HALE FLEX, HALE FLEX AP, HALE FLEX CBP, HALE FLEX MBP, HALE FLEX RSD Operation Installation Maintenance Manual
OPERATION INSTALLATION MAINTENANCE
MANUAL
FOR HALE FLEX SERIES
SINGLE STAGE BOOSTER PUMPS
BY
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
607 NW 27th Ave, Ocala, FL 34475
(800) 533.3569
(800) 520.3473 (FAX)
www.haleproducts.com
MANUAL P/N FSG–MNL–00183 Revision B
COPYRIGHT © 2018 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED
TABLE OF CONTENTS
Section Title Page
1. SAFETY ............................................................................................................................................. 1
1.1. Safety Headings ........................................................................................................................ 1
1.2. Training ..................................................................................................................................... 1
1.3. Safety Summary ....................................................................................................................... 1
2. GENERAL INSTRUCTIONS ............................................................................................................... 5
2.1. Overview .................................................................................................................................... 5
2.2. Pump Specifications and Numbering ...................................................................................... 5
2.2.1 Optional Pump Panel Identification Plates ....................................................................... 5
2.2.2 Identification Plate ............................................................................................................. 6
3. TRANSPORT AND STORAGE ........................................................................................................... 7
3.1. Shipping, Movement, And Installation Preparations .............................................................. 7
3.2. Pump Gearbox Shipped Without Fluid .................................................................................... 7
3.3. Storage ...................................................................................................................................... 7
4. PUMP OVERVIEW ............................................................................................................................ 9
5. INSTALLATION .............................................................................................................................. 11
5.1. Warnings And Cautions ......................................................................................................... 11
5.2. Risk Assessment ................................................................................................................... 11
5.3. Special Tools .......................................................................................................................... 11
5.4. Mounting A Hale Booster Pump ........................................................................................... 11
5.4.1 Hardware Requirements ................................................................................................ 13
5.4.1.1 Mounting Hardware .................................................................................................. 13
5.4.1.2 Thread Lock, Bonding, Or Sealant Compound ....................................................... 14
5.4.1.3 Driveshaft Hardware ................................................................................................ 14
5.4.2 Inlet And Discharge Connections ................................................................................... 14
5.4.3 Booster Pump Drains ...................................................................................................... 14
5.4.4 Priming Connections ....................................................................................................... 14
6. COMMISSIONING, STARTUP, OPERATION, AND SHUTDOWN .................................................... 15
6.1. Installation Verification ......................................................................................................... 15
6.2. Performance Verification ...................................................................................................... 15
6.3. Initial Startup ......................................................................................................................... 15
6.4. Draft Operation Notes ........................................................................................................... 17
6.5. Hydrant Or Relay Operation .................................................................................................. 18
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TABLE OF CONTENTS – CONTINUED
Section Title Page
6.6. Pump Cavitation .................................................................................................................... 18
6.6.1 Discharge Pressure Cavitation Warning Signs .............................................................. 18
6.6.2 Vacuum Compound Gauge Warning Signs.................................................................... 18
6.6.3 General Considerations to Prevent Cavitation .............................................................. 19
6.7. Post Operation Notes ............................................................................................................ 19
7. PREVENTIVE MAINTENANCE ....................................................................................................... 21
7.1. Preventive Maintenance Plan and Schedule ....................................................................... 21
7.2. Maintenance Log ................................................................................................................... 21
7.3. Extreme Conditions Maintenance Guidelines ..................................................................... 21
7.3.1 Freezing Weather ............................................................................................................ 22
7.3.2 Contaminated Water ....................................................................................................... 22
7.4. Booster Pump Preventive Maintenance Procedures .......................................................... 22
7.4.1 After Each Use ................................................................................................................. 22
7.4.2 Quarterly Maintenance (every three months) ............................................................... 22
7.4.2.1 Check Gearbox Fluid Level ...................................................................................... 22
7.4.2.2 Perform Vacuum Test ............................................................................................... 23
7.4.3 Annual Pump Maintenance ............................................................................................ 23
7.4.3.1 Performance Testing ................................................................................................ 23
7.4.3.1.1 Test Procedure ................................................................................................... 23
7.4.4 Triennial Pump Maintenance ......................................................................................... 24
7.4.4.1 Fluid Change Procedure ........................................................................................... 24
7.4.4.1.1 Recommended Gearbox Lubricants ................................................................. 26
8. SYMPTOMS, CAUSES, AND REMEDIES ....................................................................................... 27
8.1. Loss Of Suction Fault Flow Chart .......................................................................................... 27
8.1.1 Loss Of Suction Symptoms, Causes, And Remedies .................................................... 29
8.2. Cavitation Fault Flow Chart ................................................................................................... 30
8.2.1 Cavitation Symptoms, Causes, And Remedies ............................................................. 31
APPENDIX A. MANUFACTURER'S INFORMATION ....................................................................... A–1
MANUFACTURER'S INFORMATION ................................................................................................... A–1
WARRANTY ........................................................................................................................................ A–1
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FSG–MNL–00183 REVISION HISTORY
CHANGE
DATE
AFFECTED PAGES
LIST OF FIGURES
Number Title Page
Figure 1. Pump Panel Identification Plate (Placard) ....................................................................... 5
Figure 2. Pump Serial Number Locations ........................................................................................ 6
Figure 3. Pump Model Codes ........................................................................................................... 6
Figure 4. Hale Booster Pump Inlet And Outlet ................................................................................. 9
Figure 5. Visually Determining Engine Or Opposite Engine Rotation .......................................... 10
Figure 6. Typical Booster Pump Mounting .................................................................................... 12
Figure 7. Grade 5 And Class 8.8 Bolt Marking ............................................................................. 13
Figure 8. Grade 8 And Class 10.9 Bolt Marking ........................................................................... 14
Figure 9. Check Gearbox Oil Level ................................................................................................. 16
Figure 10. Gearbox Drain ............................................................................................................. 24
Figure 11. Fill Gearbox With Fluid ................................................................................................ 25
Figure 12. Fluid Level ................................................................................................................... 25
Figure 13. Loss Of Suction Fault Flow Chart ............................................................................... 28
Figure 14. Cavitation Fault Flow Chart ........................................................................................ 30
LIST OF TABLES
Number Title Page
Table 1. Hale Flex Series Single Stage Booster Pump Drawings .................................................. 9
Table 2. Flex Series Inlet And Discharge Connections ............................................................... 14
Table 3. Preventive Maintenance Plan and Schedule ................................................................ 21
Table 4. Fluid Change Tools And Consumables List ................................................................... 24
Table 5. Recommended Gearbox Lubricant ................................................................................ 26
Table 6. Loss Of Suction SCR Table ............................................................................................. 29
Table 7. Cavitation SCR Table ...................................................................................................... 31
Revision A 15 January 2019 All – Initial Release
Cover (graphic), 1,10,28,29,30 (website URL), 13 (Hardware),
Revision B 8 May 2019
14 (Sealant), 23 (Pump Vacuum Test), 24 (Triennial Pump
Maintenance), 26 (Recommended Gearbox Lubricants)
iii
Abbreviations And Acronyms
Abbreviations used in this manual are commonly used units of measure and are NOT defined or
listed. The acronyms used in this manual are defined below.
AHJ Authority Having Jurisdiction
CV Constant Velocity
EN 1028-1 Fire-Fighting Pumps Centrifugal Pumps - General And Safety Requirements
FAST Factory Authorized Service Team
NFPA National Fire Protection Association
NPT American National Standard Taper Pipe Thread
OEM Original Equipment Manufacturer
PPE Personal Protection Equipment
PTO Power Take Off
SAE Society of Automotive Engineers
SB Service Bulletin
SCR Symptom, Cause, Remedy
TRV Thermal Relief Valve
iv
1. SAFETY
Read and comply with all safety items in this manual before operating the pump. Only fully trained
personnel may operate or maintain pump.
If EN 1028 is applicable to the user, the end user must maintain the equipment in an operational
condition, as per regulation 5 in the Provision and Use of Work Equipment Regulations 1998.
1.1. Safety Headings
DANGERS, WARNINGS, CAUTIONS, or NOTICES that immediately precede a step apply directly to that
step and all sub steps. DANGERS, WARNINGS, CAUTIONS, or NOTICES that precede an entire procedure apply to the entire procedure. DANGERS, WARNINGS, CAUTIONS, and NOTICES consist of two
parts: a heading (that identifies possible result if disregarded) and a statement of the hazard (that
provides the minimum precautions). NOTES are used to highlight operating or maintenance procedures, practices, conditions or statements that are not essential to protection of personnel or
equipment. NOTES may precede or follow the step or procedure, depending upon the information
and how it pertains to the procedure/step. The headings used and their definitions are.
INDICATES A HAZARDOUS SITUATION, WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS
INJURY OR DEATH.
INDICATES A HAZARDOUS SITUATION, WHICH IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH.
INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY.
ADDRESSES PRACTICES NOT RELATED TO PERSONAL INJURY.
NOTE
Highlights an essential aspect of an operating or maintenance procedure, condition, or
statement and/or provides pertinent ancillary information.
1.2. Training
Pump Training is available through the Hale Training Academy and may be accessed via the Hale
Products Inc. website (www.haleproducts.com), Godiva √erified Training (godiva.co.uk), or through
your local dealer or vehicle manufacturer.
1.3. Safety Summary
The following warnings are used in this manual. A booster pump is not a complete machine and safety as well as performance is impacted by installation as well as use.
A PRESSURE HAZARD MAY EXIST EVEN WHEN THE PUMP IS NOT RUNNING. PRIOR TO
REMOVING HOSES, OR CAPS FROM PUMP CONNECTIONS, RELIEVE PRESSURE BY OPENING DRAINS. BLEEDER VALVES SHOULD ALSO BE USED WHEN CONNECTING TO AN INTAKE FROM PRESSURIZED SOURCE.
1
ALWAYS FOLLOW LOCAL GUIDELINES FROM THE AHJ AND THE APPARATUS MANUFACTURER.
ALWAYS FOLLOW PROPER OPERATING PROCEDURES. THE PUMP OPERATOR AND INDIVIDUALS AROUND THE APPARATUS MUST BE FAMILIAR WITH THE PUMP OPERATING INSTRUCTIONS AS WELL AS OTHER OPERATING GUIDELINES FOR THE APPARATUS, AND
ACCESSORIES.
ALWAYS STOP THE ENGINE, SET THE PARKING BRAKE, AND CHOCK THE WHEELS BEFORE GOING UNDER THE TRUCK FOR ANY REASON.
DO NOT EXCEED OPERATING PRESSURE LIMITS OF PUMP, INSTALLED PLUMBING,
HOSE(S), OR EQUIPMENT IN USE.
DO NOT LEAVE THE DRIVERS POSITION IN THE CAB OR OPEN THE THROTTLE UNLESS
ALL SAFETY INTERLOCK INDICATORS ARE ILLUMINATED.
DO NOT REACH INSIDE THE PUMP SUCTION WHEN THE ENGINE IS RUNNING. CONTACT
WITH MOVING COMPONENTS MAY RESULT IN SERIOUS INJURY. DO NOT REMOVE OR ALTER GUARDS.
OPEN AT LEAST ONE DISCHARGE VALVE SLIGHTLY TO PREVENT THE PUMP FROM OVERHEATING. IF THE PUMP RUNS COMPLETELY CLOSED, IT MAY HEAT THE WATER ENOUGH
TO SCALD A PERSON.
OPERATORS, INSTALLERS, AND MAINTENANCE PERSONNEL MUST BE TRAINED AND
QUALIFIED FOR ALL THE ACTIVITIES THEY PERFORM.
THE PUMP SHIFT CONTROL AND PUMP SHIFT INDICATOR SYSTEM ON THE APPARATUS
MUST BE INSTALLED IN ACCORDANCE WITH MANUFACTURERS INSTRUCTIONS AND
REGULATIONS SUCH AS NFPA.
ALL BOOSTER PUMPS WEIGH OVER 100 LBS. USE APPROPRIATELY RATED LIFTING
EQUIPMENT. IMPROPER LIFTING (OR UNDERRATED EQUIPMENT) RESULTS IN A
STRIKE/CRUSH HAZARD.
ALWAYS USE PROPER PPE. OIL MAY BE TOXIC. DISPOSE OF OIL PROPERLY PER AHJ
GUIDELINES.
2
DO NOT REPLACE FASTENERS WITH OTHER THAN HALE PART NUMBERS PROVIDED.
FOLLOW DEPARTMENT PROCEDURES TO SET WHEEL CHOCKS WHEN PUMPING.
USE PPE TO PROTECT HANDS AND FINGERS FROM SHARP EDGES. THE EDGES OF THE
BLADES ON THE INDUCER OR IMPELLER MAY BE SHARP.
ALLOWING INTAKE PRESSURES TO FALL BELOW ESTABLISHED LIMITS MAY RESULT IN
DAMAGE TO THE WATER SUPPLY PIPING WHEN PUMPING FROM HYDRANT.
BEFORE LAY OUT AND INSTALLATION OF THE DRIVELINE, CONSULT APPARATUS AND/OR
DRIVELINE COMPONENT MANUFACTURER FOR GUIDANCE AND REFER TO HALE SB90
FOR ALIGNMENT OF DRIVESHAFT AND PUMP DRIVE.
CHECK MAGNETIC DRAIN PLUG FOR DEBRIS. IF SIGNIFICANT METAL FRAGMENTS ARE
PRESENT, REPORT CONDITION TO AHJ SO SERVICE CAN BE PERFORMED.
DO NOT ALLOW A WHIRLPOOL AT THE SUCTION STRAINER WHEN DRAFTING.
DO NOT EXCEED 15 DEGREE ANGLE IN OPERATION OF PUMP SYSTEM.
DO NOT EXCEED POWER TRAIN LIMITS WHEN INSTALLING A PUMP. A MEANS TO CONTROL THE ENGINE OUTPUT WHEN PTO IS ENGAGED SHOULD BE CONSIDERED.
DO NOT OPERATE PUMP WITHOUT SUCTION STRAINER IN PLACE.
DO NOT OPERATE PUMP WITHOUT WATER OR WITHOUT DISCHARGING WATER FOR EXTENDED TIME, IT MAY OVERHEAT CAUSING DAMAGE.
DO NOT RUN ENGINE HIGHER THAN 1200 RPM DURING PRIMING.
DO NOT RUN THE PRIMER FOR MORE THAN 45 SECONDS. IF PRIME IS NOT ACHIEVED IN
30 - 45 SECONDS, STOP AND LOOK FOR AIR LEAKS OR BLOCKED SUCTION HOSE.
DO NOT USE THE RED IDLE BUTTON UNLESS AN EMERGENCY AS DEFINED BY THE AHJ
EXISTS.
3
FAILURE TO INSTALL THE ENGINE SPEED INTERLOCK SYSTEM PROPERLY MAY RESULT
IN PTO DAMAGE.
FOLLOW PTO AND VEHICLE MANUFACTURER PTO INSTRUCTIONS.
HALE PUMPS ARE SHIPPED WITHOUT OIL. FILL GEARBOX WITH FLUID LISTED IN TABLE 5
BEFORE OPERATION.
IF THE DISCHARGE PRESSURE DOES NOT INCREASE, AND INTAKE GAUGE READING
DOES NOT FALL BELOW ZERO (0), OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND WITHIN 30 SECONDS, STOP THE PUMP AND CHECK FOR AIR
LEAKS.
OPEN AT LEAST ONE DISCHARGE VALVE SLIGHTLY TO PREVENT THE PUMP FROM OVERHEATING. OVERHEATING CAN DAMAGE THE PUMP SEAL, AND OTHER PUMP PARTS.
PUMP ASSEMBLY HAS BOTH METRIC AND SAE HARDWARE.
PUMP DISCHARGE PRESSURE SHOULD INCREASE WITH ENGINE SPEED WHEN OPENING
THROTTLE. IF ENGINE SPEED INCREASES WITHOUT INCREASE IN PRESSURE, THE PUMP
MAY BE CAVITATING.
4
2. GENERAL INSTRUCTIONS
This manual covers the Hale Flex Series of single stage booster pumps and provides basic information on Hale AP, CBP, MBP, or RSD Flex Series of booster pumps when local procedures do NOT
exist. Basics of operation, installation verification, and maintenance are covered.
Additional information is available in FSG–MNL–00184, Technical Manual For Hale Single Stage
Booster Pumps. This manual and additional information such as pump curves and rating charts can
be found on the flash drive provided with the pump or on the Hale website (www.haleproducts.com).
ALWAYS FOLLOW LOCAL GUIDELINES FROM THE AHJ AND THE APPARATUS MANUFACTURER.
2.1. Overview
This manual ONLY covers the Flex Series of single stage booster pumps.
2.2. Pump Specifications and Numbering
Each pump has a unique serial number that can be found in multiple locations. Model numbers define major pump features.
For detailed booster pump specifications, refer to the Hale Products website (www.hale products.com). Hale Products Inc. policy is one of continuous development. Hale therefore reserves the
right to amend specifications without notice or obligation.
2.2.1 Optional Pump Panel Identification Plates
Figure 1 shows the Hale pump panel identification plate. This placard has the same data as the identification plate on the pump. The placard is optional and shipped loose with the pump when selected.
Figure 1. Pump Panel Identification Plate (Placard)
5
2.2.2 Identification Plate
The plate is stamped with the appropriate model, input drive type, capacity (NFPA rated flow shown)
and units code, gear ratio code, gearbox type code, and serial number. Figure 1 is an example of
Hale pump identification plate marking conventions
Figure 2. Pump Serial Number Locations
Figure 3. Pump Model Codes
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