumps

APPENDIX B MEASUREMENTS

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

CONVERSIONS

TO CONVERT TO MULTIPLY BY

Feet Head ...................................... Pounds Pressure ................................................. 2.31

FT.-LB. (Torque) ................................ N-m ......................................... 1.3558

GALLONS .................................. LITERS ....................................... 3.785

HP (Horsepower) ........................ KW (Kilowatts) ................................. 0.7457

One Pound per Square Inch ................. One Bar .................................................... 0.0690

One Pound per Square Inch .................... KPA ......................................................... 0.001

Pounds per Square Inch ..................... Feed Head ..................................... 0.433

BAR ........................................... PSI ........................................... 4.504

PSI ........................................... BAR ........................................ 0.06895

Manual p/n: 029-0020-79-0 47

4DK Series Pumps

NOTES

________________________________________________________________________

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

4DK Series Pumps

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 buyer takes delivery of the products 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 services

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 Service

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.

Manual p/n: 029-0020-79-0 49

4DK Series Pumps

Hale Products Inc.

A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A.

Telephone ....................... 1-610-825-6300

Fax .................................. 1-610-825-6440

Web ...................... www.haleproducts.com

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

Hale 4DK 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

SECTION 4 TROUBLESHOOTING

SECTION 5 MAINTENANCE AND REPAIR

OVERVIEW

GENERAL REPAIR GUIDELINES

OIL SEALS (Input/Tail Shafts)

Figure 7: Oil Seal Replacement

GEAR BOX and PUMP

Removal

Installation

GEAR BOX COVER

Installation

TAIL SHAFT

Removal and Disassembly

Removal

Figure 8: Tail Shaft Assembly

Inspection

Reassembly and Installation

Figure 9: Shaft End Gap

INPUT SHAFT

Removal and Disassembly

Figure 10: Input Shaft Assembly

Inspection

KPS SHIFT CYLINDER

Reassembly and Installation

Removal

Figure 11: KPS Shift Cylinder Assembly

Installation

Figure 12: KPS Shift Cap Assembly

KPS SHIFT CAP and SWITCH

Removal

Installation

Figure 13: Shift Switch Detail

GEAR SHIFT FORK

Removal

Installation

IDLER SHAFT

Removal

Inspection

Installation

Figure 14: Idler Shaft Assembly

PUMP BODY/ IMPELLER

Pump Body Disassembly

Figure 15: Pump Body and Impeller Assembly

Figure 16: Impeller / Mechanical Seal Assembly