Hale 80FC User Manual
Pump Ends
(Series 20FS, 30FS, 40FB, 50FB, 50FB-U-U,
50FB-U-M, 60FB, FB50, FB75, FB100, 80FC)
Installation, Operation and
Service Maintenance Manual
Hale Products Inc. ◆ A Unit of IDEX Corporation
700 Spring Mill Avenue
Telephone: 610-825-6300
Web......www.haleproducts.com
◆ Conshohocken, PA 19428 U.S.A.
◆ FAX: 610-825-6440
Manual p/n: 029-0020-61-0
NOTICE !
Hale Products, Inc. cannot assume responsibility for product failure resulting from
improper maintenance or operation. Hale is responsible only to the limits stated in
the product warranty. Product specifications contained in this manual are subject
to change without notice.
All Hale products are quality components -- ruggedly designed, accurately
machined, precision inspected, carefully assembled and thoroughly tested. In
order to maintain the high quality of your unit, and to keep it in a ready condition, it
is important to follow the instructions on care and operation. Proper use and good
preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER
IN YOUR CORRESPONDENCE.
ECN No REV CHANGE FROM BY DATE APVD
0592 A INITIAL RELEASE LwH 06/11/2007 MAL
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
Conshohocken, PA 19428 USA
Manual p/n: 029-0020-61-0, Rev. -A
Printed in U.S.A.
WRITTEN BY LwH ISSUE DATE COPYRIGHT ©
CHECKED BY PW 06/11/2007
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
© Hale Products, Inc. 2007
All Rights Reserved
Table of Contents ❑
Contents Page
Pump Ends, Pumping Systems
1 Safety Precautions................................................................................................. 11
1.1 Definitions.........................................................................................................................12
1.2 General ..............................................................................................................................13
1.3 Fuel Safety ........................................................................................................................ 16
1.4 Battery Safety ................................................................................................................... 17
2 Overview ................................................................................................................ 19
2.1 Pump Ends ....................................................................................................................... 19
Figure 2-1: Typical Pump End Pumping Systems ..............................................................19
20FS-2M / 20FS-3M / 20FS-4M Series, with Gearbox ..............................................................19
30FS2 / 30FS3 / 30FS4 Series, with Gearbox ...........................................................................20
40FB / 50FB Series, Bell Housing or Pedestal Mount (-U-U Series) .........................................20
FB50 / FB75 / FB100 Series, Bell Housing Mount .....................................................................20
60FBG Series, with Gearbox .....................................................................................................21
60FJ Series, Bell Housing Mount...............................................................................................21
80FC Series, Bell Housing Mount..............................................................................................21
80FC (-G or -U) Series, with gearbox (-G) or pedestal (-U) .......................................................21
2.2 Pumping System Overview .............................................................................................22
Figure 2-2: Typical 20FS Series Pump System Overview..................................................23
Figure 2-3: Typical 30FS Series Pump System Overview..................................................24
Figure 2-4: Typical 40 / 50FB Series Pump System Overview...........................................25
Figure 2-5: Typical FB50, FB75 and FB100 Series Engine Mount
Pump End Overview.......................................................................................26
Figure 2-6: Typical 60FBG Series Pump System Overview...............................................27
Figure 2-7: Typical 80FC Series Pump System Overview..................................................28
Figure 2-8: Typical 80FC-U Series Pedestal Pump System Overview...............................29
Figure 2-9: Check Valve Option, Discharge .......................................................................30
2.3 Principles of Operation ................................................................................................... 31
Centrifugal Force ..............................................................................................................................31
Figure 2-10: Centrifugal Force - Rotating Disk ...................................................................31
Figure 2-11: Pump Water Flow, Cutwater ..........................................................................32
2.4 Pump Components .......................................................................................................... 32
Volute, Pump Body...........................................................................................................................32
Figure 2-12: Typical Pump and Gearbox Overview............................................................33
Impeller.............................................................................................................................................33
Figure 2-13: Impeller Operation..........................................................................................33
Clearance Rings ...............................................................................................................................34
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Contents - continued Page
2.4 Pump Components - continued
Mechanical Seal ...............................................................................................................................34
Figure 2-14: Typical Mechanical Seal Overview ................................................................ 34
Ball Bearings ....................................................................................................................................35
2.5 Gearbox Option................................................................................................................ 35
2.6 Pedestal Mounting Option .............................................................................................. 35
Figure 2-15: Pedestal Mount .............................................................................................. 35
2.7 Hale Engine Mount Bell Housing.................................................................................... 36
Figure 2-16: Bell Housing Mount........................................................................................ 36
2a Accessories / Options.............................................................................................37
2a.1 Anodes.............................................................................................................................. 37
Figure 2a-1: Hale 1-1/4” NPT Anode..................................................................................37
2a.2 Auxiliary Cooling ............................................................................................................. 38
Gearbox Manifold Coolers ............................................................................................................... 38
Figure 2a-2: Typical Gearbox Manifold Coolers................................................................. 38
Heat Exchanger, “K” Series.............................................................................................................. 38
2a.3 Pressure and Relief Valve Control ................................................................................. 38
Figure 2a-3: Model “K” Heat Exchanger ............................................................................. 39
P Series Relief Valve System........................................................................................................... 39
Figure 2a-4: P Series Relief Valve Control.........................................................................39
Thermal Relief Valves (TRV)............................................................................................................ 39
Figure 2a-5: Thermal Relief Valve, TRV............................................................................. 40
TRV-L Kit ...................................................................................................................................40
2a.4 Priming Systems.............................................................................................................. 41
Figure 2a-6: Rotary Vane ESP Priming Pump ................................................................... 41
Priming Valves.................................................................................................................................. 41
Figure 2a-7: SPVR Priming Valves .................................................................................... 42
Figure 2a-8: PVG Priming Valves.......................................................................................42
2a.5 Pump Shift, Automatic (VPS / KPS) ............................................................................... 42
Figure 2a-9: Automatic Pump Shift Overview..................................................................... 43
Figure 2a-10: Pump Shift Control Valve............................................................................. 43
2a.6 Torrent SVS Valves..........................................................................................................44
Figure 2a-11: Typical SVS Valve Primary Components.................................................... 44
3 Basic Operation ..................................................................................................... 45
3.1 Overview ........................................................................................................................... 45
3.2 Fluid Levels ...................................................................................................................... 45
3.3 Preparing to Tow.............................................................................................................. 46
4
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Table of Contents ❑
Contents - continued Page
3.4 Pumping Operations ........................................................................................................ 46
Initial Start Up ...................................................................................................................................46
Pumping Operations .........................................................................................................................47
Figure 3-1: Typical Portable Pump Installation...................................................................47
Draft Operation Limiting Factors.......................................................................................................49
3.5 Relief Valve Procedures .................................................................................................. 50
Standard Relief Valve Procedures....................................................................................................50
TPM Relief Valve Procedures...........................................................................................................50
Figure 3-2: TPM / PMD Relief Valve Control......................................................................51
3.6 Post Operation Procedures.............................................................................................51
4 Preventive Maintenance ....................................................................................... 53
4.1 Overview ........................................................................................................................... 53
Preventive / General Maintenance ...................................................................................................53
Engine........................................................................................................................................53
Skid and/or Trailer......................................................................................................................54
Pump, Gearbox and Pedestal ....................................................................................................54
Accessories................................................................................................................................54
4.2 Post-Operation ................................................................................................................. 54
4.3 Extreme Conditions ......................................................................................................... 55
During Freezing Weather..................................................................................................................55
4.4 Weekly ............................................................................................................................... 55
Gearbox Option ................................................................................................................................56
To Check / Add Oil.....................................................................................................................56
Figure 4-1: Typical Drain, Fill and Level Plugs ...................................................................57
Pedestal Option ................................................................................................................................57
To Check / Add Oil.....................................................................................................................57
Figure 4-2: Typical Pedestal Oil Servicing..........................................................................58
Check / Add Engine Fluids ...............................................................................................................58
Relief Valve Test...............................................................................................................................58
Governor Test...................................................................................................................................59
Priming System.................................................................................................................................59
Valve Maintenance ...........................................................................................................................59
Verify All Gauges are in Working Order............................................................................................60
Intake Strainers.................................................................................................................................60
Inspect Water and Foam Tanks........................................................................................................60
Operate Pump Controls ....................................................................................................................60
4.5 Monthly.............................................................................................................................. 60
Valve Lubrication ..............................................................................................................................61
Check Gearbox or Pedestal Lubrication ...........................................................................................61
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Contents - continued Page
4.5 Monthly - continued
Pump and Flange Bolts ....................................................................................................................61
Priming System Test (Dry Vacuum Test) ......................................................................................... 61
Figure 4-3: PVG Priming Valve Handle.............................................................................. 61
4.6 Annually............................................................................................................................ 62
Pump Head Bearing Lubrication....................................................................................................... 63
Figure 4-4: Pump Head Bearing Lubrication ...................................................................... 63
Change Gearbox Oil ......................................................................................................................... 63
Change Pedestal Oil......................................................................................................................... 64
Relief Valve System Check ..............................................................................................................65
Check Drain Lines to Multi-Drain ......................................................................................................65
Clean Priming Pump.........................................................................................................................66
Performance Testing Overview ........................................................................................................ 66
Figure 4-5: Pump Ratings (GMP/LPM)...............................................................................66
Tank-to-Pump Flow Rate Test.......................................................................................................... 67
Performance Testing Equipment and Materials................................................................................ 67
Performance Testing ........................................................................................................................68
Worn Clearance Rings and Impeller Hubs ....................................................................................... 69
Anode Check ..................................................................................................................................70
Figure 4-6: Hale Anode ...................................................................................................... 70
5 Troubleshooting.....................................................................................................71
5.1 Engine and Trailer............................................................................................................ 71
5.2 Pump ................................................................................................................................. 71
Figure 5-1: Sample, Serial Nameplate ............................................................................... 71
Figure 5-2: Troubleshooting Chart...................................................................................... 71
Pump Loses Prime or Will Not Prime. .............................................................................. 71
Insufficient Pump Capacity. ..............................................................................................73
Insufficient Pressure. ........................................................................................................ 74
Remote Control Difficult to Operate..................................................................................74
Engine Speeds Too HIGH for Required Capacity or Pressure.........................................74
Cavitation.......................................................................................................................... 75
Relief Valve Does Not Relieve Pressure When Relief Valves are Closed. ...................... 75
Relief Valve Does Not Recover and Return to Original Pressure
Setting After Opening Valves. .................................................................................... 76
Relief Valve Opens When Control Valves are Locked Out. .............................................76
Unable to Obtain Proper Setting on Relief Valves............................................................ 76
Discharge Valves Are Difficult to Operate. .......................................................................76
Water/Moisture in Pump Gearbox. ...................................................................................77
Rotation Symptoms. ......................................................................................................... 77
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Table of Contents ❑
Contents - continued Page
6 Repair..................................................................................................................... 79
6.1 Overview ........................................................................................................................... 79
6.2 General Repair Guidelines .............................................................................................. 79
Before You Begin..............................................................................................................................79
Table 6-1: Typical Torque Values Chart .............................................................................81
Gearbox and Pedestal Assemblies................................................................................................... 82
6.3 Cleaning and Inspection Guidelines .............................................................................. 82
Bearings............................................................................................................................................83
Tools Required ................................................................................................................................. 83
6a Servicing the Pump ............................................................................................... 85
6a.1 General Preparation.........................................................................................................85
6a.2 20FS Series Pump Only................................................................................................... 85
Bearing Housing ............................................................................................................................... 85
Figure 6a-1: 20FS Series, Pump and Bearing Housing Overview......................................86
Removing the Pump .........................................................................................................................87
Pump Body (Halves) ..................................................................................................................87
Impellers (2) ...............................................................................................................................87
Mechanical Seal – 20FS Series Pump Only .............................................................................. 88
Installation Notes – Pump Body and Impellers ..........................................................................88
Oil Seal, Pump Shaft ........................................................................................................................89
Figure 6a-2: Oil Seal, Pump Shaft ......................................................................................89
Installation – Pump Head ...........................................................................................................90
6a.3 All other Pumps................................................................................................................ 90
Suction Flange..................................................................................................................................90
Figure 6a-3: Typical Suction Flange Option .......................................................................91
Installation Notes – Suction Flange............................................................................................91
Volute (Pump Body)..........................................................................................................................91
Figure 6a-4: Typical Pump Disassembly Overview............................................................92
Installation Notes – Volute (Pump Body) ................................................................................... 93
Impeller.............................................................................................................................................94
For 30 FS series pump...............................................................................................................94
For all other pump models .........................................................................................................94
Figure 6a-5: Placing Edges for Impeller Removal ..............................................................95
Clearance Rings, Impeller Measurement .........................................................................................95
Figure 6a-6: Clearance Ring and Impeller ID / OD Measurement......................................96
Installation Notes – Impeller ............................................................................................................. 96
6a.4 Pump Shaft Oil Seals, with Bell Housing....................................................................... 97
Pump Head Assembly – 30 FS Series Only .....................................................................................98
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❑ Table of Contents
Contents - continued Page
Pump Head Assembly – 30 FS Series Only - continued
Pump Shaft Oil Seal, 30 FS Series............................................................................................98
Figure 6a-7: Replacing 30 FS Series Pump Shaft Oil Seal................................................ 98
Installation Notes – Pump Head, 30 FS Series.........................................................................99
Bell Housing (Flywheel) Adapter, FB40 – FB100 Series Only........................................................99
Pump Shaft Oil Seal, 40 – 100 FB Series.................................................................................. 99
Figure 6a-8: Replacing 40FB - 100FB Series Pump Shaft Oil Seal .................................100
Pump Shaft Bearings, FB40 – FB100 Series...........................................................................101
Installation Notes – Pump Head, FB40 – FB100 Series .........................................................101
Bell Housing (Flywheel) Adapter, 80 FC Series Only.................................................................... 102
Pump Shaft Oil Seal, 80 FC Series Only ................................................................................. 102
Figure 6a-9: Replacing 80 FC Series Pump Shaft Oil Seal .............................................. 103
Pump Shaft Bearings, 80 FC Series Only................................................................................ 104
Installation Notes – Bell Housing Adapter, 80 FC Series Only ...............................................104
6a.5 Pump Shaft Oil Seals, with Pedestal Mount................................................................ 105
Pedestal Mount, Pump Shaft Oil Seals ......................................................................................... 105
Figure 6a-10: Pedestal Mount Pump Shaft Oil Seals (2),
40 / 5- FB-U and 80 FC-U Series ............................................................. 106
Pump Shaft Bearings............................................................................................................... 108
Installation Notes – Pedestal .................................................................................................. 108
6a.6 Pump Shaft Oil Seals, with Gearbox............................................................................ 109
6b Mechanical Seal Assembly.................................................................................. 111
6b.1 Removing the Seal......................................................................................................... 111
Figure 6b-1: Typical Mechanical Seal Assembly.............................................................. 111
6b.2 Installing Seal................................................................................................................. 112
Figure 6b-2: Typical Mechanical Seal Insertion Tool........................................................ 113
Impeller and Volute Installation Notes............................................................................................ 113
6c Gearbox Service................................................................................................... 115
6c.1 General Preparation....................................................................................................... 115
6c.2 20 / 30 FSG Series Gearbox .......................................................................................... 116
Removing the Gearbox and Bell Housing ......................................................................................116
Figure 6c-1: 20 / 30 FS Series Gearbox and Bell Housing Overview............................... 117
Drive Shaft Oil Seal ........................................................................................................................ 118
Drive Shaft and Gearbox Assembly ...............................................................................................118
Pump Shaft.....................................................................................................................................119
Gearbox Installation Notes – 20 / 30 FS Series ............................................................................. 119
6c.3 50 / 60 / 80 FBG Series Gearbox................................................................................... 120
Pump Shaft and Shaft Oil Seal .......................................................................................................120
Figure 6c-2: Pump Shaft Oil Seal, 50/60/80 FBG Series, with Gearbox ..........................121
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Table of Contents ❑
Contents - continued Page
6c.3 50 / 60 / 80 FBG Series Gearbox - continued
Installation Notes – Pump Shaft and Seal, 50/60/80 FBG..............................................................122
Gearbox and Bell Housing Assemblies ..........................................................................................123
Bell Housing (Flywheel) Adapter..............................................................................................123
Drive Shaft Oil Seal..................................................................................................................123
Figure 6c-3: Gearbox and Bell Housing Overview,
50/60/80 FBG Series Pump End ...............................................................124
Gearbox, Intermediate and Drive Shafts..................................................................................125
Installation Notes – Gearbox and Bell Housing, 50/60/80 FBG..................................................... 126
7 Installation ........................................................................................................... 127
7.1 Overview ......................................................................................................................... 127
7.2 Frame Mounting .............................................................................................................127
General Mounting ........................................................................................................................... 128
7.3 Plumbing Connections ..................................................................................................128
7.4 Fluid Levels..................................................................................................................... 128
7.5 Check Flywheel Run Out ............................................................................................... 129
S.A.E. Housing Pilot Bore............................................................................................................... 129
S.A.E. Housing Mounting Face....................................................................................................... 130
Flywheel Pilot Bearing Bore............................................................................................................130
Drive Disk Pilot Bore.......................................................................................................................130
Drive Disk Mounting Face...............................................................................................................130
Appendix A: Glossary......................................................................................... 131
Appendix A-1: Measurements ........................................................................... 135
Conversion Chart ...........................................................................................................135
Appendix C: Alternate Lubricant Manufacturers .......................................... 137
Table C-1: Alternate Lubricant Manufacturers..................................................................137
Appendix C1: Lube and Sealant Specifications .............................................. 139
Table C1-2: Oil Capacity and Recommendation ..............................................................139
Grease............................................................................................................................................140
Loctite Sealant................................................................................................................................ 140
Oil ................................................................................................................................................... 140
Recommended Cleaners ................................................................................................................140
Appendix D: Hose Friction Loss ....................................................................... 141
Table D-1: Hose Friction Loss (PSI / BAR 100 Feet) ....................................................... 141
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❑ Table of Contents
Contents - continued Page
Appendix E: Nozzle Size vs. Pressure................................................................ 143
Chart E-1: Nozzle Flow and Pressure Ratings, Part 1 ..................................................... 143
Chart E-2: Nozzle Flow and Pressure Ratings, Part 2 ..................................................... 144
Appendix F: Cavitation....................................................................................... 145
Figure F-1: Sample, Cavitation Regions........................................................................... 145
Process of Cavitation......................................................................................................................145
Warning Signs of Cavitation (Discharge and Gauges) ................................................................... 146
Discharge Pressure .................................................................................................................146
Vacuum Compound Gauge ..................................................................................................... 146
To Eliminate Cavitation................................................................................................................... 146
During Operations ......................................................................................................................... 147
Figure F-2: Lift Loss from Temperature............................................................................147
Figure F-3: Lift Loss from Elevation.................................................................................. 147
Figure F-3a: Lift Loss from Barometric Reading............................................................... 147
Preventive Measures...................................................................................................................... 147
Figure F-4: Hose Size vs. Pump Rating Capacity ............................................................148
Express Warranty ............................................................................................... 149
Hale Products, Inc. ........................................................................................................................ 150
8 Drawing Package................................................................................................. 151
Pump Ends ..............................................................................................................................152
Available Options..................................................................................................................... 152
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1 Safety Precautions
HALE PUMP ENDS (SERIES 20* THROUGH 80*) ENGINE MOUNTED PUMPING
SYSTEMS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS.
FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES
LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL.
ALL SUPPLIED DOCUMENTATION (ENGINE, HALE PUMP MANUALS, ETC.)
MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY
BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL
OR OPERATE ANY PUMPING SYSTEM.
WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCEDURES, INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN.
Safety ❑
IMPORTANT !
Hale is a registered trademark of Hale Products, Incorporated. All other brand and product
names are the trademarks of their respective holders.
* For a breakdown of the models/series pump ends in this manual, see
heading “Pump Ends ” on page 19.
NOTICE !
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED
IN THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING
JURISDICTION FOR UNIT LAYOUT AND CONNECTION OF HOSES, VALVES
AND DRAIN COCKS.
ALL FASTENERS ON THE PUMP END ASSEMBLIES ARE SELECTED FOR
THEIR APPLICATION. CLASS1 DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN CLASS1 PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTERNATIVE POSES A SERIOUS
SAFETY RISK.
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ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC
ADHESIVE / SEALANT, SUCH AS LOCTITE
®
#242, #246 OR EQUIVALENT.
11
❑ Safety
NOTICE ! - continued
ALSO REVIEW THE SAFETY INFORMATION FOUND IN THE ENGINE MANUFACTURER’S OPERATING AND MAINTENANCE MANUAL, PROVIDED WITH
THE ENGINE.
1.1 DEFINITIONS
DANGER - Immediate hazard which WILL result in severe personal injury or
death if the warning is ignored.
DANGER !
WARNING !
WARNING - Hazards or unsafe practices which COULD result in severe
personal injury or death if the warning is ignored.
CAUTION !
CAUTION - Hazards or unsafe practices which COULD result in minor or
moderate personal injury if the warning is ignored.
NOTICE !
NOTICE - Practices which could result in damage to the apparatus or other
property.
Carbon Monoxide Poisoning Hazard
12
Corrosive Hazard
Electrical Shock Hazard
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Eye Protection required when operating equipment
Flammable Fuel Hazard
Hearing Protection required when operating equipment
Hot Surfaces Hazard
1.2 GENERAL
Safety ❑
Read all instructions, including the Engine Manufacturer’s Operating
and Maintenance Manual, thoroughly before beginning
any installation, service or operation process.
❑ Use care when removing the pump assembly from its packaging to pre-
vent personal injury and/or damage to the system.
❑ Use all mounting bolt holes provided on the gearbox, pedestal and/or the
pump to support the assembly. See the appropriate assembly plate
drawing, located at the back of this manual, for additional installation
information.
❑ Installation should be performed by a trained and qualified installer, such
as your authorized Hale representative. Be sure the installer has sufficient knowledge, experience and the proper tools before attempting any
installation.
WARNING !
THE HALE PUMP ENDS, GEARBOX OR PEDESTAL ASSEMBLIES (IF
INCLUDED) CAN BE HEAVY AND BULKY. ADDING ACCESSORIES TO THE
SYSTEM ALSO INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING
FOR THE APPROXIMATE WEIGHT.
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BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVERHEAD CRANE, JACKS, CHAINS, STRAPS, ETC.) CAPABLE OF HANDLING
THE LOAD WHEN REMOVING OR INSTALLING THE HALE PUMP END
ASSEMBLY.
13
❑ Safety
❑ The installer is responsible for observing all instructions and safety pre-
❑ Fluids - To meet various shipping regulations, oil is drained from the
❑ When mounting pumping system on a skid, truck, trailer or other movable
❑ DO NOT run the engine in a closed-in area. Proper ventilation for engine
cautions in his or her daily routine as dictated by regional safety ordinances or departmental procedures.
gearbox (or pedestal unit) reservoir prior to shipping from the factory.
At installation and before operation, oil must be added to the appropriate
levels. (See Section 4, heading “ Replace Gearbox Oil,” on page 59.)
For pedestal fluid fill / replacement, see heading “Change Pedestal Oil”
on page 64.
See separate documentation provided with the engine for proper fluids to
use and quantities required.
equipment, it is preferred to have the resting points under the frame as
close as possible under the frame cross-members. This prevents undo
strain on the frame and engine.
cooling and engine exhaust MUST BE provided.
❑ If an exhaust extension is required to vent gases to the outside, it is
important to construct the exhaust extension to prevent excessive
exhaust back pressure.
WARNING !
EXHAUST GASES CONTAIN CARBON MONOXIDE, WHICH IS AN ODORLESS
AND DEADLY POISON. PROPER EXHAUST VENTILATION MUST BE PROVIDED TO PREVENT THE ACCUMULATION OF EXHAUST GASES.
❑ The exhaust system components may smoke during the initial break-in
period. This smoking should stop after the pump is run several times.
❑ Be careful not to touch the exterior of a HOT engine, especially the muf-
fler and the surrounding area. The engine is hot enough to be painful or
cause burns / injury.
❑ DO NOT permanently remove or alter any protective feature, guard or
insulating devices, or attempt to operate the system when these guards
are removed.
❑ Do not run the engine with the covers removed.
14
Doing so voids the Hale pump warranty. Also see heading “Express
Warranty” on page 149.
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Safety ❑
WARNING!
NO MODIFICATIONS MAY BE MADE TO THE HALE PUMP END ASSEMBLY
WITHOUT PRIOR WRITTEN PERMISSION FROM:
Hale Products, Incorporated
Fire Suppression Division
700 Spring Mill Avenue
Conshohocken, PA 19428 U.S.A.
Telephone ..........610-825-6300
Fax .....................610-825-6440
Web....................www.haleproducts.com
❑ Any of the preceding could affect system capacity and/or safe operation
of the system and is a serious safety violation which could cause personal injury or could affect safe operation of the pump.
❑ Make sure proper personal protective equipment is used when operating
or servicing the apparatus.
WARNING!
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALLING FORCE (PRESS) FITTED PARTS. WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHEN HANDLING PARTS THAT REQUIRE HEATING FOR
INSTALLATION AND/OR REMOVAL. FAILURE TO COMPLY MAY RESULT IN
SERIOUS EYE OR HAND INJURY.
DO NOT OVERHEAT PARTS CONSTRUCTED OF BRONZE (E.G. IMPELLER).
OVERHEATING (PART TURNS RED OR BLUE) CAN WEAKEN THE PART AND
IT MUST THEN BE REPLACED.
❑ DO NOT operate the system at pressures higher than the maximum
rated pressure. Always use the lowest possible relief valve settings to
enhance operator and equipment safety. Also see Section 2 “Introduction” on page 17 for additional information.
❑ Relieve all system pressure, then drain all water from the system before
servicing any of its component parts.
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❑ Use only pipe, hose and fittings which are rated at or above the maxi-
mum pressure rating at which the water pump system operates.
❑ Per NFPA 1962 requirements, large diameter hose, marked “supply
Hose 3-1/2” to 5” (89 - 127 mm) diameter” shall not be used at operating
pressures exceeding 185 PSI (13 BAR).
15
❑ Safety
❑ If leakage from the drain hole in the pump head is noticed or suspected,
❑ If a pump is operated without water for extended periods, or without dis-
❑ Keep equipment, i.e., engine controls and linkage, cylinder fins, muffler,
❑ Prevent accidental starting by always removing the battery ground (neg-
Large diameter hose, marked “Supply Hose 6” to 5” (152 mm) diameter”
shall not be used at operating pressures exceeding 135 PSI (9 BAR).
the mechanical seal must be inspected and/or replaced.
charging water, it could overheat. This can damage the mechanical seal,
impeller or the drive mechanism.
etc. and surrounding area clean. Cluttered areas invite accidents and
could effect engine operation.
Remove all oil deposits from equipment and surrounding area. Accumulations of grease and oil may present a hazard.
ative —) wire (BLACK) before working on the engine or the equipment
driven by the engine.
❑ Maximum speed of the engine is factory set. DO NOT tamper with the
governor springs, links or other parts to run at higher speeds. Excessive
speed increases the hazard of personal injury and reduces engine life.
❑ Familiarize yourself with all controls, learn how to STOP the engine
quickly in an emergency.
❑ DO NOT reduce the pressure on the INTAKE gauge below zero (0).
Serious damage to the water main could result.
❑ Use only PAC-EASE Rubber Lubricant Emulsion (or equal) on the rubber
mechanical seal parts to ease installation. DO NOT use other lubricant
types as damage to the mechanical seal and seat could occur.
❑ Before connecting any cord sets or wiring harnesses, inspect the seal
washer in the connector.
If the seal washer is missing or damaged, water can enter the connector
causing corrosion. This could resulting in possible system failure.
1.3 FUEL SAFETY
❑ Carefully read and understand the “Engine Manufacturer’s Operating
and Maintenance Instructions” before attempting to operate, service or
disassemble the engine or any of its parts. Also see Section 4 “Operation” on page 27.
16
WARNING !
POSITIVELY NO SMOKING !!
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Safety ❑
WARNING ! - continued
❑ Gasoline is a highly combustible fuel. The improper use, handling or
storage of gasoline can be dangerous. Prevent accidents by following
these safety recommendations, plus those furnished by your regional
safety ordinances or departmental procedures:
● Use gasoline as a fuel, NEVER as a cleaning fluid.
● Use only an approved container to hold or store gasoline. NEVER
store gasoline in familiar containers, such as milk containers or soap
bottles.
● Store gasoline in a cool location, out of reach of children.
NEVER store gasoline near heat sources, open flame or sources
using a pilot light or other devices that can create a spark.
● DO NOT refuel with the engine running. Add fuel to a COOL engine
only. Spilled fuel on a hot engine or muffler may cause a fire or an
explosion. Fill fuel tank out-of-doors and wipe up any spills
immediately.
● Make sure all fuel lines and connectors are secure.
● Provide a fire extinguisher when working with gasoline. Be sure the
extinguisher is in operating condition; check the pressure gauge or
indicator. Be familiar with its proper use.
Consult your local fire department for the correct type of extinguisher
for your application. Extinguishers rated ABC by the National Protection Association are appropriate for most applications.
● For proper handling, storing and transporting of fuel, follow fuel tank
manufacturer’s instructions sheet and/or instructions printer on the
tank.
❑ Do not operate the engine when an odor of gasoline is present or other
explosive conditions exist.
❑ Sparking can occur if a wire terminal does not fit firmly on the spark plug.
Reform terminal if necessary.
❑ Do not check for a spark with the spark plug or wire removed. Use an
approved tester.
1.4 BATTERY SAFETY
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The battery contains concentrated sulfuric acid which can cause severe
chemical burns. When the battery is charging, it releases hydrogen, a colorless, odorless and highly explosive gas which can be ignited by a spark.
Eliminate all sparks or flames from the charging area.
17
❑ Safety
❑ Always assume the battery is emitting hydrogen and employ proper
❑ Do not smoke, use an open flame, or create arcs or sparks near the
❑ Consult the label on your battery for information on cell-type,
❑ Packaged with every battery are specific instructions for battery
❑ Always disconnect the battery before performing any truck mainte-
WARNING !
safety precautions.
battery.
ampere-hour capacity, charge rate and normal full-charge voltage.
safety, care and use, and a Material Safety Data Sheet (MSDS).
Read these documents thoroughly before performing any service to
the battery.
nance and be sure to wear protective clothing and safety glasses
when working with battery acid or the battery in general.
❑ Neutralize acid spills immediately with Bicarbonate of Soda! If acid
contacts the skin or eyes, wash with water immediately and seek
medical help at once.
❑ Never place a tool or any metal object on top of the battery
where it could possibly touch battery terminals causing a
short or serious electrical shock.
❑ Use caution when changing battery connectors to ensure
that the polarity is not reversed. Always connect the BLACK wire
“last” and to the NEGATIVE (—) terminal; the RED wire to the POSITIVE (+) terminal.
❑ Keep vent plugs in place and clean at all times
❑ When replacing this battery, use the same type battery as specified
on the rating nameplate.
❑ Be sure to install and retighten any battery restraints.
18
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2Overview
2.1 PUMP ENDS
Introduction ❑
Figure 2-1: Typical Pump End Pumping Systems
The Hale Pump End Series Pumping Systems fulfill many types of in-service fire fighting applications. The pumps are available in configurations
providing a wide range of pressures and flows to suit most user requirements in a transportable unit. (See Figure 2-1: “Typical Pump End Pumping
Systems.”)
The Pump End series pumping systems are capable pumping water from
draft, relay or hydrant and can deliver discharge pressures up to approximately 800 PSI (55 BAR) and flow up to approximately 3,000 GPM (11,356
LPM / 189 LPS), NFPA 1901 performance rated. For a unit overview, see
heading, 2.2 “Pumping System Overview” beginning on page 22.
Pump end systems are available in the following models:
20FS-2M / 20FS-3M / 20FS-4M Series, with Gearbox
❑ Standard centrifugal pump and gearbox assembly with universal
mounting bracket designed to bolt directly to either SAE #4 or #5
engine flywheel bell housing and available for gasoline or diesel
engines.
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19
❑ Introduction
❑ Pump delivers discharge pressures up to 800 PSI (55 BAR) and flow
rates up to approximately 100 GPM (379 LPM / 6 LPS), NFPA 1901
performance rated.
❑ Suction — 2” (51 mm) female NPT flange
❑ Discharge — 1-1/2” (38 mm) female NPT
30FS2 / 30FS3 / 30FS4 Series, with Gearbox
❑ Standard centrifugal pump and gearbox assembly with universal
mounting bracket designed to bolt directly to either SAE #8 or #10
engine flywheel housing and available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 300 PSI (21 BAR) and flow
rates up to approximately 400 GPM (1,514 LPM / 25 LPS), NFPA
1901 performance rated.
❑ Suction — 3” (76 mm) female NPT flange / 4” (102 mm) Victaulic
❑ Discharge — 2” (51 mm) female NPT / #115 flange
®
40FB / 50FB Series, Bell Housing or Pedestal Mount (-U-U
❑ Standard centrifugal pump end with universal mounting bracket
and -U-M Series)
designed to bolt directly to either SAE #10 or #11 engine flywheel
housing and available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 250 PSI (17 BAR) and flow
rates up to approximately 800 (40FB) and 1,000 (50FB) GPM (3,028 3,785 LPM / 51 - 63 LPS), NFPA 1901 performance rated.
❑ Suction — 5” (127 mm) female NPT flange, optional
❑ Discharge — 4” (102 mm) female NPT flange, optional
FB50 / FB75 / FB100 Series, Bell Housing Mount
❑ Standard centrifugal pump end with universal mounting bracket
designed to bolt directly to either SAE #4 or #3 engine flywheel housing and available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 350 PSI (24 BAR) and flow
rates up to approximately 500 (40FB) and 1,000 (50FB) GPM (1,893 3,785 LPM / 32 - 63 LPS), NFPA 1901 performance rated.
❑ Suction — 4-1/2”, 5” or 6” (114 mm, 127 mm or 152 mm)) male NS
thread
20
❑ Discharge — 2-1/2” (64 mm) female NS thread, or optional 3” (76 mm)
valve
❑ Blank Flange Option — 2-1/2”, 3” up to 5” (64 mm, 76 mm up to 127
mm). Consult Hale Products for additional information and various
tube lengths available.
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Introduction ❑
60FBG Series, with Gearbox
❑ Standard centrifugal pump and gearbox assembly with universal
mounting bracket designed to bolt directly to either SAE #2 or #3
engine flywheel housing and available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 250 PSI (17 BAR) and flow
rates up to approximately 1,500 GPM (5,678 LPM / 95 LPS), NFPA
1901 performance rated.
❑ Suction — 6” (152 mm) female NPT flange, optional
❑ Discharge — 4” (102 mm) flange / 4” NPT check valve, optional
60FJ Series, Bell Housing Mount
❑ Standard centrifugal pump end with universal mounting bracket
designed to bolt directly to either SAE #10 or #11 engine flywheel
housing and splined shaft, available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 250 PSI (17 BAR) and flow
rates up to approximately 1,200 GPM (4,543 LPM / 76 LPS), NFPA
1901 performance rated.
❑ Suction — 6” (152 mm) female NPT flange, optional
❑ Discharge — 4” (102 mm) flange / 4” NPT check valve, optional
80FC Series, Bell Housing Mount
❑ Standard centrifugal pump end with universal mounting bracket
designed to bolt directly to either SAE #11 or #4 engine flywheel housing and available for gasoline or diesel engines.
❑ Pump delivers discharge pressures up to 160 PSI (11 BAR) and flow
rates up to approximately 3,000 GPM (11,356 LPM / 189 LPS), NFPA
1901 performance rated.
❑ Suction — 8” (203 mm) female NPT flange, optional
❑ Discharge — 6” (152 mm) flange, optional
80FC (-G or -U) Series, with gearbox (-G) or pedestal (-U)
❑ Standard centrifugal pump and gearbox (or pedestal) assembly with
universal mounting bracket designed to bolt directly to either SAE #?
or #? engine flywheel housing and available for gasoline or diesel
engines.
❑ Pump delivers discharge pressures up to 250 PSI (17 BAR) and flow
rates up to approximately 3,000 GPM (11,356 LPM / 189 LPS), NFPA
1901 performance rated.
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❑ Suction — 8” (203 mm) female NPT flange, optional
❑ Discharge — 4” (152 mm) flange / 6” NPT check valve, optional
21
❑ Introduction
NOTICE !
PERFORMANCE OF PUMP END PUMPING SYSTEMS MEET OR EXCEED
NFPA 1921 REQUIREMENTS. FOR COMPLETE NFPA 1921 COMPLIANCE,
THE PUMPING UNITS MUST BE MARKED WITH SPECIFIC LABELS. CONSULT FACTORY IF THESE LABELS ARE REQUIRED.
2.2 PUMPING SYSTEM OVERVIEW
❑ Typical 20FS Series — see Figure 2-2: “Typical 20FS Series Pump Sys-
tem Overview” on page 23.
❑ Typical 30FS Series — see Figure 2-3: “Typical 30FS Series Pump Sys-
tem Overview” on page 24.
❑ Typical 40 / 50FB Series — see Figure 2-4: “Typical 40 / 50FB Series
Pump System Overview” on page 25.
❑ Typical FB50 / FB75 / FB100 Series — see Figure 2-5: “Typical FB50,
FB75 and FB100 Series Engine Mount Pump End Overview” on page
26.
❑ Typical 60FB / 60FJ Series — see Figure 2-6: “Typical 60FBG Series
Pump System Overview” on page 27.
❑ Typical 80FC / 80FCG Series — see Figure 2-7: “Typical 80FC Series
Pump System Overview” on page 28.
❑ Typical Check Valve Option, Discharge — see Figure 2-9: “Check
Valve Option, Discharge” on page 30.
22
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Introduction ❑
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Figure 2-2: Typical 20FS Series Pump System Overview
23
❑ Introduction
24
Figure 2-3: Typical 30FS Series Pump System Overview
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Introduction ❑
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Figure 2-4: Typical 40 / 50FB Series Pump System Overview
25
❑ Introduction
Figure 2-5: Typical FB50, FB75 and FB100 Series Engine Mount Pump End Overview
26
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Introduction ❑
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Figure 2-6: Typical 60FBG Series Pump System Overview
(Shown with G Series Gearbox)
27
❑ Introduction
28
Figure 2-7: Typical 80FC Series Pump System Overview
(Shown with Engine Mount Bell Housing)
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Introduction ❑
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Figure 2-8: Typical 80FC-U Series Pedestal Pump System Overview
29
❑ Introduction
Figure 2-9: Check Valve Option, Discharge
(Size determined by pump discharge)
30
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