APS/MBP
Silencer Series Booster Pumps
Operation and 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: 029-0020-83-0
NOTICE !
Class1 cannot assume responsibility for product failure resulting from improper
maintenance or operation. Class1 is responsible only to the limits stated in the
product warranty. Product specifications contained in this manual are subject to
change without notice.
All Class1 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 CHANGE FROM BY DATE APVD
05-019 A INITIAL RELEASE LwH 01/20/2005 MAL
Manual p/n: 029-0020-83-0, Rev. -B
Printed in U.S.A.
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
Conshohocken, PA 19428 USA
DRAWN BY LwH ISSUE DATE
CHECKED BY PRW 01/20/2005
© Hale Products, Inc. 2005
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
COPYRIGHT ©
All Rights Reserved
Table of Contents ❑
Contents Page
Silencer Series Booster Pumps
1 Safety Precautions.................................................................................11
1.1 Guidelines............................................................................................................. 11
2 Introduction...........................................................................................15
2.1 Overview ...............................................................................................................15
Table 2-1: Booster Pump Capacity.............................................................................. 15
2.2 Principles Of Operation ...................................................................................... 16
Centrifugal Force................................................................................................................ 16
Figure 2-2: Centrifugal Force, from Rotating Disk ....................................................... 16
Figure 2-3: Pump Water Flow, Cutwater .....................................................................17
2.3 BOOSTER Pump Components............................................................................17
Impeller and Shaft Assembly.............................................................................................. 17
Pump Body......................................................................................................................... 18
Figure 2-4: Overview of Hale Booster Pump and Gearbox ......................................... 18
Mechanical Seal.................................................................................................................18
Figure 2-5: Mechanical Seal Overview........................................................................ 18
Gearbox.............................................................................................................................. 19
2.4 Pump Drives .........................................................................................................19
Figure 2-6: Pump/Engine Rotation .............................................................................. 19
HALE Power Takeoff (PTO) Driven Pumps ....................................................................... 20
Hale Engine Mounted Pumps............................................................................................. 20
Hale Hydraulic-Drive Pumps .............................................................................................. 20
2.5 Accessories .......................................................................................................... 20
Priming Systems ................................................................................................................ 21
Figure 2-7: Rotary Vane and ESP Priming Pumps...................................................... 21
Priming Valves ................................................................................................................... 22
Figure 2-8: SPVR Priming Valves ............................................................................... 22
Figure 2-9: PVG Priming Valves.................................................................................. 23
Silencer Series Booster Pump, p/n: 029-0020-83-0
3
❑ Table of Contents
Contents - continued Page
2.5 Accessories - continued
Pressure Control ...............................................................................................................23
The P Relief Valve System .......................................................................................... 23
Figure 2-10: P Series Relief Valve System Arrangement ........................................... 23
How the Relief System Works ..................................................................................... 24
Thermal Relief Valve (TRV)......................................................................................... 24
Figure 2-11: Thermal Relief Valve, TRV ..................................................................... 24
TRV-L Kit ..................................................................................................................... 25
Anodes......................................................................................................................... 25
Figure 2-12: Hale Anode ............................................................................................. 25
Manifolds ..................................................................................................................... 26
Figure 2-13: Typical Manifold Assembly Option.......................................................... 26
3 Operation ...............................................................................................27
3.1 Stationary Pumping Operations..........................................................................27
Pumping from a Hydrant (General Operation).................................................................. 27
Figure 3-1: Driver’s Compartment Indicator Lights ..................................................... 28
Figure 3-2: Pump Operator’s Panel ............................................................................ 29
Draft Limiting Factors......................................................................................................... 30
Table 3-3: Base Line NFPA Ratings ........................................................................... 31
Pumping from Draft............................................................................................................ 31
Pumping from Onboard Water Tank.................................................................................. 33
3.2 Pump and Roll Operation ...................................................................................35
3.3 Relief Valve Procedures.......................................................................................35
Figure 3-4: TPM Relief Valve Control ......................................................................... 36
3.4 Cavitation ..............................................................................................................36
Figure 3-5: Sample, Cavitation Regions ..................................................................... 36
Process of Cavitation......................................................................................................... 37
Warning Signs of Cavitation (Discharge and Gauges) ...................................................... 37
Discharge Pressure ..................................................................................................... 37
Vacuum Compound Gauge ......................................................................................... 38
4
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
3.4 Cavitation - continued
To Eliminate Cavitation ...................................................................................................... 38
During Operations ............................................................................................................. 38
Table 3-6: Lift Loss from Elevation .............................................................................. 38
Table 3-7: Lift Loss from Elevation .............................................................................. 39
Preventive Measures.......................................................................................................... 39
Table 3-8: Hose Size vs. Pump Rating Capacity......................................................... 39
3.5 Post Operation Procedure................................................................................... 40
4 Preventive Maintenance .......................................................................41
4.1 Overview ...............................................................................................................41
4.2 Post-Operation .....................................................................................................41
Drain Pump ........................................................................................................................41
4.3 Extreme Conditions ............................................................................................. 41
During Freezing Weather ...................................................................................................42
4.4 Weekly................................................................................................................... 42
Relief Valve Test ................................................................................................................ 42
Figure 4-1: TPM Relief Valve Control.......................................................................... 43
Priming System ..................................................................................................................43
Pump Shift Warning Indicator Lights.................................................................................. 43
Valve Maintenance............................................................................................................. 44
Intake Strainers ..................................................................................................................44
Auxiliary Engine.................................................................................................................. 44
Verify All Gauges are in Working Order ............................................................................. 44
Operate Pump Controls...................................................................................................... 44
Inspect Water and Foam Tanks .........................................................................................45
Check Roof and Bumper Turrets........................................................................................45
Silencer Series Booster Pump, p/n: 029-0020-83-0
5
❑ Table of Contents
Contents - continued Page
4.5 Monthly..................................................................................................................45
Gearbox Lubrication .......................................................................................................... 45
Figure 4-2: Gearbox Capacity / Recommended Lubricants ........................................ 45
Figure 4-3: Typical Drain, Fill and Level Plugs............................................................ 46
Drive Line and Flange Bolts............................................................................................... 46
Priming System Test (Dry Vacuum Test)........................................................................... 46
Figure 4-4: PVG Priming Valve Handle....................................................................... 47
4.6 Annually ................................................................................................................48
Replace Gearbox Oil.......................................................................................................... 48
Check Drain Lines to Multi-Drain ....................................................................................... 48
Tank-to-Pump Flow Rate Test........................................................................................... 49
Performance Testing Overview.......................................................................................... 50
Figure 4-5: Pump Ratings (GMP/LPM) ....................................................................... 50
Performance Testing Equipment and Materials........................................................... 50
Performance Testing ................................................................................................... 51
Table 4-6: Nozzle Flow and Pressure Ratings, Part 1 ................................................ 52
Table 4-7: Nozzle Flow and Pressure Ratings, Part 2 ................................................ 53
Worn Clearance Rings and Impeller Hubs......................................................................... 54
Anode Check .....................................................................................................................54
Figure 4-8: Hale Anode ............................................................................................... 54
5 Troubleshooting ....................................................................................55
Figure 5-1: Sample, Serial Nameplate ........................................................................ 55
Figure 5-2: Troubleshooting Charts ............................................................................ 55
PTO Will Not Engage ............................................................................................. 55
Pump Loses Prime or Will Not Prime..................................................................... 55
Insufficient Pump Capacity..................................................................................... 57
Insufficient Pressure............................................................................................... 57
Valve Remote Control Difficult to Operate ............................................................. 57
Engine Speeds Too HIGH for Required Capacity or Pressure .............................. 57
Cavitation ............................................................................................................... 58
Relief Valve Does Not relieve Pressure When Valves are Closed ........................ 59
6
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
Figure 5-2: Troubleshooting Charts - continued
Relief Valve Does Not Recover and Return to Original
Pressure Setting After Opening Valves.................................................................. 59
Relief Valve Opens When Control Valve is Locked Out......................................... 59
Unable to Obtain Proper Setting on Relief Valve ................................................... 59
Discharge Valves Difficult to Operate..................................................................... 60
Water in Pump Gearbox ......................................................................................... 60
Rotation Symptoms ................................................................................................ 60
6 Repair.....................................................................................................61
Figure 6-1: Silencer Series Booster Pump .................................................................. 61
Figure 6-2: Gearbox Capacity / Recommended Lubricants ........................................62
Table 6-3: Torque Values Chart .................................................................................. 62
6.1 Overview ...............................................................................................................62
6.2 General Repair Guidelines ..................................................................................63
Before You Begin... ............................................................................................................ 63
Cleaning and Inspection Guidelines................................................................................... 65
Hale Recommended Cleaners ...........................................................................................66
Tools Required................................................................................................................... 66
6.3 Pump and Gearbox Assembly ............................................................................67
Installing the Assembly to Apparatus ................................................................................. 68
6.4 Servicing the Booster Pump ............................................................................... 69
Volute (Pump Body) ........................................................................................................... 69
Figure 6-4: Booster Pump Parts Breakdown ............................................................... 69
Figure 6-5: Typical Water Cooling Lines ..................................................................... 70
Installation Notes – Volute ........................................................................................... 70
Impeller............................................................................................................................... 71
Inspection – Clearance Rings ...................................................................................... 72
Figure 6-6: Clearance Ring ID Measurement.............................................................. 72
Installation Notes – Clearance Rings ........................................................................... 72
Inspection – Impeller ....................................................................................................72
Figure 6-7: Impeller OD Measurement ........................................................................ 72
Installation Notes – Impeller........................................................................................ 73
Silencer Series Booster Pump, p/n: 029-0020-83-0
7
❑ Table of Contents
Contents - continued Page
6.5 Mechanical Seal Assembly..................................................................................74
Figure 6-8: Mechanical Seal Overview / Replacement ............................................... 74
Removing the Seal............................................................................................................. 74
Installing Seal..................................................................................................................... 75
6.6 Pump head ............................................................................................................77
Figure 6-9: Oil Seal Replacement / Pump Head Parts................................................ 77
Removing the Pump Head and Oil Seal ............................................................................ 78
Installation Notes – Pump Head and Oil seal .............................................................. 78
6.7 “B” Series Gearbox ..............................................................................................79
Oil Seal – Input Shaft......................................................................................................... 79
Figure 6-10: Oil Seal, Input Shaft................................................................................ 80
Installation Notes ......................................................................................................... 80
Figure 6-11: Typical Bearing and Seal Insertion Tools ............................................... 81
6.8 Dismantle the B Series Gearbox .........................................................................81
Figure 6-12: B Gearbox Parts Identification ................................................................ 82
Figure 6-13: Typical Angular Bearing Insertion Tool................................................... 84
Installation....................................................................................................................84
Figure 6-14: Angular Contact Bearing Orientation ...................................................... 85
6.9 Available options..................................................................................................87
Hydraulic Drive Option ....................................................................................................... 87
Figure 6-15: Hydraulic Drive Option............................................................................ 87
Installation Notes ......................................................................................................... 87
Tachometer Drive Option................................................................................................... 88
Figure 6-16: Tachometer Drive Option........................................................................ 88
Installation Notes ......................................................................................................... 88
7 Installation .............................................................................................89
7.1 OVERVIEW ............................................................................................................89
7.2 FRAME MOUNTING ..............................................................................................89
Mounting Holes..................................................................................................................89
8
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
7.3 DRIVELINE ISSUES.............................................................................................. 90
Drive Line and Flange Bolts ............................................................................................... 90
Issues................................................................................................................................. 90
Table 7-1: Maximum Recommended Driveline Lengths.............................................. 91
7.4 PLUMBING CONNECTIONS.................................................................................91
8 Maintenance Kits ..................................................................................93
8.1 Recommended spare parts kits.......................................................................... 93
Level 1 ............................................................................................................................... 93
Figure 8-1: Typical Level 1 Basic Repair Kit................................................................ 93
Level 2................................................................................................................................ 93
Figure 8-2: Typical Level 2 Intermediate Repair Kit .................................................... 93
Table 8-3: Level 2 Kit Part Numbers ........................................................................... 94
Complete Overhaul ............................................................................................................94
Figure 8-4: Additional Booster Pump Maintenance Kits, Level 3 ................................ 94
Appendix A: Glossary.........................................................................95
Appendix A-1: Measurements .............................................................99
CONVERSIONS..................................................................................................... 99
Appendix C: Alternate Lubricant Manufacturers ..........................101
Table C-1: Alternate Lubricant Manufacturers........................................................... 101
Table C-2: Alternate Lubricant Manufacturers, continued ......................................... 102
Appendix D: Hose Friction Loss .......................................................103
Table D-1: Hose Friction Loss (PSI/Bar 100 Feet) .................................................... 103
Express Warranty...............................................................................105
Hale Products, Inc...................................................................................................... 106
Silencer Series Booster Pump, p/n: 029-0020-83-0
9
❑ Table of Contents
Contents - continued Page
Drawings ..........................................................................................Plate #
Installation / Parts
APS Silencer Series Booster Pump Installation and Identification...............................1027A
MBP Silencer Series Booster Pump Installation and Identification..............................1026A
Available Options
Anti-Corrosion Anode, Plate #869A...............................................................................869A
ESP Priming Pump........................................................................................................821A
P Series Relief Valve - Option.......................................................................................547C
PVG Priming Valve - Option................................................................................
Shift Indicator Lights, Wiring Schematic, PTO...............................................................825A
SPV Priming Valve - Option...........................................................................................828A
TRV/TRVM Relief Valve System - Option......................................................................729A
..........480G
10
Silencer Series Booster Pump, p/n: 029-0020-83-0
1 Safety Precautions
THE HALE SILENCER SERIES BOOSTER PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE
FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE
TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND
WITHIN THIS MANUAL.
ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE SILENCER SERIES
BOOSTER PUMP.
Hale is a registered trademark of Hale Products, Incorporated. All other brand and product
names are the trademarks of their respective holders.
Safety Precautions ❑
IMPORTANT !
1.1 GUIDELINES
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES, GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED
IN THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
❑ Use care when removing the Booster Pump assembly from its packaging
to prevent personal injury and/or damage to the system.
❑ To fully support the booster pump assembly, use all mounting bolt holes
provided on the gearbox and/or the booster pump.
❑ Installation should be performed by a trained and qualified installer, such
as your authorized Hale service representative. Be sure the installer has
sufficient knowledge, experience and the proper tools before attempting
any installation.
NOTICE !
Silencer Series Booster Pump, p/n: 029-0020-83-0
11
❑ Safety Precautions
THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY,
WEIGHING UP TO 145 LBS. (54 KGS.). ADDING ACCESSORIES INCREASES
THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES
CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE
SILENCER SERIES BOOSTER PUMP AND GEARBOX ASSEMBLIES.
❑ The installer is responsible for observing all instructions and safety pre-
cautions in his or her daily routine as dictated by regional safety ordinances or departmental procedures.
❑ DO NOT permanently remove or alter any protective feature, guard or
insulating devices, or attempt to operate the system when these guards
are removed.
Doing so voids the Silencer Booster Pump warranty.
❑ Any of the above could affect system capacity and/or safe operation of
the system and is a serious safety violation which could cause personal
injury or could affect safe operation of the pump.
WARNING !
WARNING!
NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THE SILENCER
SERIES BOOSTER PUMP ASSEMBLY WITHOUT PRIOR WRITTEN PERMIS
SION 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
❑ Rotating drive line parts can cause injury. Be extremely careful that NO
part of your body (head, feet, arms, legs, fingers, hair) is in an area of
rotating parts where you could be subject to injury.
❑ Make sure everyone is clear of the apparatus. Verify the parking brake is
set and the wheels are chocked to prevent any movement of the
apparatus.
12
Silencer Series Booster Pump, p/n: 029-0020-83-0
Safety Precautions ❑
❑ DO NOT operate the system at pressures higher than the maximum
rated pressure. (Also see Table 2-1: “Booster Pump Capacity” on page
13.)
❑ Relieve all system pressure, then drain all water from the system before
servicing any of its component parts.
❑ Use only pipe, hose and fittings which are rated at or above the maxi-
mum pressure rating at which the water pump system operates.
❑ If a pump is operated without water for extended periods, or without dis-
charging water, it could overheat. This can damage the mechanical seal
or the drive mechanism.
❑ DO NOT attempt to pump until all the “GREEN” pump indicators in the
cab and panel are ON. (Also see Figure 3-2: “Pump Operator’s Panel”
on page 27.)
❑ DO NOT advance the throttle unless the "OK TO PUMP" indicator is ON.
❑ 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.
Silencer Series Booster Pump, p/n: 029-0020-83-0
13
❑ Safety Precautions
Notes
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14
Silencer Series Booster Pump, p/n: 029-0020-83-0
2 Introduction
2.1 OVERVIEW
Hale Products currently offers the Silencer Series Booster Pumps in two
models:
❑ APS – Single-Stage, Centrifugal Attack Pump (250-500 GPM/1,000-
2,000 LPM), with three primary drive options: truck transmission PTO,
hydraulic drive or direct engine mount.
❑ MBP – Single-Stage, Centrifugal, “High Volume” Attack Pump (500-
1,000 GPM/2,000-4,000 LPM), also with three primary drive options:
truck transmission PTO, hydraulic drive or direct engine mount.
Unless otherwise indicated, these procedures apply to all models of Hale
Silencer Series Booster Pumps.
Introduction ❑
The Hale line of booster pumps are the favorites of fire fighters throughout
the world. Booster pumps can be used as initial attack pumps or as auxil
iary pumps in conjunction with the apparatus main pump. They offer the
versatility, dependability, reliability, ease of operation and reduced mainte
nance that is so necessary to effective fire fighting.
Hale booster pumps are compact in size and lightweight for easy mounting.
The apparatus builder must supply the transmission PTO (power takeoff)
and connecting shaft.
Hale offers two models of the silencer series booster pumps. The anticipated use and position on the apparatus determines the model selected as
well as the drive unit. Flow capacities are shown in Table 2-1: “Booster
Pump Capacity.”
Model Type Capacity
APS Single-Stage Silencer Series
HIGH Volume Attack Pump.
MBP Single-Stage Silencer Series
HIGH Volume Attack Pump
Up to 500 GPM (1,893LPM). NFPA Rated at 250 to 500
GPM (946 to 1,893LPM), per Standard 1901.
Up to 1,000 GPM (3,785LPM). NFPA Rated at 500 to
1,000 GPM (1,983 to 3,785LPM), per Standard 1901.
-
-
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table 2-1: Booster Pump Capacity
15
❑ Introduction
2.2 PRINCIPLES OF OPERATION
Centrifugal Force
Hale booster pumps are centrifugal pumps that operate on the principle of
centrifugal force created by a rapidly spinning disk.
trifugal Force, from Rotating Disk.”)
As the disk is rotated, it throws water from the center toward the outer circumference of the disk. The
velocity at which the water travels from the center
directly relates to the diameter of the disk and the
speed of rotation.
When water is confined in a closed container, such
as the volute (pump body), the velocity of the water
is converted to pressure that rises to a level depen
dent on the speed of rotation.
(See Figure 2-2: “Cen-
-
There are three interrelated factors that regulate
the performance of a centrifugal pump:
❑ SPEED (RPM) If the speed of rotation
Figure 2-2: Centrifugal
Force, from Rotating
Disk
increases with flow held constant, fluid pressure
increases.
❑ PRESSURE If pressure changes with speed held constant, the flow,
measured in gallons or liters per minute (GPM/LPM), changes inversely;
if pressure increases, flow decreases.
Pressure is usually measured in pounds per square inch (PSI) or BAR.
❑ FLOW If the pressure is held constant, the flow increases with an
increase in the speed of rotation. Flow is measured in the number of gal
lons of fluid per minute (GPM or LPM) that a pump can deliver when supplied from draft.
A centrifugal pump is preferred by the fire protection service 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 dif
ference in pressure or 75 PSI (5.2 BAR). This contributes to improved performance with reduced maintenance. Decreased maintenance is aided by
the fact a centrifugal pump has few moving parts.
-
-
16
Silencer Series Booster Pump, p/n: 029-0020-83-0
As the impeller rotates, the
water moving outward in the
impeller creates reduced pres
sure or a vacuum in the suction
eye allowing atmospheric pres
sure to push water into the
pump impeller, replacing the
water discharged.
During operation water enters
the suction eye of the impel
ler. The rotating impeller
vanes develop discharge pres
sure and direct the water to the
discharge opening.
The cutwater is a wedge that
divides the water between the
volute (pump body) and the
pump discharge.
Introduction ❑
-
-
-
Figure 2-3: Pump Water Flow, Cutwater
2.3 BOOSTER PUMP COMPONENTS
(See Figure 2-4: “Overview of Hale Booster Pump and Gearbox,” on page
18.)
The silencer series booster pump consist of:
❑ Impeller and Shaft Assembly
❑ Volute (Pump Body)
❑ Mechanical Seal
❑ B Series Gearbox
Impeller and Shaft Assembly
Power is transmitted through the B Series gearbox to a high-quality, bronze
impeller.
on page 18.)
(See Figure 2-4: “Overview of Hale Booster Pump and Gearbox,”
Silencer Series Booster Pump, p/n: 029-0020-83-0
17
❑ Introduction
Pump Body
(See Figure 2-4: “Overview of Hale Booster
Pump and Gearbox.”)
As water discharges
from the impeller, it
enters the volute (pump
body). The volute is
shaped so that its area
increases from the cut
water to its full capacity
at the volute throat. This
gradual increase in size
maintains a constant
average velocity through
the volute.
Standard APS and MBP
volutes are constructed
from fine-grain cast iron. For areas where salt water is commonly used, a
bronze version of the Model APS is available.
-
Figure 2-4: Overview of Hale Booster Pump and
Gearbox
The volute is a single piece, and must be removed to service the impeller,
clearance rings, and mechanical seal. Removal of the volute can often be
accomplished without removing the pump and gearbox assembly from the
apparatus.
Mechanical Seal
The mechanical seal is
common to Hale booster
pumps.
“Mechanical Seal Overview.”)
The stationary seat is in
constant contact with a
rotating seal ring to pre
vent leakage. The sealing diaphragm is made of
a rubber elastomer spe
cifically designed for hightemperature operations.
(See Figure 2-5:
-
-
Figure 2-5: Mechanical Seal Overview
18
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Note: Mechanical seals do not drip like older pump packing. A Hale Booster
Pump with a drip from the seal requires service.
WARNING !
IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR
WITHOUT DISCHARGING WATER, IT COULD OVERHEAT. THIS CAN DAM
AGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.
-
Gearbox
Hale Silencer Series Pumps are equipped with a B Series Gearbox that utilizes helical gears to reduce operating noise. To accommodate a wide
range of engines, transmissions, and PTOs, this speed increasing gearbox
is available in a variety of ratios. All Silencer series pumps feature a stan
dard water cooler that uses water flowing through the pump to lower gearbox temperatures when required.
-
2.4 PUMP DRIVES
Three common booster pump drives are used on fire fighting apparatus:
❑ Operation from a
Power Take-Off
(PTO) from the truck
transmission or drive
train
❑ A stand-alone drive
with separate engine
(auxiliary engine)
❑ Hydraulic motor
Hale booster pumps
produce the volumes
and pressures shown
on their performance
curves. However, max
imum pump performance is sometimes
limited by the power
capacity and speed limits of the engine, transmission, and PTO.
-
Figure 2-6: Pump/Engine Rotation
Silencer Series Booster Pump, p/n: 029-0020-83-0
19
❑ Introduction
Hale booster pumps are available for either engine rotation (clockwise), or
opposite engine rotation (counterclockwise) PTO operation.
5: “Mechanical Seal Overview,” on page 18.)
NEVER OPERATE A BOOSTER PUMP ABOVE THE DERATED CONTINUOUS
TORQUE RATING FOR ITS TRANSMISSION OR PTO, OR ABOVE THE REC
OMMENDED PTO OUTPUT SPEED AS RECOMMENDED BY THE PTO
MANUFACTURER.
HALE Power Takeoff (PTO) Driven Pumps
Silencer series booster pumps feature a 1-1/2” (38mm) input shaft for connection to a PTO driveline. An optional 1410 companion flange is also
available.
(See Figure 2-
WARNING !
-
Hale Engine Mounted Pumps
Silencer series booster pumps are available with an adapter to accept #3
and #4 SAE bell housings. Elastomeric couplings are also available for 61/5” (165mm), 10” (254mm) and 11.5” (292mm) clutch discs.
Hale Hydraulic-Drive Pumps
Silencer series boosters pumps are available with an adapter to accept
SAE “C” two and four bolt hydraulic motors with SAE “C” splined output
shafts.
2.5 ACCESSORIES
In addition to the basic Hale booster pump, the following options are available to complete system installation:
❑ Priming Systems
20
❑ Pressure Control Devices (Relief Valves or Governors)
❑ Manifolds
❑ Anodes
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Priming Systems
Priming pumps are used to evacuate air in the suction hose and pump.
`The vacuum created allows atmospheric pressure to push water from the
static source through the suction hose and into the pump.
Hale booster pumps use Rotary Vane Positive Displacement type pumps for
priming.
(See Figure 2-7: “Rotary Vane and ESP Priming Pumps.”)
The priming pump has a rotor mounted off-center (eccentric) to the pump
body housing. The rotor vanes slide in grooves and are held against the
body housing by centrifugal force. As a vane turns toward the discharge, it
recedes into the rotor compressing the air.
As the rotor continues past the discharge, the vane advances outward from
the groove and against the body housing. During this cycle, the space
between the rotor and housing case fills with air. The vanes, acting as wip
ers, force air out of the discharge, creating a vacuum in the main pump
allowing atmospheric pressure to push water into the hose and suction side
of the pump.
The Hale ESP series priming pump is an environmentally friendly primer
that does not require a separate lubricant reservoir. The vanes and pump
body are self-lubricating for maintenance free operation.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 2-7: Rotary Vane and ESP Priming Pumps
-
21
❑ Introduction
An ESP series priming pump also uses a single control to open the priming
valve between the booster and the priming pumps, and start the priming
motor.
(See Figure 2-7: “Rotary Vane and ESP Priming Pumps,” on page
21.)
Priming Valves
Hale priming valves open when the priming pump is operated to allow the
air to escape from the pump.
Two priming valves are offered:
❑ Hale Semi-Automatic Priming Valve for Remote Mounting (SPVR)
22
Figure 2-8: SPVR Priming Valves
A hose is connected from the SPVR to the priming tap on the booster
pump body. A single push-button on the operator’s panel starts the
priming pump motor. When a vacuum is created, the SPVR opens.
(See Figure 2-8: “SPVR Priming Valves.”)
Releasing the push-button stops the priming pump and the SPVR
closes.
❑ The Hale PVG Priming Valve
The PVG is mounted on the pump operator’s panel. The PVG is a combination valve and switch.
When the handle on the PVG is pulled out, the valve opens and the
switch energizes the primer motor.
(See Figure 2-9: “PVG Priming
Valves,” on page 23.) Pushing the handle in de-energizes the motor and
closes the valve.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Figure 2-9: PVG Priming Valves
Pressure Control
The P Series relief valve system is a bronze, variable-pressure setting relief
valve that prevents undue pressure per the requirements of NFPA Standard
1901. An indicator light on the operator control panel signals when the
valve is open.
The P Relief Valve System
The P relief valve system consists of a panel mounted control valve (PM)
and a P25, P30 or P30V relief valve.
(See Figure 2-10: “P Series Relief
Valve System Arrangement.”)
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 2-10: P Series Relief Valve System Arrangement
23
❑ Introduction
The valve is mounted in the discharge piping and plumbed back to the
pump suction. Valve connections are either flanged or Victaulic
ure 2-10: “P Series Relief Valve System Arrangement,” on page 23.)
How the Relief System Works
A pressure line mounted in the pump discharge pressure tap provides pressure to the diaphragm in the PM control valve. The handwheel on the PM
control either increases or decreases the spring tension on the diaphragm.
The seat of the P series relief valve is kept closed by pump discharge pres
sure. Also see Figure 2-10: “P Series Relief Valve System Arrangement” on
page 23.
As the pump pressure increases, more pressure is applied to the diaphragm
in the PM control valve.
As the pressure on the diaphragm increases beyond the set point, the stem
moves off its seat, allowing pump pressure to push on the piston in the relief
valve. This causes the relief valve seat to lift, allowing excess pressure to
dump back to the pump suction side.
™
. (See Fig-
-
After the pressure equalizes, the piston returns to the closed position as the
pressure in the relief valve bleeds off through an orifice.
An Amber indicator light on the PM control illuminates when the relief valve
is OPEN.
Thermal Relief Valve (TRV)
The Thermal Relief Valve
protects the pump from over
heating. (See Figure 2-11:
“Thermal Relief Valve, TRV.”)
The optional TRV unit is
attached to the discharge pip
ing either by flange mounting
or 1-1/4” NPT threaded con
nection (38mm for the Model
TRVM).
The valve monitors the temperature of the water in the
pump. When the tempera
ture exceeds 120°F (48.9°C),
-
Figure 2-11: Thermal Relief Valve, TRV
the valve automatically opens
and depending on the instal
lation, discharges a small amount of water either to the ground or into the
water tank allowing cooler water to enter.
24
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
After the temperature returns to a safe level, the valve closes.
TRV-L Kit
(See Figure 2-11: “Thermal Relief Valve, TRV,” on page 24.)
The TRV-L kit includes a chrome panel placard with a warning lamp, a lamp
test button, and a pre-assembled wire harness. The light illuminates when
the TRV is open and discharging water.
An optional buzzer provides audible warning. The buzzer mounts on the
operator panel.
Anodes
(See Figure 2-12: “Hale Anode.”)
The Hale Anode System helps prevent damage caused by galvanic corrosion in the pump. Galvanic action pits the pump and pump shaft material
through the electrolysis of water in the pump. The popularity of noncorro
sive water tanks and piping has increased this type of corrosion in today’s
fire pumps.
The Hale Anode System is a sacrificial metal, which helps to
diminish or prevent corrosion.
The anode fits on any Hale truck
mounted pump, regardless of
age or model.
The Anode kit is designed for
installation in the standard Hale
115 series flange opening. On
fabricated manifolds and similar
applications, the installer is to
provide 1-1/4” NPT openings and
install anodes directly. It is rec
-
Figure 2-12: Hale Anode
ommended that one anode be
installed on each suction manifold and one on the discharge side. Typically,
three are used. Anodes can be mounted in any position, horizontal or
vertical.
Zinc anodes should be inspected every twelve (12) months. Replace when
over 75% of the zinc has been consumed. Performance of the anode varies
with water quality and PH. Anodes conform to Mil Spec. A18001.
Silencer Series Booster Pump, p/n: 029-0020-83-0
25
❑ Introduction
Manifolds
(See Figure 2-13: “Typical Manifold Assembly Option.”)
26
Figure 2-13: Typical Manifold Assembly Option
Silencer Series Booster Pump, p/n: 029-0020-83-0
3 Operation
This section provides information and procedures for the operation of Hale
silencer series booster pumps. Included are post-operation procedures and
procedures for pumping from:
❑ a hydrant
❑ draft
❑ an onboard tank
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES, GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED
IN THE APPARATUS MANUFACTURER'S MANUAL.
Operation ❑
NOTICE !
REFER TO PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
3.1 STATIONARY PUMPING OPERATIONS
Pumping from a Hydrant (General Operation)
1. Bring the truck to a complete stop and apply the truck parking brake.
CAUTION !
REFER TO DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS
AND LAYING OUT SUCTION AND DISCHARGE HOSES.
ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.
2. Shift the truck transmission to the NEUTRAL position.
Silencer Series Booster Pump, p/n: 029-0020-83-0
27
❑ Operation
Figure 3-1: Driver’s Compartment Indicator Lights
3. Engage the PTO (power take-off) per the PTO manufacturer’s instructions.
The GREEN shift warning indicator light illuminates, indicating a complete
shift.
(See Figure 3-1: “Driver’s Compartment Indicator Lights.”)
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN
PUMP LIGHTS IN THE CAB ARE ON.
4. Exit the driving compartment only after all the above steps are completed and
you are sure that the appropriate lights in the cab and panel are ON.
CAUTION !
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS
ALSO SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 29.)
ON.
5. Verify that the pump panel shift indicator green “OK TO PUMP” light is ON
and that all hose connections are complete.
6. Open the hydrant. Bleed off the air from the suction hose.
28
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
Figure 3-2: Pump Operator’s Panel
7. If necessary, open the suction valve to allow water to flow into the pump.
8. To eliminate air pockets, open appropriate valve to expel air or prime the pump,
if so equipped.
Also see heading “Pumping from Draft” on page 31.
9. Note the discharge pressures and intake pressures as applicable, then open
the engine throttle gradually until the master discharge gauge indicates the
desired pressure.
10. Set the automatic relief valve or governor control system according to your
company policy, if so equipped.
CAUTION !
DO NOT REDUCE THE PRESSURE ON THE INTAKE GAUGE BELOW
DEPARTMENT LIMITS. SERIOUS DAMAGE TO THE WATER MAIN COULD
RESULT.
11. If the master intake gauge shows a vacuum before the desired discharge
pressure or flow is reached, it indicates that you are receiving all the water the
suction piping (hydrant) can supply.
Silencer Series Booster Pump, p/n: 029-0020-83-0
29
❑ Operation
If you need to increase pressure when this occurs, the pump flow must be
reduced or the water supply improved.
12. As the throttle is increased, the pressure gauge reading increases with engine
speed. If the engine speed increases without an increase in pressure, the
pump could be cavitating.
See Section 3.4 “Cavitation” on page 36.
Cavitation can occur on a hydrant and it indicates the need to reduce the flow
or improve the water supply.
13. 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. Set the automatic relief valve according to department policy. If no policy
exists,
see heading “Pumping from Draft” on page 31.
IMPORTANT !
IF THE PUMP OVERHEATS AND IT IS NOT EQUIPPED WITH A HALE TRV
VALVE, OPEN THE VALVE TO ACCESS THE BYPASS (PUMP COOLER) LINE,
IF SO EQUIPPED, OR OPEN THE VALVE TO THE BOOSTER TANK TO CIRCU
LATE WATER.
15. When pumping operations are completed, gradually reduce the pump pressure
until the engine returns to IDLE speed.
See heading “Pumping from Draft” on
page 31.
16. Disengage the PTO per the PTO manufacturer’s instructions.
Draft Limiting Factors
(See Table 3-3: “Base Line NFPA Ratings,” on page 31.)
The effect of raised water temperatures when pumping from a positive pressure source (i.e., a hydrant) is negligible on fire pump performance. However, when pumping from draft, elevated water temperature does have a
limiting effect.
-
30
Water temperature above 95°F (35°C) causes a noticeable decrease in lift
when drafting.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
Another factor that can limit LIFT
when drafting is barometric pres
sures below 29 in.Hg. High elevations and storm conditions can
affect maximum flow available from
any pump.
Pumping from Draft
1. Get as close to the water source as
-
Water
Temperature
F° (C°)
60° (16°) NFPA Base Line
70° (21°) 0.3 (7.6)
80° (27°) 0.6 (15.2)
90° (32°) 1.1 (28.0)
100° (38°) 1.7 (43.2)
110°
(43°)
Lift Losses
Head Ft. (mm)
2.5 (63.5)
practical. The pump can draw 100%
of its rated capacity with less than a
Table 3-3: Base Line NFPA Ratings
10 foot (3.05 meters) vertical lift and
20 feet (6 meters) of suction hose.
As the lift increases to above 10 feet (3 meters), pump capacity is reduced.
2. Bring the truck to a complete stop and apply the truck parking brake.
CAUTION !
REFER TO DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS
AND LAYING OUT SUCTION AND DISCHARGE HOSES. ALL VALVES, DRAIN
COCKS, AND CAPS SHOULD BE CLOSED.
3. Shift the truck transmission to NEUTRAL.
4. Make appropriate suction hose connections. Use a high flow suction hose
basket strainer and keep hose out of silt laden areas.
5. Engage the PTO (power take-off) per the PTO manufacturer’s instructions.
(Within a few seconds the shift warning indicator lights, indicating a complete
shift.)
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN
PUMP LIGHTS IN THE CAB AND PANEL ARE ON.
6. Exit the driving compartment only after all the above steps are completed and
the indicator lights in the cab and on the panel are ON.
Silencer Series Booster Pump, p/n: 029-0020-83-0
31
❑ Operation
WARNING !
DO NOT ADVANCE THE THROTTLE UNLESS THE “OK TO PUMP” INDICATOR
IS ON.
7. Verify the pump panel shift indicator light is ON.
8. Activate the priming pump by pulling the control handle located on the pump
panel or pressing the push-button.
Running the engine at speeds higher than 1,200 RPM during priming is not
recommended. It does not improve the priming operation but can cause
damage to the pump.
CAUTION !
IF DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE
GAUGE READING DOES NOT FALL BELOW ZERO, OR THE PRIMING PUMP
DOES NOT DISCHARGE WATER TO THE GROUND
ONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
WITHIN 30 TO 45 SEC-
STOP THE PUMP AND CHECK FOR AIR LEAKS OR
SEE SECTION 5 “TROUBLESHOOTING,” ON PAGE 55.
POSSIBLE PROBLEMS.
9. Monitor the intake and discharge master gauges. The pump is primed when
the intake reading falls below zero (0), and the discharge pressure starts to
increase. Water can also discharge to the ground.
10. Gradually open the discharge valve until water emerges in a steady stream.
Then open the engine throttle gradually until the desired pressure or flow is
achieved.
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 is cavitating. Reduce the flow from the pump to maintain pressure.
Note: Also see heading “Cavitation” on page 36.
11. If a pump shutdown is desired while pumping from draft, reduce the engine
speed to idle, and close the discharge valves.
To resume pumping, open the throttle and discharge valves. To prevent the
pump from overheating due to continued churning without water flow, open
the tank fill valve, the pump cooler valve, or discharge to ground.
32
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
12. Set the automatic relief valve, or governor according to department policy.
See Section 3.3 “Relief Valve Procedures” on page 35.
13. After completing pumping procedures, gradually reduce the engine RPM to
IDLE speed.
See heading “Post Operation procedure” on page 40.
14. Disengage the PTO per the PTO manufacturer’s instructions.
Pumping from Onboard Water Tank
1. Bring the truck to a complete stop and apply the truck parking brake.
NOTICE !
REFER TO THE FIRE DEPARTMENT PROCEDURES ON SETTING WHEEL
CHOCKS AS WELL AS LAYOUT AND CONNECTION OF SUCTION AND DIS
CHARGE HOSES.
-
2. Shift the truck transmission to the NEUTRAL position.
3. Engage the PTO (power take-off) per the PTO manufacturer’s instructions.
(Within a few seconds the shift warning indicator lights, indicating a complete
shift.)
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN
PUMP LIGHTS IN THE CAB AND PANEL ARE ON.
4. Exit the driving compartment only after all the above steps are completed and
the indicator lights in the cab and on the panel are ON.
5. Verify the pump panel shift indicator light is ON.
6. Verify that the green “OK TO PUMP” pump panel shift indicator is ON.
WARNING !
DO NOT ADVANCE THE THROTTLE UNLESS THE “OK TO PUMP” INDICATOR
IS ON.
Silencer Series Booster Pump, p/n: 029-0020-83-0
33
❑ Operation
7. Open the tank suction valve (tank-to-pump).
8. Check the master discharge gauge to see if priming is necessary. If necessary,
start the priming pump by either pulling the control handle located on the pump
panel or pressing the prime push-button.
CAUTION !
IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE
GAUGE READING DOES NOT FALL BELOW ZERO (0), OR THE PRIMING
PUMP DOES NOT DISCHARGE WATER TO THE GROUND IN 30 SECONDS,
DO NOT CONTINUE TO RUN THE PRIMING PUMP. STOP THE PUMP AND
CHECK FOR AIR LEAKS OR POSSIBLE PUMP PROBLEMS.
“TROUBLESHOOTING,” ON PAGE 55.
9. Watch the discharge master pressure gauge. When the pump is primed, the
pressure starts to increase. You can also hear water splashing on the ground
from the primer, indicating that the pump is primed.
SEE SECTION 5
10. Open the engine throttle gradually until the desired pressure or flow is reached.
As the throttle is opened, the discharge pressure gauge reading increases
with the engine speed. If the engine speed increases without an increase in
pressure, the pump could be cavitating and additional flow is not available.
Running the pump while cavitating can damage the pump.
Note: Also see heading “Cavitation” on page 36.
WARNING !
DO NOT OPEN THROTTLE UNLESS ALL GREEN PUMP INDICATOR LIGHTS
ARE ON.
11. Gradually open the discharge valves until the water emerges as a steady
stream. Then open the discharge valves to the desired setting.
12. Set the automatic relief valve or governor according to your fire department
policy. If your fire department does not have a policy to follow,
“Relief Valve Procedures” on page 35.
13. To avoid pump overheating, open the auxiliary pump cooler or slightly open
the tank fill valve. Eventually the booster tank water will become hot. It is
advisable to run at reduced speeds/pressures when not flowing water.
see heading
34
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
14. After completion of pumping procedures, gradually reduce the engine RPM
until it is at an IDLE speed.
40.
15. Disengage the PTO per the PTO manufacturer’s instructions.
See heading “Post Operation procedure” on page
3.2 PUMP AND ROLL OPERATION
During pump and roll operation, it is necessary to slow the forward motion of
the apparatus to the PTO (Power Take-Off) manufacturer's recommended
engagement speed.
The following outlines a general pump and roll procedure:
1. Slow the apparatus to a safe PTO engagement speed as recommended by
the PTO manufacturer. Note that this speed may be STOPPED.
Note: Many PTOs must be engaged while the apparatus is STOPPED.
2. Engage the PTO (power take-off) per the PTO manufacturer’s instructions.
3. Verify the PUMP ENGAGED light is ON.
4. Open the valve between the tank and pump suction.
5. Observe pump discharge pressure and verify the pump pressure increases.
6. Prime the pump if necessary.
7. Open the discharge valves and commence operations.
3.3 RELIEF VALVE PROCEDURES
Be sure to select the correct procedure based on how the truck is equipped.
(See Figure 3-4: “TPM Relief Valve Control,” on page 36.) Some trucks may
utilize a governor in place of the relief valve.
1. Set the pressure indicator on the PMD control valve to a position slightly above
the normal operating pressure (even before water starts to flow).
2. After normal operating pressure has been achieved (as indicated on the master
pressure gauge while the pump is discharging water), slowly move the
adjusting hand wheel counterclockwise until the relief valve opens.
Silencer Series Booster Pump, p/n: 029-0020-83-0
35
❑ Operation
The amber indicator light illuminates. (See
Figure 3-4: “TPM Relief Valve Control.”)
3. Turn the hand wheel slowly clockwise until the
indicator light goes out. The relief valve will
operate at the set pressure.
4. When the pump is not in operation, turn the
hand wheel clockwise back to a position
slightly above the normal operating pressure.
More complete and detailed information can
be found in the relief valve manual.
CAUTION !
THE PRESSURE INDICATOR ON THE PANEL
IS ONLY A ROUGH INDICATION OF TPM
SETTING. ALWAYS USE THE PRECEDING
PROCEDURE TO PROPERLY SET THE TPM
RELIEF VALVE SYSTEM.
TROL.”)
(SEE FIGURE 3-4: “TPM RELIEF VALVE CON-
Figure 3-4: TPM Relief
Valve C o n t ro l
3.4 CAVITATION
(See Figure 3-5: “Sample,
Cavitation Regions.”)
Cavitation can occur while
pumping from draft, in relay, or
from a hydrant. The operator
must be aware of the warning
signs and immediately correct
the situation.
Cavitation can damage the
impeller and other sensitive
components, impair pump per
formance, and reduce flow
capacity. The damage done
during any one period of cavi
tation is not great, but the
effects are cumulative. Implosions occurring during cavitation break away
or erode tiny pieces of metal from the internal parts and the pump casing.
When enough metal has been chipped away, the impeller becomes unbal
anced causing a strain and vibration on bearings, bushings and shafts.
-
-
Figure 3-5: Sample, Cavitation Regions
-
36
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
Process of Cavitation
Cavitation occurs when a centrifugal pump attempts to discharge more
water than it is receiving. When cavitation occurs, bubbles are created
under the vacuum, formed near the eye of the impeller.
Cavitation is often referred to as “the pump running away from the fluid supply.” This means the operator is trying to pump more water out of the pump
than is going into the pump.
The formation of bubbles in the low pressure regions of the impeller cause
the impeller to “slip” in the water, since the impeller is designed to move liq
uid not the air in the bubbles. (See Figure 3-5: “Sample, Cavitation
Regions,” on page 36.)
When increased discharge flow exceeds the intake, bubbles form in the lowpressure region at the eye of the impeller. The pressure of the water in the
pump drops as it flows from the suction flange through the suction nozzle
and into the impeller.
-
As flow from the pump increases, the vacuum at the impeller increases. As
the vacuum increases, the water near the impeller eye begins to boil and
vaporizes.
Once the vapor pockets (bubbles) enter the impeller, the process begins to
reverse itself. As the vapor reaches the discharge side of the pump, it is
subjected to a high positive pressure and condenses back to a liquid.
This sudden change from vapor to liquid generates a shock effect that damages the impeller and pump housing. Usually there are thousands of tiny
vapor pockets (bubbles). It is the collapsing (or implosion) of these bubbles
that causes the characteristic sound of cavitation that has been described
as rocks tumbling in the pump.
Warning Signs of Cavitation (Discharge and Gauges)
Discharge Pressure
In a properly functioning pump, an increase in RPM increases the discharge
pressure and volume. An increase in engine RPM that does not cause an
increase in the pump discharge pressure is the most reliable indication that
a pump is approaching cavitation.
Silencer Series Booster Pump, p/n: 029-0020-83-0
37
❑ Operation
Vacuum Compound Gauge
Do not depend entirely on the vacuum (compound) gauge to indicate when
a pump is nearing cavitation. The vacuum gauge is usually tapped into the
intake chamber several inches away from the leading edge of the impeller
eye where the greatest amount of vacuum occurs. The vacuum gauge does
not take into account ambient temperature nor atmospheric pressure and is
not accurate near zero (0) on the vacuum scale.
To Eliminate Cavitation
To eliminate cavitation, the operator must be aware of the warning signs
listed above. Low barometer, high elevation, and elevated water tempera
ture also contributes 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 most common way to eliminate cavitation is to decrease the amount of
water being discharged by decreasing engine speed or closing discharge
valves. However, this also results in a reduction of flow.
Cavitation is also eliminated by increasing the pump inlet pressure. This is
accomplished with reduced vertical lift, reduced inlet losses, or running from
positive pressure supplies.
During Operations
❑ Do not increase pump speed
beyond the speed at which the
pressure ceases to rise. The
higher the elevation above sea
level, the lower the atmo
spheric pressure and less lift.
(See Table 3-6: “Lift Loss from
Elevation.”)
❑ Open the throttle gradually and
watch the pressure gauge and
the tachometer, if equipped.
An increase in engine RPM
without a corresponding
increase in pressure indicates
cavitation.
Elevation
Feet (Meters)
2,000 (610) NFPA Base Line
3,000 (914) 1.1 (0.33)
4,000 (1,219) 2.2 (0.67)
5,000 (1,524) 3.3 (1.00)
6,000 (1,829) 4.4 (1.34)
7,000 (2,134) 5.5 (1.67)
8,000 (2,438) 6.6 (2.01)
9,000 (2,743) 7.7 (2.35)
10,000 (3,048) 8.8 (2.68)
Table 3-6: Lift Loss from Elevation
Lift Loss
Feet (Meters)
38
Silencer Series Booster Pump, p/n: 029-0020-83-0
❑ Monitor the water temperature.
Operation ❑
Table 3-3: “Base Line NFPA Ratings” on page 31 shows the
amount of lift loss as tempera-
Barometric Reading
in. (mb)
29.9 (1,012.5) NFPA Base Line
Lift Loss
Head Ft. (mm)
tures rise.
29.7 (1,005.8) 0.2 (0.6)
❑ Monitor barometric pressure.
NFPA standard sets a baseline
of 29.9”Hg.
(See Table 3-7: “Lift
Loss from Elevation.”)
29.5 (999) 0.5 (0.15)
29.3 (999.2) 0.7 (0.21)
29.1 (985.4) 0.9 (0.27)
28.9 (987.7) 1.1 (0.33)
28.7 (971.9) 1.4 (0.43)
Preventive Measures
Table 3-7: Lift Loss from Elevation
❑ Regularly inspect suction hoses
to check for air leaks. Air leaks can also cause cavitation.
❑ Consider the size of the suction hose. Table 3-8: “Hose Size vs. Pump
Rating Capacity” lists the NFPA pre-selected hose sizes for each pumprating capacity. Using the appropriately sized hose minimizes the occurrence of cavitation. An undersized suction hose can lead to cavitation.
Hose Diameter
in. (mm)
3”
(76)
4”
(102)
4.5”
(127)
5”
(127)
6”
(152)
Dual
6” (152)
Flow
gpm (lpm)
250 (946) 5.2 (20)
350 (1,325) 2.5 (9.5)
500 (1,893) 5.0 (19) 3.6 (13.6)
750 2,839) 11.4 (43) 8.0 (30) 4.7 (18 1.9 (7.2)
1,000 (3,785) 14.5 (55) 8.5 (32) 3.4 (13)
1,250 (4,732) 13 (49) 5.2 (20)
1,500 (5,678) 7.6 (29) 1.9 (7.2)
1,750 (6,625) 10.4 (39) 2.6 (10)
2,000 (7,571) 3.4 (13)
2,500 (9,464) 5.2 (20)
Lift Loss (gpm (lpm)
Table 3-8: Hose Size vs. Pump Rating Capacity
❑ Consider the piping within the truck. Suction losses can result from addi-
tional suction piping added to the fire pump during assembly.
❑ Follow the maintenance and inspection procedures.
Silencer Series Booster Pump, p/n: 029-0020-83-0
39
❑ Operation
❑ Cavitation can also occur when air enters the pump. The pump could be
primed, however, air leaks can cause rough operation and an increase of
engine speed without an increase in pressure or flow. If an air leak is
suspected,
refer to Section 5 “Troubleshooting” on page 55.
3.5 POST OPERATION PROCEDURE
1. Return the engine to idle.
2. Slowly close all valves.
5. Place the transmission in NEUTRAL or PARK.
3. Slowly shift from PUMP to ROAD to disengage the pump.
4. Drain the pump (especially important in freezing weather):
❑ Open the discharge valves, remove suction tube caps, and discharge valve
caps.
❑ Open the pump body drain cocks or Hale multiple drain valve. If a multiple
drain valve is used, all pump drain lines should be connected to this valve.
❑ After the pump is completely drained, replace all caps and close all valves.
5. If sea water, dirty water, alkaline water or foam solution has been used, flush
the pump with clean water.
6. Remove the wheel chocks only when preparing to leave the scene.
7. Fill out the Pump Run Log, indicating total pumping time and total out-of-station
time.
8. Report all pump, vehicle and equipment malfunctions, and irregularities to the
proper authority.
9. Know and follow all local procedures.
40
Silencer Series Booster Pump, p/n: 029-0020-83-0
4 Preventive Maintenance
4.1 OVERVIEW
Hale Silencer Series Booster Pumps require minimal care and maintenance. Preventive maintenance tasks take little time to perform and consist
primarily of leak testing, lubrication and cleaning.
The procedures provided in this section are for normal use under normal
operating conditions. Extreme conditions require additional maintenance to
ensure lengthened pump life and continuing dependability.
4.2 POST-OPERATION
Preventive Maintenance ❑
Drain Pump
1. Inspect the suction hose and rubber washers, as well as the washers in the
suction tube caps.
2. Remove any foreign matter from the hose and coupling.
3. Replace worn, damaged, or dry washers.
4. Verify all discharge valves, drain valves and drain cocks are closed.
5. Tighten the suction caps.
4.3 EXTREME CONDITIONS
Extreme conditions occur when the pump has been operated during freezing weather or when pumping from a water source that contains material
that is harmful to the pump if not purged.
Silencer Series Booster Pump, p/n: 029-0020-83-0
41
❑ Preventive Maintenance
During Freezing Weather
In freezing weather, drain the pump as follows:
1. Open all discharge and suction valves, remove suction tube caps and discharge valve caps.
2. Open pump body drain cocks and/or Hale multiple drain valve.
3. After the pump is completely drained, replace all caps and close all valves.
Pumping from Salt Water, Contaminated Water, or with Foam Solution
Thoroughly flush the pump and suction hoses using fresh water from a
hydrant or other clean water source.
After pumping foam, flush as above until all residue of foam is flushed from
the system.
4.4 WEEKLY
❑ Test the relief valve system
❑ Test the priming system
❑ Test the pump shift warning indicator lights
❑ Perform valve maintenance
❑ Check and clean the intake strainers
❑ Check any auxiliary engines
❑ Verify all gauges are in working order
❑ Operate pump controls
❑ Inspect water and foam tanks
❑ Check roof and bumper turrets
❑ Follow local maintenance and test procedures
Relief Valve Test
42
When the relief valve is not in operation, keep the hand wheel set above the
normal operating pressure.
(See Figure 4-1: “TPM Relief Valve Control,” on
page 43.)
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
1. Prepare to pump from the onboard water tank, having the discharge flow
directed back to the water tank.
2. Increase the pump pressure up to normal operating pressure as indicated on the master pressure gauge per normal operating procedures.
3. Turn the relief valve hand wheel counterclockwise until the valve opens. The relief valve is
open when the AMBER indicator light is ON and
the pressure begins to drop.
(See Figure 4-1:
“TPM Relief Valve Control.”)
4. Turn the relief valve hand wheel clockwise. The
pressure should return. Cycle the relief valve a
few times to ensure that the hand wheel turns
freely. Observe the pressure gauge and indi
-
cator light for proper valve operation.
5. Return the relief valve hand wheel and the
apparatus to normal operational condition.
Figure 4-1: TPM Relief
Valve C o n t ro l
Priming System
Run primer weekly to ensure proper operation.
With all the valves closed and capped, actuate the primer and make sure
the intake gauge drops below zero (0). The gauge should hold below zero.
If air leaks are heard or the gauge bounces back up to zero (0), the pump or
valves require service.
Pump Shift Warning Indicator Lights
CAUTION !
MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS. VERIFY THE
PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT
ANY MOVEMENT OF THE APPARATUS.
1. Follow the operating procedures in Section 3 to engage the pump if no local
procedures exist.
Silencer Series Booster Pump, p/n: 029-0020-83-0
43
❑ Preventive Maintenance
2. Verify that the warning indicators in the cab and the pump control panel function
properly.
3. Verify that the indicator lights on the control panel function properly and agree
with the indicators in the cab.
4. Repair or replace any malfunctioning indicators.
Valve Maintenance
Properly functioning valves are integral to the operation of the pump. Refer
to the separate valve manual for proper valve maintenance procedures.
Intake Strainers
❑ Check and clean any debris from the intake.
❑ Repair or replace any damaged strainers.
Auxiliary Engine
If the pump is powered by a separate engine, check the engine, fuel tanks
and drive for wear and proper operation.
Verify All Gauges are in Working Order
Any gauge that is repeated in the cab or another panel, must agree with the
gauge on the operator's panel. Gauges not reading within 10% of the cali
brated test gauge must be removed from service and re-calibrated.
Operate Pump Controls
-
44
Operate the pump drive controls to verify the pump engages. Verify the
indicator lights work properly.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Inspect Water and Foam Tanks
Visually inspect water and foam tanks for proper level and gauge readings.
If any debris is present, flush the tanks to protect the pump from wear
caused by dirty water or foam concentrate.
Check Roof and Bumper Turrets
If the apparatus is so equipped, verify that the turrets function properly, and
no leaks are present. Make repairs immediately.
Visually inspect all piping and valves on the pump and auxiliary equipment
for corrosion or damage.
4.5 MONTHLY
Preventive Maintenance ❑
❑ Check the gearbox oil
(See Figure 4-2: “Gearbox Capacity / Recommended Lubricants.”)
❑ Check the drive line bolts
❑ Perform the dry vacuum test
Gearbox Lubrication
Gearbox
Orientation
Vertical
Horizontal
(Right or
Left Hand)
Inverted
All lubricants must
meet service rating API
GL-5 requirements
Approximate
Capacity
2 Quarts
(1.9 Liters)
1.5 Quarts
(1.4 Liters)
1.75 Quarts
(1.7 Liters)
Capacity Chart
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 4-2: Gearbox Capacity / Recommended Lubricants
45
❑ Preventive Maintenance
Incorrect oil types or amounts of oil result in unnecessary loss of power and
high oil temperature. Change the oil every 12 months, depending on pump
usage. All lubricants must meet service rating API GL-5 requirements.
(See Figure 4-2: “Gearbox Capacity / Recommended Lubricants,” on page
45.)
Note: Hale recommends using an SAE EP-90, 80W90 Lubricant or
“RoadRanger” Full Synthetic SAE 50 Transmission Lubricant, manufactured by
®
the Eaton
Corporation, or equivalent.
1. Remove the gearbox oil fill plug, and
check the level of the oil in the gearbox.
(See Figure 4-3: “Typical Drain, Fill and
Level Plugs.”)
2. The oil level should be up to the bottom
of the plug hole.
3. If the oil appears white or “milky,” a
water leak is indicated. Remove the
drain plug and drain the oil into a suit
able container. Examine the oil for
metal flakes or other contamination.
-
4. Either of these conditions indicates
maintenance is required on the unit.
Drive Line and Flange Bolts
Figure 4-3: Typical Drain, Fill and
Level Plugs
Check all drive line and flange bolts to ensure:
1. No bolts are missing.
2. All bolts are tight. Use a torque wrench to torque bolts to the drive train
manufacturer's recommended specifications.
Priming System Test (Dry Vacuum Test)
(Refer to NFPA 1901 or NFPA 1911)
1. Close all valves and drains. Cap all suction openings and the outlet of the
suction side relief valve (if equipped).
46
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
2. Connect a test vacuum gauge or manometer to the intake test gauge connection on
the pump panel.
3. Engage the priming pump until the gauge
indicates at least 22” Hg vacuum.
(See
Figure 4-4: “PVG Priming Valve Handle.”)
4. Compare the readings of the test gauge
and the apparatus gauge. Note any differ
ence.
-
Figure 4-4: PVG Priming Valve
Handle
5. STOP the priming pump and observe the gauge. If the vacuum falls more
than 10” Hg. in 5 minutes, it is an indication of at least one air leak.
6. Vacuum leaks can often be detected by ear if the apparatus engine is turned
OFF. Correct leaks immediately before returning the pump to service.
7. Test the suction hose as follows:
a. Attach the suction hose to the pump.
b. Place a suction tube cap on the end of the hose in place of a strainer.
c. Close all valves and drains. Cap all suction openings and the outlet of the
suction side relief valve (if so equipped).
d. Connect a calibrated vacuum gauge or manometer to the intake test gauge
connection on the pump panel.
e. Engage the priming pump until the gauge indicates at least 22” Hg vacuum.
f. Watch the gauge. If the vacuum falls more than 10 inches in 5 minutes,
it indicates at least one air leak.
g. Verify the test gauge and the apparatus gauge display the same readings.
Repair or replace any gauges that do not display the correct pressure.
IMPORTANT !
IF LEAKS CANNOT BE DETECTED BY FOLLOWING THE PROCEDURE, IT IS
ADVISABLE TO TEST THE PUMP HYDROSTATICALLY. TO TEST:
❑ OPEN ALL VALVES
❑ PLACE CAPS ON ALL VALVES
❑ CONNECT A POSITIVE PRESSURE SOURCE
❑ INSPECT THE PUMP FOR LEAKS
Silencer Series Booster Pump, p/n: 029-0020-83-0
47
❑ Preventive Maintenance
4.6 ANNUALLY
❑ Replace the pump gearbox oil. (See Figure 4-2: “Gearbox Capacity /
Recommended Lubricants,” on page 45.)
❑ Check individual drain lines from the pump to the multi-drain to ensure
proper drainage and protection from freezing temperatures.
❑ Test tank-to-pump flow rate. (See page 49.)
❑ Clean ESP Primer, if installed. (See separate manual provided.)
❑ Perform the yearly pump test to check performance levels. (See NFPA
Standard 1911 for more details.)
Replace Gearbox Oil
1. Remove the drain plug (magnetic) and drain the gearbox oil into a suitable
container.
(See Figure 4-3: “Typical Drain, Fill and Level Plugs,” on page 46.)
Note: Assembly orientation determines which plugs are used for oil fill, drain and
level detection. See installation plate drawings located at the back of this manual.
2. Examine the oil for contamination (e.g., water – turns the oil a milky color or
settles to the bottom). Properly dispose of the used oil.
3. Inspect the magnetic drain plug. If metal filings are present on the drain plug,
remove the cover plate to visually inspect and clean the internal components.
Repair or replace components as necessary. See Section 6 “Repair” on page
61
4. Replace the cooler or cover, if necessary. Remove the oil fill plug and the
level detect plug. Clean the drain plug (magnetic).
5. Fill the gearbox with an approved gear oil until oil just begins seeping from the
level plug opening.
See Figure 4-3: “Typical Drain, Fill and Level Plugs” on
page 46 for fluid types and quantities.)
6. Install all plugs.
48
Check Drain Lines to Multi-Drain
Drains are supplied on the pump and piping at the lowest points where
water could collect and freeze, rendering the pump ineffective.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
Most of these drains are piped together to a multi-drain to allow the entire
system to be drained by one valve.
It is necessary to inspect each line of the multi-drain to ensure the entire
system is draining when the valve is operated. Inspect each connection
and verify the individual lines to the multi-drain are free of debris. Repair or
replace any lines that are damaged, kinked, or corroded.
Tank-to-Pump Flow Rate Test
Note: This procedure is provided as a reference only. It does not supersede any
local procedures.
1. Fill the water tank until it overflows.
2. Close the tank fill line, bypass the cooling line, and all the pump intakes.
3. Attach sufficient hose lines and nozzles to pump the desired discharge rate.
4. With the pump in gear, open the discharge to which the hose is attached and
begin pumping water.
5. Increase the engine throttle until the maximum consistent pressure is obtained
on the discharge gauge.
6. Close the discharge valve without changing the throttle setting. Refill the tank
through the top fill opening or a direct tank line. The bypass valve may be
opened during this time to prevent pump overheating.
7. Reopen the discharge valve, and check the flow through the nozzle using a
Pitot tube or flow meter. Adjust the engine throttle to bring the pressure to the
amount previously determined.
8. Compare the flow rate measured to the NFPA minimum or the designed rate
of the pump. If the flow rate is lower, a problem exists in the tank-to-pump
line. The minimum flow rate should be continuously discharged until 80% of
the tank is discharged.
The pump should not experience mechanical problems, power loss, or overheat during the test.
Silencer Series Booster Pump, p/n: 029-0020-83-0
49
❑ Preventive Maintenance
Performance Testing Overview
The yearly standard performance test consists of checking the pump
(according to its rating) at three capacities and comparing the results to
when the pump was first placed in service. This provides some measure of
any performance deterioration.
LPM),” on page 50.)
A pump must be able to pump FULL capacity at 150 PSI, 70% capacity at
200 PSI and 50% capacity at 250 PSI.
(See Figure 4-5: “Pump Ratings (GMP/
Capacity
FULL 150 (10)
70% 200 (14)
50% 250 (17)
Pressure
PSI (BAR)
250
(946)
250
(946)
150
(568)
125
(473)
Pump Rating in GPM (LPM)
350
(1,325)
350
(1,325)
245
(927)
175
(663)
450
(1,703)
450
(1,703)
315
(1,192)
225
(852)
500
(1,893)
500
(1,893)
350
(1,325)
250
(946)
750
(2,893)
750
(2,839)
525
(1,987)
375
(1,420)
1,000
(3,785)
1,000
(3,785)
700
(2,650)
500
(1,893)
Figure 4-5: Pump Ratings (GMP/LPM)
Performance Testing Equipment and Materials
To accurately test pumper performance, requires a Pitot gauge, a calibrated
pressure gauge, and a vacuum gauge or manometer.
All gauges must be carefully tested for accuracy. Testing is appropriately
accomplished with a certified dead weight gauge tester.
Use smooth bore test nozzles of accurate size with the Pitot Gauge, or
other suitable measuring device. The volume pumped is then determined
by referring to the discharge tables for smooth nozzles. Preferably, nozzles
are used on a deluge gun for greatest accuracy. A stream straightener, just
upstream of the nozzle, is advisable.
50
REFER TO LOCAL PROCEDURES FOR PUMP TESTING PROCEDURES
AND PRACTICES AS WELL AS APPLICABLE NFPA STANDARDS.
For Pitot Gauge accuracy, the nozzle pressures should be between 30 and
85 PSIG (2.1 and 6.0 BAR).
(See Table 4-6: “Nozzle Flow and Pressure
Ratings, Part 1,” on page 52.) Also see Table 4-7: “Nozzle Flow and Pressure Ratings, Part 2” on page 53.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
The amount of discharge hose required for the service tests is dependent
on the flow requirements and capacity test point. Provide adequate hose to
discharge the rated capacity with a flow velocity less that 35 ft./sec.
Also
see “Appendix D: Hose Friction Loss” on page 103 at the back of this
manual.
Since NFPA standards specify both GPM and pressure, it is usually necessary to restrict the flow somewhat to build up the pump pressure. In normal
pumping, this restriction would be caused by the friction loss in the lines. It
is common practice to gate the discharge valves as required to maintain
pressure.
Performance Testing
Note: The NFPA standards require a 10% reserve in pressure at the capacity
run when the apparatus is delivered.
1. Check the relief valve according to the Relief Valve Test procedure. See
heading “Relief Valve Test” on page 42.
2. Perform steps 2 and 3 of the Post-Operation procedures. See Section
3.5 “Post Operation procedure” on page 40.
3. Run the standard pump test in accordance with NFPA standards to
check pump performance.
4. “Silencer” Series Pumps rated below 750 GPM are tested fifty (50) minutes per NFPA 1901, 14-13.2.3.2.
Run the engine to stabilize engine temperature, then run the pump for:
❑ Thirty (30) minutes at FULL capacity and at 150 PSI (10 BAR)
❑ Ten (10) minutes at 70% capacity and at 200 PSI (14 BAR)
❑ Ten (10) minutes at 50% capacity and at 250 PSI (17 BAR)
5. For Model “MBP” Series Pumps, rated at 750 GPM and 1,000 GPM
(2,839 and 3,785 LPM) a three (3) hour test is required, as follows:
❑ Two (2) hours at FULL capacity and at 150 PSI (10 BAR)
❑ Thirty (30) minutes at 70% capacity and at 200 PSI (14 BAR)
❑ Thirty (30) minutes at 50% capacity and at 250 PSI (17 BAR)
Silencer Series Booster Pump, p/n: 029-0020-83-0
Additionally, an engine overload test is required which consists of pumping at FULL capacity and at 165 PSI (11 BAR) for ten (10) minutes.
51
❑ Preventive Maintenance
SEZISELZZONSUOIRAVta)MPL(MPG
elzzoN
erusserP
)RAB(ISP )31("2/1 )61("8/5 )91("4/3 )22("8/7 )4.52("1 )92("8/1-1 )23("4/1-1 )53("8/3-1
)1.2(03
)4.2(53
)7.2(04
)1.3(54
)5.3(05
)8.3(55
)1.4(06
)3.4(26
)4.4(46
)6.4(66
)7.4(86
)8.4(07
)0.5(27
)1.5(47
)2.5(67
)551(14)242(46)843(29)374(521)716(361)087(602)269(452)661,1(803
)761(44 )162(96 )573(99 )115(531 )666(671 )048(222 )140,1(572 )752,1(233
)871(74)692(37)104(601)545(441)117(881)109(832)311,1(492)433,1(553
)981(05 )592(87 )424(211 )975(351 )357(991 )459(252 )771,1(113 )734,1(773
)102(35)013(28)744(811)016(161)597(012)700,1(662)242,1(823)305,1(793
)802(55 )623(68 )964(421 )046(961 )338(022 )650,1(972 )203,1(443 )975,1(714
)022(85)143(09)294(031)666(671)178(032)201,1(192)363,1(063)746,1(534
)022(85 )543(19 )005(231 )876(971 )688(432 )121,1(692 )583,1(663 )376,1(244
)322(95)253(39)705(431)986(281)109(832)931,1(103)404,1(173)007,1(944
)722(06 )653(49 )515(631 )007(581 )219(142 )551,1(503 )724,1(773 )627,1(654
)132(16)363(69)225(831)117(881)729(542)471,1(013)054,1(383)357,1(364
)532(26 )763(79 )035(041 )917(091 )939(842 )291,1(513 )964,1(883 )977,1(074
)832(36)573(99)835(241)137(391)459(252)802,1(913)294,1(493)608,1(774
)242(46 )973(001 )545(441 )247(691 )569(552 )322,1(323 )015,1(993 )828,1(384
)642(56)283(101)355(641)057(891)089(952)242,1(823)335,1(504)558,1(094
)sretemilliM(sehcnIni,eziSelzzoN
)4.5(87
)5.5(08
)9.5(58
)2.6(09
)6.6(59
)9.6(001
)2.7(501
)6.7(011
)9.7(511
)3.8(021
)052(66 )093(301 )065(841 )167(102 )299(262 )752,1(233 )255,1(014 )878,1(694
)052(66)493(401)865(051)867(302)700,1(662)631(63)175,1(514)009,1(205
)752(86 )504(701 )385(451 )597(012 )730,1(472 )700,1(743 )026,1(824 )169,1(815
)562(07)614(011)206(951)818(612)760,1(282)700,1(753)666,1(044)810,2(335
)372(27 )824(311 )716(361 )048(222 )490,1(982 )700,1(663 )117,1(254 )170,2(745
)082(47)934(611)263(761)368(822)421,1(792)700,1(673)657,1(464)721,2(265
)882(67 )154(911 )746(171 )288(332 )151,1(403 )700,1(583 )208,1(674 )771,2(575
)592(87)264(221)366(571)509(932)771,1(113)700,1(493)448,1(784)032,2(985
)303(08 )374(521 )876(971 )429(442 )802,1(913 )700,1(304 )588,1(894 )972,2(206
)703(18)184(721)217(381)349(942)032,1(523)700,1(214)729,1(905)823,2(516
Table 4-6: Nozzle Flow and Pressure Ratings, Part 1
52
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
SEZISELZZONSUOIRAVta)MPL(MPG
elzzoN
erusserP
)RAB(ISP )83("2/1-1 )14("8/5-1 )54("4/3-1 )84("8/7-1 )15("2 )75("4/1-2 )46("2/1-2 )67("3
)1.2(03
)4.2(53
)7.2(04
)1.3(54
)5.3(05
)8.3(55
)1.4(06
)3.4(26
)4.4(46
)6.4(66
)7.4(86
)8.4(07
)0.5(27
)1.5(47
)2.5(67
)4.5(87
)5.5(08
)9.5(58
)2.6(09
)6.6(59
)9.6(001
)2.7(501
)6.7(011
)9.7(511
)3.8(021
)683,1(663)826,1(034)588,1(894)560,2(275)464,2(156)911,3(428)058,3(710,1)245,5(464,1
)594,1(593 )657,1(464 )730,2(835 )933,2(816 )166,2(307 )963,3(098 )651,4(890,1 )589,5(185,1
)106,1(324)878,1(694)771,2(575)894,2(066)348,2(157)006,3(159)444,4(471,1)104,6(196,1
)696,1(844 )789,1(525 )903,2(016 )056,2(007 )710,3(797 )028,3(900,1 )317,4(542,1 )787,6(397,1
)197,1(374)101,2(555)434,2(346)497,2(837)081,3(048)420,4(360,1)079,4(313,1)451,7(098,1
)878,1(694 )302,2(285 )555,2(576 )039,2(477 )533,3(188 )122,4(511,1 )312,5(773,1 )305,7(289,1
)169,1(815)203,2(806)966,2(507)260,3(908)384,3(029)014,4(561,1)444,5(834,1)048,7(170,2
)199,1(625 )933,2(816 )017,2(617 )211,3(228 )045,3(539 )284,4(481,1 )435,5(264,1 )869,7(501,2
)520,2(535)773,2(826)657,2(827)161,3(538)695,3(059)455,4(302,1)126,5(584,1)390,8(831,2
)650,2(345 )114,2(736 )797,2(937 )012,3(848 )356,3(569 )626,4(222,1 )807,5(805,1 )222,8(271,2
)680,2(155)944,2(746)938,2(057)952,3(168)017,3(089)496,4(042,1)697,5(135,1)343,8(402,2
)611,2(955 )384,2(656 )688,2(167 )903,3(478 )367,3(499 )267,4(852,1 )978,5(355,1 )464,8(632,2
)641,2(765)125,2(666)229,2(277)453,3(688)618,3(800,1)038,4(672,1)269,5(575,1)585,8(862,2
)771,2(575 )555,2(576 )469,2(387 )093,3(898 )968,3(220,1 )598,4(392,1 )540,6(795,1 )307,8(992,2
)702,2(385)985,2(486)200,3(397)544,3(019)229,3(630,1)369,4(113,1)521,6(816,1)028,8(033,2
)332,2(095 )326,2(396 )040,3(308 )094,3(229 )179,3(940,1 )720,5(823,1 )402,6(936,1 )739,8(163,2
)462,2(895)756,2(707)180,3(418)635,3(439)420,4(360,1)190,5(543,1)482,6(066,1)150,9(193,2
)233,2(616 )737,2(327 )671,3(938 )546,3(369 )541,4(590,1 )742,5(683,1 )774,6(117,1 )133,9(564,2
)004,2(436)618,2(447)662,3(368)157,3(199)662,4(721,1)204,5(724,1)666,6(167,1)006,9(635,2
)464,2(156 )698,2(567 )853,3(788 )858,3(810,1 )483,4(851,1 )945,5(664,1 )848,6(908,1 )168,9(506,2
)925,2(866)869,2(487)544,3(019)259,3(440,1)794,4(881,1)396,5(405,1)720,7(658,1)811,01(37
)395,2(586 )440,3(408 )925,3(239 )050,4(070,1 )706,4(712,1 )338,5(145,1 )002,7(209,1 )863,01(937,2
)456,2(107)511,3(328)116,3(459)541,4(590,1)717,4(642,1)079,5(775,1)073,7(749,1)116,01(3
)417,2(717 )481,3(148 )596,3(679 )042,4(021,1 )328,4(472,1 )601,6(316,1 )735,7(199,1 )358,01(768,2
)177,2(237)252,3(958)477,3(799)133,4(441,1)529,4(103,1)532,6(746,1)007,7(430,2)480,11(8
)sretemilliM(sehcnIni,eziSelzzoN
6,2
08,2
29,2
6. If the apparatus does not reach performance levels, proceed to Section
7. Compare the results of this test to those from when the apparatus was
8. If the apparatus performance has dropped appreciably compared to its
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table 4-7: Nozzle Flow and Pressure Ratings, Part 2
5 “Troubleshooting” on page 55.
delivered.
original performance, the unit needs servicing.
53
❑ Preventive Maintenance
Worn Clearance Rings and Impeller Hubs
Before assuming that clearance ring wear is at fault or that clearance ring
replacement requires pump disassembly, it is advisable to thoroughly check
other possible causes of low performance.
Clearance rings limit the internal bypass of water from the discharge side of
the pump back to suction. The radial clearance between the impeller hub
and the clearance rings is only a few thousandths of an inch when new. In
clear water, the clearance rings continue to effectively seal for many hours
of operation.
In dirty or sandy water, the impeller hub and clearance rings wear faster.
The more wear, the greater the bypass and lower pump performance.
It should not be necessary to replace clearance rings until a loss in pump
performance is noticed during the annual test –
Overview” on page 50. For clearance ring and impeller service, proceed to
Section 6, heading “Impeller” on page 71.
see “Performance Testing
Often, replacement of the clearance rings reduces the bypass and restores
the pump to near original performance. A complete restoration requires that
the impellers also be replaced.
maintenance and repair information if pump disassembly is required.
See Section 6 “Repair” on page 61 for
Anode Check
The zinc anodes should be
inspected every 12 months.
Replace when over 75% of the zinc
has been consumed. Performance
of the anode life varies with water
quality and pH. Anodes conform to
MIL Spec. A180001.
Figure 4-8: Hale Anode
54
Silencer Series Booster Pump, p/n: 029-0020-83-0
5 Troubleshooting
Table 5-2 lists conditions, possible causes
and suggested corrective action mea
sures. Before calling Hale Products or a
Hale authorized parts service center for
assistance, eliminate problem causes
using the following table.
If you cannot correct a problem, please
have the Model and Serial numbers
ready prior to calling the Hale Customer
Service Technician Department for assis
tance. Customer Service telephone number: 610-825-6300.
Troubleshooting ❑
-
-
Figure 5-1: Sample, Serial Nameplate
Condition
PTO WILL NOT ENGAGE
PUMP LOSES
PRIME OR WILL
NOT PRIME
Note: Weekly priming is recommended to ensure
proper operation.
See Section “Priming Valves” on page
22.
Chart continued on
next page.
Note: The serial number location varies depending on the pump model, but it is
generally displayed on the pump operator's panel and/or the side of the gearbox.
Possible
Cause
• Consult the PTO Manufacturer’s Instructions.
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE
GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ILLUMINATED
Electric priming
system
Defective priming
system
Suction lifts too high
• NO recommended engine speed is required to operate the electric primer. However, 1,000 engine RPM maintains the electrical
system while providing enough speed for initial pumping opera
tions. Also see heading “Priming Valves” on page 22.
• Check the priming system by performing a “Dry Vacuum Test” per
NFPA standards. If the pump holds vacuum, but primer pulls less
than 22” Hg, it could indicate excessive wear in the primmer.
• Also see heading “Priming Valves” on page 22.
• Repair and/or replace accordingly.
• DO NOT attempt lifts exceeding 22 feet (6.7 meters) except at low
elevation.
Suggested Corrective Action
-
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 5-2: Troubleshooting Charts
55
❑ Troubleshooting
Condition
PUMP LOSES
PRIME OR WILL
NOT PRIME continued
Possible
Cause
Blocked suction
strainer
Suction connections
Air trapped in suction line
Insufficient priming
DO NOT RUNTHE PRIMER OVER FORTH-FIVE (45) SECONDS. IF PRIME IS
NOT ACHIEVED WITHIN 45 SECONDS, STOP AND LOOK FOR CAUSES
Suggested Corrective Action
• Remove obstruction from suction hose strainer.
• Thoroughly clean strainer screen.
• Avoid placing any part of the suction hose higher than the suction
intake.
• Suction hose should be laid out with continuos decline to fluid
supply.
• Avoid placing any part of suction hose higher than the suction
intake.
• Suction hose should be laid with continuous decline to fluid
supply.
• Proper priming procedures should be followed.
• Do not release the primer control before assuring a complete
prime.
• Open the discharge valve slowly during completion of prime to
ensure complete prime.
NOTICE !
(AIR LEAKS OR BLOCKED SUCTION HOSES.)
Chart continued on
next page.
Air trapped in suction line.
Pump pressure too
low when nozzle is
opened.
Air leaks
• Avoid placing any part of suction hose higher than the suction
intake.
• Suction hose should be laid with continuous decline to fluid
supply.
• If air trapped in hose is unavoidable, repeated priming may be
necessary to eliminate air pockets in suction hoses.
• Prime pump again and maintain higher pump pressure while
opening the discharge valve slowly.
• Attempt to located and correct air leaks using the following
• procedures:
•
• Perform “Dry Vacuum Test” on pump per NFPA standards with 22”
minimum vacuum required with loss not to exceed 10” of vacuum
in five (5) minutes.
• If a minimum of 22” of vacuum cannot be achieved, the priming
device or system may be defective, or the leak is too big for the
primer to overcome (such as an open valve).
• After priming shut off the engine. Audible detection of a leak is
often possible.
56
Figure 5-2: Troubleshooting Charts
Silencer Series Booster Pump, p/n: 029-0020-83-0
Troubleshooting ❑
Condition
PUMP LOSES
PRIME OR WILL
NOT PRIME continued
INSUFFICIENT PUMP CAPACITY
Possible
Cause
Insufficient engine
power
Relief valve improperly set - if so
equipped
Suction hose diameter is too small for
the volume being
discharged
Suggested Corrective Action
• Connect the suction hose from the hydrant or the discharge of
another pumper to pressurize the pump with water and look for
visible leakage and correct. A pressure of 100 PSI (6.9BAR)
should be sufficient. DO NOT exceed pressure limitations of
pump, accessories or piping connections.
• The suction side relief valve can leak. Plug the valve outlet
connection and retest
• Engine power check and tune up may be required for peak engine
and pump performance.
• Also see heading “ROTATION SYSPTOMS” on page 60.
• If relief valve pressure is set too low it allows the valve to open
and bypass water.
• Reset the relief valve pressure accordingly.
• See Section 4 Preventive Maintenance, heading “Relief Valve
Test” on page 42.
• Use larger sustain hose.
• Shorten total length by remove one length at a time.
• Reduce volume of discharge.
INSUFFICIENT PRESSURE
VALVE REMOTE
CONTROL DIF
FICULT TO
OPERATE
ENGINE SPEEDS
TOO HIGH FOR
REQUIRED
CAPACITY OR
PRESSURE
Restriction in suction line at strainer
Air leaks
Partial collapse of
the lining in the suc
tion hose
Insufficient engine
power
Lack of lubrication
Lift too high, suction
hose too small
• Remove any debris restricting entrance of water at the strainer.
• See Section 4 Preventive Maintenance, heading “Intake Strainers” on page 44.
• See heading “Air leaks” under condition “ Pump Loses Prime or
WIll Not Prime” on page 56.
• Damage to the outer lining may allow air between the outer and
-
inner linings causing a partial collapse.
• Replace hose and retest.
• See previous section, Insufficient Pump Capacity.
• Lubricate the remote control linkages and collar with oil.
• Higher than normal lift (10 ft./3.1m)) causes higher engine
speeds, high vacuum and rough operation.
• Use larger suction hose.
• Move the pump closer to the water source.
Chart continued on next page.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 5-2: Troubleshooting Charts
57
❑ Troubleshooting
Condition
ENGINE SPEEDS
TOO HIGH FOR
REQUIRED
CAPACITY OR
PRESSURE continued
Possible
Cause
Faulty suction hose
Blockage at suction
hose entry
Worn pump impeller(s) or clearance
rings
Impeller blockage
Suggested Corrective Action
• Inner line of suction hose may collapse when drafting and is usually undetectable.
• Try a different suction hose on the same pump.
• Test for comparison against original hose.
• Clean suction hose strainer of obstruction. See Section 4 Preventive Maintenance, heading “Intake Strainers” on page 44.
• Follow recommended practices for laying suction hose.
• Keep off the bottom of the fluid supply by at least 2 feet (0.6
meters) below the surface of the fluid.
• Repair and/or replace as needed. See Section 6 Repair, heading
“Servicing the Booster Pump” on page 69.
• A blocked impeller can prevent loss of both capacity and
pressure.
• Back flushing the pump from discharge to suction may free the
blockage.
• Removing half the pump body may be necessary - this is considered a major repair.
CAVITATION
(Pump beginning
to cavitate.)
Note: Also see
heading “Cavitation” on page 36.
Chart continued on
next page.
Pump is approaching “Cavitation”
Discharging more
water than the pump
is taking in
Air leak
Drafting too high
Water temperature
too high
Figure 5-2: Troubleshooting Charts
• Gate the discharge valves to allow pressure to increase. This
reduces the flow.
• Reduce the throttle opening to the original pressure setting.
• Also see heading “Cavitation” on page 36.
• Increase the flow into the pump with more and/or larger intake
lines.
• Gate the discharge valves to reduce flow and maintain pressure.
• Verify that the air bleeder on the suction tube is NOT open.
• Locate and eliminate all air leaks during maintenance.
• Verify lift hose, hose friction, water temperature and other lift limiting factors are reduced or eliminated.
• Locate the pump closer to the water source.
• Reduce volume discharge by lowering the RPM or gating the discharge valves.
• Locate a source of cooler water.
58
Silencer Series Booster Pump, p/n: 029-0020-83-0
Troubleshooting ❑
Condition
RELLEF VALVE
DOES NOT
RELIEVE PRES
SURE WHEN
VALVES ARE
CLOSED
RELIEF VALVE
DOES NOT
RECOVER AND
RETURN TO
ORIGINAL
PRESSURE SET
TING AFTER
OPENING
VA LV E S
RELIEF VALVE
OPENS WHEN
CONTROL
VA LV E I S
LOCKED OUT
Possible
Cause
Incorrect setting of
control (PDM) Valve
-
Relief valve
inoperative
Dirt in system causing sticky or slow
reaction
Relief valve
-
inoperative
Drain hole in housing, piston or sensing valve is blocked
Suggested Corrective Action
• Check and repeat proper procedures for setting relief valve
system.
• See Section 3 Operation, heading “Relief Valve Procedures” on
page 35.
• Possibly in need of lubrication. Remove valve from pump, dismantle, clean and lubricate.
• Refer to relief valve manual and follow maintenance instructions
for disassembly, cleaning and lubrication.
• Check and repeat proper procedures for setting the relief valve
system.
• See Section 3 Operation, heading “Relief Valve Procedures” on
page 35.
• Blocked bleed orifice - clean the bleed orifice with a small wire or
straightened paper clip.
• Refer to relief valve manual and follow maintenance instructions
for disassembly, cleaning and lubrication.
• Clean the valve drain hole with a small wire or straightened paper
clip.
• Refer to relief / sensing valve manual and follow maintenance
instructions for disassembly, cleaning and lubrication.
UNABLE TO
OBTAINE
PROPER SET
TING ON
RELIEF VALVE
Chart continued on
next page.
Using the wrong
procedures
Blocked strainer
Dirty control valve
“Hunting” condition
• Check instructions for setting the relief valve and reset.
• See Section 3 Operation, heading “Relief Valve Procedures” on
page 35.
• Check and clean the strainer in the supply line from the pump discharge to the control valve. Check truck manual for the exact
location.
• Check and clean tubing lines related to the relief and control
valves.
• Remove the control valve and clean.
• Insufficient water supply from the pump to the control valve.
• Check the strainer and relief valve system for flow restrictions.
• Remove and clean the control valve.
Figure 5-2: Troubleshooting Charts
Silencer Series Booster Pump, p/n: 029-0020-83-0
59
❑ Troubleshooting
Condition
DISCHARGE
VALVES DIFFI
CULT TO OPERATE
WAT E R IN P UM P GEARBOX
ROTATION SYMPTOMS
(Reduced pressure
60-100 PSI [4.1-
6.9BAR] and
reduced flow.)
-
Possible
Cause
Lack of lubrication
Valve in need of
more clearance for
operation
Leak coming from
above the pump
Leaking mechanical
seal
Wrong impeller
installed
Impellers installed
backwards (twostage pump)
Suggested Corrective Action
• Recommended weekly lubrication of discharge and suction valve.
• Use a good grade petroleum based silicone grease.
• Foe Hale Products, SVS Valves, etc., use Never-Seize® White
Food Grade with PTFE.
• Refer to separate valve manual for addition information.
• Multi-gasket design allows additional gaskets fro more clearance
and free operation.
Note: Adding too many gaskets to the valve eventually causes leakage.
• Check all piping connections and tank overflow for possible spillage falling directly onto the pump gearbox.
• Repair accordingly.
• Inspect the oil seal and replace as needed. If the oil seal checks
OK, then the mechanical seal may need to be replaced.
• If a mechanical seal is installed there must be no leaks. See Section 6 Repair, heading “Mechanical Seal Assembly” on page 74.
• Verify the new impeller vanes are oriented the same as the old
impeller before installing.
tion,” on page 3-19.)
• Refer to relief / sensing valve manual and follow maintenance
instructions for disassembly, cleaning and lubrication.
• Verify the impellers are in the correct order - p/n: 016-0280-00-0 is
installed closest to the gearbox in an “Engine Rotation” applica
tion and CLosest to the front in a “Opposite Engine Rotation”
application.
(See Figure 2-6: “Pump/Engine Rota-
-
60
Wrong application
attempted
IT IS POSSIBLE TO REASSEMBLE THE PUMP INCORRECTLY OR WITH
THE WRONG PARTS. ALWAYS COMPARE THE REPLACEMENT PARTS
WITH THE ORIGINAL HARDWARE. CONTACT CUSTOMER SERVICE AT HALE
• The pump was installed on an application for which it was not
intended, i.e., front mount vs. rear mount.
NOTICE !
PRODUCTS TO ANSWER QUESTIONS OR CONCERNS.
Figure 5-2: Troubleshooting Charts
Silencer Series Booster Pump, p/n: 029-0020-83-0
6 Repair
Preventive Maintenance ❑
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 6-1: Silencer Series Booster Pump
61
❑ Preventive Maintenance
Gearbox
Orientation
Vertical
Horizontal
(Right or
Left Hand)
Inverted
All lubricants must
meet service rating API
GL-5 requirements
Approximate
Capacity
2 Quarts
(1.9 Liters)
1.5 Quarts
(1.4 Liters)
1.75 Quarts
(1.7 Liters)
Figure 6-2: Gearbox Capacity / Recommended Lubricants
Bolt Size
Lock Nut size
3/8-16 Zinc-Plated Steel 30 (41)
Material
Minimum Torque
Ft.-Lb. (N-m)
7-16-14 Zinc-Plated Steel 50 (68)
7/16-14 Silicon Bronze 29 (39)
- 06 Zinc-Plated Steel 32-60 (43-81)
- 07 Zinc-Plated Steel 32-60 (43-81)
6.1 OVERVIEW
This section describes the removal, inspection, and reinstallation (as
required for maintenance and repair) of the Silencer Series Booster Pump
and gearbox components. To completely dismantle the pump and gearbox,
follow the disassembly instructions in the order which they appear in this
text. At any point in the disassembly process, the unit can be reassembled
by following the instructions in the reverse.
Service should be performed by a trained and qualified service technician,
or your authorized Hale Products service representative. Be sure you have
sufficient knowledge, experience and the proper tools.
Table 6-3: Torque Values Chart
62
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
It is recommended to use Hale genuine replacement parts for optimum
safety of the equipment and its operators and to avoid unnecessary down
time.
For an illustrated pump and gearbox overview, see Figure 6-1: “Silencer
Series Booster Pump” on page 61.
6.2 GENERAL REPAIR GUIDELINES
Before You Begin...
Figure 6-1: Silencer Series Booster Pump, on page 61, for a pump and
gearbox overview.
READ ALL INSTRUCTIONS THOROUGHLY
BEFORE BEGINNING ANY SERVICE REPAIR.
-
1. Place apparatus out of service in accordance with your departmental
procedures.
2. Park the vehicle on a level surface. Set the parking brake and chock the front
and rear wheels.
3. Match mark, tag and/or note the orientation of all mechanical and electrical
components and connections to the pump and/or gearbox before disconnect
ing or removing them. This aids in proper reassembly.
4. Determine best method for servicing, i.e., servicing while in the apparatus or
removal from the top or bottom of the apparatus.
WARNING !
BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP BODY.
THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY,
WEIGHING UP TO 145 LBS. (54 KGS.). ADDED ACCESSORIES MAY
INCREASE THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT
DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR
INSTALLING THE SILENCER SERIES BOOSTER PUMP AND GEARBOX
ASSEMBLIES.
-
Silencer Series Booster Pump, p/n: 029-0020-83-0
63
❑ Preventive Maintenance
5. Make sure there is sufficient clearance above and around the apparatus to
perform your service requirements. Obtain access to the pump assembly by
removing or disconnecting other equipment as needed:
6. Where grease is called for, use a Lithium-based 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
Note: Hale SVS Torrent Stainless Valves require grease. See separate manual
for additional information.
Also see Figure 6-2: “Gearbox Capacity / Recommended Lubricants” on page
62.
7. When replacing fasteners, use the proper nuts, bolts, and other hardware.
Many are specifically rated; that is, SAE Grade 5 or higher. Unless otherwise
specified, fasteners are Grade 5 SAE.
Gearbox - Apply a coating of Loctite #246 High Temperature Removable
Threadlock (or equal) to all bolts on the gearbox before installing.
Silencer Series Pump - Apply a coating of Loctite #242 Medium Strength
Threadlock (or equal) to all bolts on the Pump before installing.
8. Before installing the mechanical seal, use alcohol swabs provided by Hale
Products Inc. to clean all grease or oil from the pump shaft and mechanical
seal running faces.
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.
64
WARNING !
DO NOT TOUCH THE CARBON SEAL WHILE INSTALLING THE MECHANICAL
SEAL. USE OF ANY OTHER LUBRICANT CAN DAMAGE THE MECHANICAL
SEAL AND SEAT.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
9. Use a pusher tool or a bearing installation tool when installing bearings and
seals to avoid cocking the bearings or marking the bearing faces.
10. BEFORE PLACING THE APPARATUS INTO OPERATION, THE PUMP
ASSEMBLY MUST BE TESTED AND CHECKED FOR LEAKS. ALL LEAKS
MUST BE REPAIRED IMMEDIATELY.
Cleaning and Inspection Guidelines
Wherever procedures call for cleaning and inspection, use the following
guidelines:
1. Inspect all components for excessive or abnormal wear.
IMPORTANT !
WHEN REASSEMBLING, ALL COMPONENTS MUST BE CLEAN AND FREE OF
DEFECTS.
2. Wherever there is a requirement for new parts, it is recommended to use only
Hale authorized replacement parts for optimum safety of the equipment and
its operators.
3. Whenever gaskets are removed, they must be replaced. Clean all gasket
material from mating surfaces before installing a new gasket. Be careful not
to score the finished surfaces.
4. Bearings and seals should be inspected whenever the parts are disassembled.
❑ Bearings and other components should be cleaned using only recom-
mended solvents.
❑ Inspect bearings for wear, pitting, and damage.
❑ Lightly oil or grease the shaft, O-ring seals and bearings before reinstalling,
especially when pressed-in.
5. Inspect the gear tooth surface for wear damage and pitting. Replace all
components that are worn, damaged, or pitted.
6. It is recommended to replace O-ring seals and gaskets to avoid unnecessary
downtime later.
7. Replace any hardware that shows signs of excessive wear.
Silencer Series Booster Pump, p/n: 029-0020-83-0
65
❑ Preventive Maintenance
Hale Recommended Cleaners
❑ Safety Kleen
❑ Stoddard Solvent
Too ls Req ui re d
❑ Lifting gear-lever hoist or chain hoist, and short choker
❑ Ball peen hammer
❑ Center punch
❑ Drift punch
❑ Allen wrenches
❑ Strap wrench
❑ Snap ring pliers
❑ Pry bars (2)
❑ Ratchets and wrenches for disassembly
❑ Torque wrench capable of 40, 65, and 135 ft.-lb. (54, 88, and 183 N-m)
❑ Pan (to collect drip oil)
❑ Disposable rags
❑ Oil dry
❑ Wedges
❑ Bearing puller
❑ Pusher tube (a small section of PVC tubing to fit over the shaft)
❑ N-06 or N-07 bearing nut socket or spanner wrench, available from:
Whittet-Higgins at www.whittet-higgins.com or,
35 Higginson Avenue, P O Box 8
Central Falls, RI 02863
Phone ........(401) 728-0700
66
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
6.3 PUMP AND GEARBOX ASSEMBLY
WARNING !
THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY,
WEIGHING UP TO 145 LBS. (54 KGS.). ADDED ACCESSORIES MAY
INCREASE THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT
DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR
INSTALLING THE SILENCER SERIES BOOSTER PUMP AND GEARBOX
ASSEMBLIES.
The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62.
Also, please review section General Repair Guidelines, on pape 63, before
beginning these procedures.
Removing the Assembly from Apparatus
1. Remove the pump and any piping drain plugs to drain the inlet (suction) side
of the pump body per your required procedures.
2. Disconnect the suction and discharge piping.
Have clean disposable shop rags and oil dry handy. Also disconnect cooling
tubes from the water manifold and pump, air lines, electrical switches and
tachometer cable as required.
3. Drain oil from the gearbox - remove the magnetic pipe plug. See Section 4:
Preventive Maintenance, heading “Replace Gearbox Oil” on page 48.
Have a suitable container available to collect excess fluid, approximately two
quarts (2 liters).
4. Disconnect the drive shaft from the gearbox.
Note: When reinstalling, apply a coating of Loctite #246 High Temperature
Removable Thread Locker (or equal) to the fasteners and torque to PTO manu
facturer’s specifications.
-
5. With the pump assembly properly supported and balanced, disconnect the
mounting brackets that secure the assembly to the apparatus.
6. Always use proper lifting and support apparatus (jacks, hoists, straps, etc.)
when servicing the unit. Exercise care when using chains to protect finished
surfaces from scratches.
Silencer Series Booster Pump, p/n: 029-0020-83-0
67
❑ Preventive Maintenance
7. Carefully remove the assembly from the apparatus.
8. Place and support the pump assembly on a stable work stand/bench of suitable
capacity (
see “WARNING !” on page 67.). Have the air vent and covers
exposed to provide easy and safe access to the internal parts.
Installing the Assembly to Apparatus
After completing repairs and/or maintenance, install the pump assembly to
the apparatus before filling with oil.
1. First, review preceding Section “Before You Begin...” on page 63.
2. Attach proper supporting devices and stabilize the assembly for transport to
the apparatus.
3. Place the pump assembly into position within the apparatus.
4. Connect the mounting brackets using the proper fasteners. Torque the
fasteners to proper values -
see Table 6-3: “Torque Values Chart” on page 62.
5. Connect the drive shaft to the gearbox. Apply a coating of Loctite #246 High
Temperature Removable Thread Locker (or equal) to the fasteners and torque
to PTO manufacturer’s specifications.
6. Fill the gearbox to the proper oil level. See Section 4: Preventive Maintenance,
heading “Replace Gearbox Oil” on page 48.
7. Reassemble and reconnect all components removed to gain access to the
pump assembly, paying particular attention to your sketch and identification
match markings/tags.
8. Test the pump for proper operation per your departmental requirements. Note
and repair any leaks.
9. Recheck and top off oil levels.
10. Return the apparatus to normal operation.
68
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
6.4 SERVICING THE BOOSTER PUMP
The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62.
Also, please review section General Repair Guidelines, on pape 62, before
beginning these procedures.
Volute (Pump Body)
(See Figure 6-4: “Booster Pump Parts Breakdown.”)
The volute is secured by hex screws (quantity dependent on pump model).
It is sealed with a gasket that must be replaced whenever the joint face is
disturbed.
APS series volutes are mounted for either engine rotation (clockwise), as
viewed from the suction inlet, or opposite engine rotation (counterclock
wise). MBP series pumps are available in the engine rotation (clockwise)
only. Note the direction of flow of the impeller for proper mounting of the
volute.
1. Remove the suction manifold (if still installed).
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 6-4: Booster Pump Parts Breakdown
-
69
❑ Preventive Maintenance
2. Unthread the compression fittings and
disconnect gearbox
cooler hoses from the
volute.
(See Figure 65: “Typical Water
Cooling Lines.”)
3. Remove the 7/16-14
bolts and hardware to
dismantle the volute
from the pump head.
Pull the volute body
from the assembly
being careful not to
damage the impeller
or scratch the sealing
surfaces of the volute.
(See Figure 6-4:
“Booster Pump Parts
Breakdown,” on page 69.)
Figure 6-5: Typical Water Cooling Lines
Note: A dead blow hammer could be needed. Tap, in a crisscross pattern,
around the volute until it is separated from the cover plate. Support the weight of
the volute as it weighs approximately 45lbs. (17kgs.).
DO NOT damage the brass clearance rings or impeller as you separate the
volute (pump body) from the pump head. The impeller, clearance rings and
mechanical seal assembly need not be removed.
4. Without removing from the volute, inspect the front clearance ring for wear
and replace accordingly.
See heading “Inspection – Clearance Rings” on page
72.
Note: Removing the clearance ring renders it defective. It must be replaced. A
usual good practice, if one ring requires replacement, the other should be
replaced as well. Also verify the impeller clearance.
Impeller” on page 72.
See heading “Inspection –
Installation Notes – Volute
To install, follow the preceding steps in the reverse order, paying attention to
the following:
❑ Review preceding sections “Before You Begin...,” on page 63 and “Clean-
ing and Inspection Guidelines,” on page 65 to ensure a thorough
installation.
70
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
❑ Replace all gaskets. Apply a small amount of grease to the gasket(s)
and align on the pump body.
❑ If the clearance rings are removed, use a press to install them back into
the pump body.
❑ When installing the pump body to the pump head, DO NOT damage the
clearance rings or impeller.
❑ Reconnect all cooling lines, piping and tubing.
❑ Inspect the system for proper operation.
❑ Return the apparatus to service.
Impeller
(See Figure 6-4: “Booster Pump Parts Breakdown,” on page 69.)
1. Remove the volute (pump body) to expose the impeller, clearance rings and
mechanical seal.
2. Remove the cotter pin from the impeller nut and set safely aside.
3. While holding the impeller with a strap wrench, remove the impeller nut.
4. To avoid damaging the impeller, use wedges (3) or a bearing puller to remove
the impeller from the pump shaft. Place the wedges or puller at the impeller
vane area where the metal is the heaviest.
Note: Tap the pump shaft end, using a dead blow hammer, to free the impeller
from the pump shaft. Use care to avoid damage to the shaft threads.
CAUTION !
DO NOT STRIKE THE IMPELLER. IRREPARABLE DAMAGE COULD RESULT.
MAKE CERTAIN THE WEDGES OR PULLER IS PLACED AT THE IMPELLER
VANES TO AVOID IRREPARABLE DAMAGE.
5. Slide the impeller from the pump shaft, then remove the impeller shaft key and
set safely aside.
6. Inspect the rear clearance ring for wear and replace accordingly. See heading
“Inspection – Clearance Rings” on page 72.
Note: Removing the rear clearance ring from the pump head renders the ring
defective and it must be replaced.
Silencer Series Booster Pump, p/n: 029-0020-83-0
71
❑ Preventive Maintenance
7. Removing the impeller may disturb the mechanical seal. A new seal must be
installed.
Inspection – Clearance Rings
(See Figure 6-6: “Clearance Ring ID Measurement.”)
Inspect both clearance ring
IDs for signs of wear.
Using a caliper, measure
the inside diameter of each
ring in several places.
If the nominal dimension
does not fall within the
acceptable range speci
fied below, the clearance
ring must be replaced.
❑ Maximum Inside
Figure 6-6: Clearance Ring ID Measurement
Diameter -
APS -............. 4.749” (121.7mm)
MBP - ............ 5.650” (143.5mm)
Installation Notes – Clearance Rings
To install, follow the preceding steps in the reverse order while reviewing the
preceding sections “Before You Begin...”
on pape 63 and “Cleaning and
Inspection Guidelines” on pape 65 to ensure a thorough installation.
Inspection – Impeller
(See Figure 6-7: “Impeller OD Measurement.”)
Inspect the impeller ring OD, on both
sides (front and back) for signs of
wear. Measure the OD diameters in
several places, using a caliper.
72
If the nominal dimension does not
fall within the specified acceptable
range the clearance ring must be
replaced.
Figure 6-7: Impeller OD Measurement
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
❑ Minimum Outside Diameter -
APS - ........4.74” (120.4mm)
MBP -......... 5.60” (142.2mm)
If the measured diameter is equal to or less than the maximum outside wear
limit a new impeller must be installed.
When new, the radial clearance between the impeller hubs and the clearance rings are between 0.005” to 0.007” (0.127-0.78mm) per side. Maximum acceptable radial clearance on used pumps is between 0.015” to
0,020” (0.381-0.508mm) per side.
If the clearance rings on the booster pump show significant wear but the
impeller itself is within the size tolerance, “undersized” clearance rings can
be installed to delay a complete rebuild. Contact Customer Service at Hale
Products at 610-825-6300.
Installation Notes – Impeller
To install, follow the preceding instructions in the reverse order, paying
attention to the following:
❑ Review preceding sections “Before You Begin...” on pape 63 and “Clean-
ing and Inspection Guidelines” on pape 65 to ensure a thorough
installation.
❑ Install the impeller shaft key into the slot on the pump shaft.
CAUTION !
DO NOT STRIKE THE IMPELLER. IRREPARABLE DAMAGE MAY RESULT.
❑ Carefully slide the impeller over the pump shaft, aligning the keyway with
the impeller key.
❑ Torque the impeller nut to 110 ft.-lb. (149 N-m).
❑ Continue tightening the impeller nut until the cotter pin can be installed to
lock the nut in place.
❑ Install cotter pin.
Silencer Series Booster Pump, p/n: 029-0020-83-0
73
❑ Preventive Maintenance
6.5 MECHANICAL SEAL ASSEMBLY
(See Figure 6-8: “Mechanical Seal Overview / Replacement.”) Also see Figure 6-4: “Booster Pump Parts Breakdown” on page 69.
Figure 6-8: Mechanical Seal Overview / Replacement
IMPORTANT !
IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS
NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL
MUST BE INSPECTED.
Removing the Seal
1. To expose the mechanical seal, remove the volute and the impeller as
described in the following sections.
❑ “Servicing the Booster Pump,” on page 69
❑ “Volute (Pump Body),” on page 69
❑ “Impeller,” on page 71
74
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
CAUTION !
MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICES. EXTREME
CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE
MATING FACES. ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN
THROUGHOUT THE ENTIRE INSTALLATION. SOLID FACES MUST BE
CLEANED WITH AN APPROPRIATE DEGREASER AND A SOFT CLOTH.
2. From the pump head, remove the:
❑ Mechanical seal spring
❑ Seal diaphragm and retainer
❑ Seal, stationary seat
(See Figure 6-8: “Mechanical Seal Overview / Replacement,” on page 74.)
3. Removing the mechanical seal renders it defective and it must be replaced.
Installing Seal
(See Figure 6-8: “Mechanical Seal Overview / Replacement,” on page 74.)
1. See CAUTION ! warning on pape 75.
2. Clean the bore of the pump head using alcohol swabs. Solid running faces
must be cleaned with alcohol wipes, supplied with the Hale repair kit.
3. Ensure that the pump body and impeller bores and all mating surfaces of the
mechanical seal assembly are absolutely clean throughout the entire installa
tion process.
4. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal)
to the O-ring on the seal head assembly and the pump shaft and seal areas.
WARNING !
OIL AND GREASE WILL DAMAGE THE MECHANICAL SEAL FACE. DO NOT
TOUCH THE FACE OF THE MECHANICAL SEAL.
-
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUAL) ON
THE RUBBER MECHANICAL SEAL PARTS TO EASE INSTALLATION. USING
ANY OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT.
Silencer Series Booster Pump, p/n: 029-0020-83-0
75
❑ Preventive Maintenance
5. Without touching the carbon seal, slide the stationary seat into the pump head.
6. Carefully push the stationary seat into the pump head bore using a soft clean
pusher tube. Verify the stationary seat is firmly seated in the pump head.
7. Clean the pump shaft with alcohol swabs.
8. Apply a generous coating of PAC-EASE Rubber Lubricant Emulsion (or equal)
to the seal diaphragm.
(See Figure 6-8: “Mechanical Seal Overview / Replace-
ment,” on page 74.)
Without touching the face of the seal ring, push the ring, diaphragm, and
retainer onto the shaft with the pusher tube.
9. Keep the shaft well lubricated and verify the seal ring seats against the
stationary seat. If binding occurs, apply additional PAC-EASE lubricant.
10. Slide the spring (supplied with the seal) onto the shaft. The spring must seat
on the seal retainer.
11. Install the impeller key, then carefully slide the impeller onto the pump shaft.
12. Install the volute using a new gasket.
76
Silencer Series Booster Pump, p/n: 029-0020-83-0
6.6 PUMP HEAD
To service the oil seal between the pump head and gearbox or to service
the gearbox, dismantle the pump head from both units.
(See Figure 6-9: “Oil Seal Replacement / Pump Head Parts.”)
Preventive Maintenance ❑
The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62.
Also, please review section General Repair Guidelines, on pape 62, before
beginning these procedures.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 6-9: Oil Seal Replacement / Pump Head Parts
77
❑ Preventive Maintenance
Removing the Pump Head and Oil Seal
(See Figure 6-9: “Oil Seal Replacement / Pump Head Parts,” on page 77.)
1. As described in the previous sections, remove the following -
❑ Volute, on pape 69
❑ Impeller, on pape 71
❑ Mechanical seal, on pape 74
2. Remove the four (4) hex screws and hardware securing the pump head to the
gearbox casing.
3. Using a soft faced (dead blow) hammer, carefully tap around the pump head
until it is separated from the gearbox. Be careful not to damage the pump shaft.
4. Scrape any gasket material between the mating surfaces of the pump head
and the pump body.
5. Remove the seal ring from the pump head on the gearbox side. Replace this
seal before reinstalling the unit.
6. Use a press to remove the oil seal and mechanical seal from the pump side
of the pump head. Oil seals cannot be reused.
Installation Notes – Pump Head and Oil seal
To install, follow the preceding instructions in the reverse order, paying
attention to the following:
❑ Review preceding sections “Before You Begin...” beginning on pape 63
and “Cleaning and Inspection Guidelines” beginning on pape 65 to
ensure a thorough installation.
❑ All critical internal components must be inspected to tolerances. See
related heading “Inspection” as follows:
● Volute, pump body, on pape 70
● Clearance rings, on pape 72
● Impeller, on pape 72
● Mechanical seal, on pape 74
78
❑ Using a press, install a “new” oil seal and the existing (or new) clearance
ring into the gearbox side of the pump head.
Silencer Series Booster Pump, p/n: 029-0020-83-0
❑ Replace all gaskets and pump head seal rings, where applicable. Apply
a coating of general-purpose grease to the gasket and align to the pump
head.
(See Figure 6-9: “Oil Seal Replacement / Pump Head Parts,” on
page 77.)
❑ Install a new seal ring into the bore of the pump head on the gearbox
side.
❑ Install the pump head on the gearbox being careful not to damage the oil
seal or pump shaft.
❑ Apply Loctite #246 High Temperature Removable Threadlock (or equal)
and install the 7/16-14 hex screws and hardware to secure the pump
head to the gearbox. Torque screws to 50 ft.-lb. (68 N-m).
6.7 “B” SERIES GEARBOX
(See Figure 6-12: “B Gearbox Parts Identification,” on page 82.)
Preventive Maintenance ❑
If necessary, review section “Pump and Gearbox Assembly,” on page 67 to
remove the assembly from the apparatus.
The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62.
Also, please review section General Repair Guidelines, on pape 62, before
beginning these procedures.
Oil Seal – Input Shaft
(See Figure 6-10: “Oil Seal, Input Shaft,” on page 80.)
1. Drain oil into an appropriate container from the gearbox. See Section 4:
Preventive Maintenance, heading “Gearbox Lubrication” on page 45.
2. Remove the screw (A) and hardware securing the flange assembly to the input
shaft.
3. Remove the shaft key and the flange retaining ring.
4. Carefully remove (pry out) the oil seal making sure not to damage the bore,
shaft or bearing.
5. Removing the seal renders it defective. It must be replaced.
Silencer Series Booster Pump, p/n: 029-0020-83-0
79
❑ Preventive Maintenance
Figure 6-10: Oil Seal, Input Shaft
Installation Notes
(See Figure 6-10: “Oil Seal, Input Shaft.”)
To install, follow the preceding steps in the reverse order, paying attention to
the following:
❑ Review preceding sections “Before You Begin...,” on page 63 and
“Cleaning and Inspection Guidelines,” on page 65 to ensure a thorough installation.
❑ Evenly press-in a new oil seal in the gearbox housing until flush
against the bearing.
Also see Figure 6-11: “Typical Bearing and Seal
Insertion Tools” on page 81.
Lightly tap the seal around the edges to ensure an “even” seat.
Notes: It is recommended to manufacture insertion tools to assure a correct
installation of the input shaft bearings and oil seal.
Bearing and Seal Insertion Tools,” on page 81.) These drawings are provided to
assist in the manufacture of these tools.
(See Figure 6-11: “Typical
80
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
Figure 6-11: Typical Bearing and Seal Insertion Tools
If the bearing tool is not available, cover the flange retaining ring
groove with thin electrical tape to avoid cutting the oil seal as it is
inserted.
❑ Add fresh oil. (See Figure 6-2: “Gearbox Capacity / Recommended
Lubricants,” on page 62.) See Section 4: Preventive Maintenance,
heading “Gearbox Lubrication” on page 45.
6.8 DISMANTLE THE B SERIES GEARBOX
(See Figure 6-12: “B Gearbox Parts Identification,” on page 82.)
1. Remove the pump and gearbox assembly from the apparatus. See heading
“Pump and Gearbox Assembly” on page 67.
With the B series gearbox separated from other equipment, place and support
the assembly on a suitable stand or work bench.
Silencer Series Booster Pump, p/n: 029-0020-83-0
81
❑ Preventive Maintenance
82
Figure 6-12: B Gearbox Parts Identification
Note: If your pump assembly includes the optional Hydraulic Dive Assembly it
must be removed from the assembly.
See heading “Hydraulic Drive Option” on
page 87.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
2. Remove the volute, impeller, mechanical seal, pump head, and pump shaft
oil seal.
See heading “Servicing the Booster Pump” on page 69.
3. Unfasten the twelve hex screws and hardware securing the drive unit cover
to the gearbox housing. Remove the drive unit cover and gasket.
4. Scrape all gasket material from mating surfaces, taking care not to scratch the
machined finishes. The gasket must be replaced.
5. Remove the two 3/4” NPT x 3/8” compression fittings that secure the brass Ushaped cooling tube to the braided cooling hoses.
To remove the cooling tube, it must be cut using a hacksaw or similar tool.
Cut the tube on the outside of the gearbox.
(See Figure 6-12: “B Gearbox
Parts Identification,” on page 82.)
6. Remove the input shaft retaining ring from the gear housing.
7. Remove the knock-out plug. A new plug should be used during installation.
8. Using a brass drift punch, push the input shaft out of the gear box while
protecting the drive gear from falling into the gearbox housing.
Once the input shaft is clear of the gearbox housing, remove the input gear
from the gearbox housing.
9. If necessary, remove the rear input shaft bearing from the input shaft using an
appropriate puller. It is not required to remove the bearing from the shaft to
clean and inspect it.
Note: If your pump assembly includes the optional Tachometer Drive Assembly,
it must be removed.
See heading “Tachometer Drive Option” on page 88.
10. Remove the four hex screws and hardware that secure the bearing cover.
Remove the bearing cover, bearing spacers, and bearing cover gasket. The
gasket is reusable if not damaged.
11. Use a drift punch to begin pushing the pump shaft assembly from the gearbox
housing towards the pump side. Be careful not to lose the pump gear key
inside the gearbox.
12. Using a bearing assembly socket or spanner wrench, remove the bearing lock
nut. The pump shaft may have to be secured using a strap wrench while the
lock nut is removed. Remove the bearing washer.
Note: 3.74 ratio gearboxes use N-06 lock nuts, while the other ratios use N-07
lock nuts.
Silencer Series Booster Pump, p/n: 029-0020-83-0
83
❑ Preventive Maintenance
13. Using a brass drift, push the pump shaft out through the pump side of the
gearbox.
As the pump shaft is removed, it may cause the pump shaft spacer, pump
gear key, and pump gear to fall off in the housing. Carefully remove these
one at a time before they fall into the housing.
Always protect these parts from being marred, scratched, etc. as they
are removed.
14. If necessary, remove the roller bearing from the pump shaft using a press. It
is not required to remove the bearing from the shaft to clean and inspect it.
15. Remove the pump shaft retaining ring from the gearbox housing.
16. Using the pusher tool or a similar tool, press the two angular contact bearings
from gearbox housing.
(See Figure 6-13: “Typical Angular Bearing Insertion
Tool.”)
Figure 6-13: Typical Angular Bearing Insertion Tool
17. Inspect and clean all components according to the Cleaning and Inspection
Guidelines
on pape 65.
Installation
(See Figure 6-12: “B Gearbox Parts Identification,” on page 82.)
To reinstall, follow the preceding steps in the reverse order, paying attention
to the following:
1. Review preceding sections “Before You Begin...,” on page 63 and
“Cleaning and Inspection Guidelines,” on page 65 to ensure a thorough
installation.
84
Silencer Series Booster Pump, p/n: 029-0020-83-0
Preventive Maintenance ❑
2. Place the gearbox housing on a steady flat surface with drive shaft
opening facing up.
3. Insert one of the two roller bearings into the bore of the gearbox
housing.
4. Slide the input gear into the gearbox housing, aligning the bore of the
drive gear with the bore of the housing.
5. Insert the key in input shaft and insert shaft into gearbox housing. Align
the input shaft in the bearing.
6. Install the other roller bearing over the drive shaft into the gearbox housing bore.
7. Install the retaining ring to hold the bearing and drive shaft in place.
8. Install a new oil seal.
9. Lift the gearbox onto its base. Apply Loctite 242 to the knock-out plug
and install the plug until it is flush with the gearbox housing.
10. Set the gearbox flat with the drive shaft facing down. Insert the roller bearing in the
bore on the pump end of the gearbox
housing.
11. Insert the pump gear key to the pump shaft
and install the pump gear. Align the pump
gear to the drive gear and install into the
gearbox.
12. Install the pump shaft spacer, then the two
angular contact bearings.
The matched angular contact bearing pair
must be assembled with the large faces of
the inner race apart from each other and the
wider (thicker) faces of the outer races
touching.
(See Figure 6-14: “Angular Con-
tact Bearing Orientation.”)
IMPROPER ORIENTATION OF THE ANGULAR CONTACT BEARINGS DURING
INSTALLATION CAUSES EXCESSIVE HEAT BUILDUP AND PREMATURE
WEAR.
Silencer Series Booster Pump, p/n: 029-0020-83-0
CAUTION !
Figure 6-14: Angular Con-
tact Bearing Orientation
85
❑ Preventive Maintenance
13. Stand the gearbox housing on its base and install the gasket and bearing cover. Secure with 7/16-14 hex screws and hardware and torque to
50 ft.-lbs. (68 N-m).
It is recommended to manufacture insertion tools to assure correct
installation of the input shaft bearings and oil seal.
(See Figure 6-11:
“Typical Bearing and Seal Insertion Tools,” on page 81.) Also see Figure
6-13: “Typical Angular Bearing Insertion Tool” on page 84. These drawings are provided to assist in the manufacture of the tool.
14. Install the drive unit cover and gasket cover. Secure in place using 5/1618 UNC screws and lock washers. For torque specs,
see Table 6-3:
“Torque Values Chart” on page 62.
15. Using Loctite™ PST or equal thread-sealing compound, install the
cooler compression fittings. Reinstall cooler lines.
16. Install the pump onto the apparatus and check operation for leaks.
repair any immediately.
86
Silencer Series Booster Pump, p/n: 029-0020-83-0
6.9 AVAILABLE OPTIONS
Hydraulic Drive Option
(See Figure 6-15: “Hydraulic Drive Option.”)
Preventive Maintenance ❑
17. If not already done, remove the hydraulic motor from the hydraulic adapter.
18. Remove the 7/16” hex screws and hardware securing the hydraulic adapter
flange to the gearbox housing.
19. Slide (pull back) the coupling from the drive shaft.
20. Remove the drive shaft key and set safely aside.
Installation Notes
(See Figure 6-15: “Hydraulic Drive Option.”)
To install, follow the preceding steps in the reverse order. Use Loctite #246
High Temperature Removable Threadlock (or equal) install the bushings
and elbows in the water manifold.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 6-15: Hydraulic Drive Option
87
❑ Preventive Maintenance
Tachometer Drive Option
(See Figure 6-16: “Tachometer Drive Option.”)
Figure 6-16: Tachometer Drive Option
1. Disconnect the tachometer cable from the tachometer drive assembly.
2. Remove the tachometer drive assembly from the adapter fitting.
3. Unthread the adapter fitting from the bearing cover.
Installation Notes
(See Figure 6-16: “Tachometer Drive Option.”)
To install, follow the preceding steps in the reverse order.
88
Silencer Series Booster Pump, p/n: 029-0020-83-0
7 Installation
7.1 OVERVIEW
This section provides guidelines and recommendations for installing the
silencer series pump assembly into your truck chassis.
7.2 FRAME MOUNTING
Also see Section “Installation and Parts Drawings,” located at the back of
this manual.
❑ Plate # 1027A ......APS Silencer Series Booster Pump Installation and
Installation ❑
Parts Identification
❑ Plate # 1026A ......MBP Silencer Series Booster Pump Installation and
Parts Identification
IMPORTANT!
TO FULLY SUPPORT THE SILENCER SERIES BOOSTER PUMP ASSEMBLY,
USE ALL MOUNTING BOLT HOLES PROVIDED IN THE GEARBOX.
Mounting Holes
Four 7/16-14 tapped holes, 0.69” (17.5mm) deep mounting holes are provided. Mounting varies depending on assembly configuration, i.e.,
❑ Horizontal
❑ Ver ti cal
❑ Inverted mount
❑ Standard engine rotation (clockwise)
❑ Opposite engine rotation (counterclockwise)
Silencer Series Booster Pump, p/n: 029-0020-83-0
89
❑ Installation
7.3 DRIVELINE ISSUES
Drive Line and Flange Bolts
Ensure that:
❑ All bolts are tight. Use a torque wrench to torque bolts to the drive train
manufacturer's recommended specifications.
❑ Bolts used are “Grade 8” strength. Wherever there is a requirement for
new parts, it is recommended to use only Hale authorized replacement
parts for optimum safety of the equipment and its operators.
Issues
It is critical to use computer driveline analysis software, such as Dana’s
“The Expert,” during driveline layout. Dana’s software is available free on
the World Wide Web at:
http://www2.dana.com/expert
When performing calculations, strive to achieve the lowest driveline torsional and inertial vibrations, making sure to avoid severe driveline angles.
Be conservative and always err on the side of SAFETY. Always measure
the drive shaft after construction to make sure it matches the computer
design.
Remember the following points while designing a driveline:
❑ Problems can occur with or without noticeable vibration.
❑ Do not measure driveline angles using a bubble protractor. Instead, use
a digital inclinometer. Remember to zero the inclinometer on the truck
frame, not the ground.
❑ Center the sliders.
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.
90
Table 7-1: Maximum Recommended Driveline Lengths, on page 91, lists the
maximum driveline length using a safety factor of 42% of critical speed.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Installation ❑
tfahS
MPR
004,2
006,2
008,2
000,3
002,3
004,3
006,3
008,3
000,4
0.2
)15(
)491,1(74)643,1(35)374,1(85)006,1(36)207,1(76)308,1(17
)341,1(54 )592,1(15 )793,1(55 )425,1(06 )626,1(46 )727,1(86
)811,1(44)542,1(94)643,1(32)374,1(85)575,1(26)156,1(56
)760,1(24 )491,1(74 )123,1(25 )224,1(65 )425,1(06 )006,1(36
)140,1(14)861,1(64)072,1(05)273,1(45)374,1(85)945,1(16
)199(93 )811,1(44 )912,1(84 )643,1(35 )224,1(65 )994,1(95
)569(83)290,1(34)491,1(74)592,1(15)793,1(55)374,1(85
)049(73 )760,1(24 )861,1(64 )072,1(05 )643,1(35 )224,1(65
)419(63)140,1(14)341,1(54)912,1(84)123,1(25)793,1(55
Table 7-1: Maximum Recommended Driveline Lengths
5.2
)46(
0.3
)67(
5.3
.04
)98(
5.4
)201(
)411(
This table is based on a 0.134” (3.4mm) wall thickness. Although wall
thickness does not have a significant effect on drive shaft length for this calculation, it does have some effect.
Extremely short drive lengths can also cause problems from excessive
operating angles. Use caution and conservative design values when utilizing air ride suspension and short rear drivelines.
More information on fire apparatus drivelines can be found in Hale OEM
Technical Bulletin # 957. For application assistance and approval, contact a
driveline equipment manufacturer, such as Spicer/Dana or Merritor.
Note: Hale assumes no liability for any information provided under this heading
“Driveline Issues.” Driveline design and truck system integration is the responsibility of the apparatus manufacturer. Failure to comply with the driveline parameters set forth can result in termination of Hale’s warranty on driveline related
issues.
7.4 PLUMBING CONNECTIONS
Also see Section “Installation and Parts Drawings,” located at the back of
this manual for more detail.
❑ Plate # 1027A ......APS Silencer Series Booster Pump Installation and
Parts Identification
Silencer Series Booster Pump, p/n: 029-0020-83-0
91
❑ Installation
❑ Plate # 1026A ......MBP Silencer Series Booster Pump Installation and
Parts Identification
The Silencer Series Booster Pump offers the following suction and discharge arrangements:
❑ Suction (Inlet) –
APS:
● Victaulic, Standard 5” (127mm) connection
● ISO 228/1-G4-1-1/2” female pipe thread
● 4-1/2” NST
Suction/Discharge Manifold Kit (See Figure 2-13: “Typical
Manifold Assembly Option,” on page 26.)
MBP:
❑ Discharge, Standard –
● Victaulic, Standard 6” (152.4mm) connection
● 4” (102mm) discharge port flange
Other flanges and manifolds are available. Contact Hale Products at 610-825-6300.
92
Silencer Series Booster Pump, p/n: 029-0020-83-0
8 Maintenance Kits
Disassembly of the pump and/or gearbox is a major undertaking that can remove a
pump from service for a considerable period of time. Gaskets and O-ring seals
must be replaced to ensure the pump is fully operational when returned to service.
It is never permissible to reassemble the pump without installing new gaskets and
seals.
Hale Products supplies repair kits designed specifically for each pump and gearbox. Other parts can be ordered by calling Hale Products Customer Service at
610-825-6300.
The next few pages is a list of the kits currently available from Hale Products. Hale
updates and adds new maintenance kits constantly; therefore, the kits shown are a
partial listing of what is available.
Maintenance Kits ❑
8.1 RECOMMENDED SPARE PARTS KITS
Level 1
A Level 1 basic repair kit, which contains
seal rings, oil seals, gaskets, the
mechanical seal, and retaining rings for
basic reassembly of the pump. Order
Hale p/n: 546-3000-00-0.
Figure 8-1: Typical Level 1 Basic Repair Kit
Level 2
A Level 2 kit includes the contents of the Level 1 kit, plus
bearings, fasteners, cooler,
keys and other wear items. To
order, (See Table 8-3: “Level 2
Kit Part Numbers,” on page
94.)
Figure 8-2: Typical Level 2 Intermediate
Silencer Series Booster Pump, p/n: 029-0020-83-0
Repair Kit
93
❑ Maintenance Kits
Model Number Kit Part Number
APS-37 546-3000-02-0
MBP/APS
(All Others)
546-3000-01-0
Table 8-3: Level 2 Kit Part Numbers
Complete Overhaul
A Level 3 kit includes the entire contents of the Level 1 and 2 kits, plus
shafts, impeller, clearance rings and gears. Order Hale kits per Table 8-3:
“Booster Pump Maintenance Kits, Level 3” below.
Model Hale Part Number Ratio Rotation
MBP 546-3000-03-0 1.64 N/A
MBP 546-3000-04-0 2.33 N/A
MBP 546-3000-05-0 2.66 N/A
MBP 546-3000-06-0 2.91 N/A
APS 546-3000-07-0 1.64 Opposite Engine
APS 546-3000-08-0 2.33 Opposite Engine
APS 546-3000-09-0 2.60 Opposite Engine
94
APS 546-3000-10-0 2.91 Opposite Engine
APS 546-3000-11-0 3.74 Opposite Engine
APS 546-3000-12-0 1.64 Engine
APS 546-3000-13-0 2.33 Engine
APS 546-3000-14-0 2.60 Engine
APS 546-3000-15-0 2.91 Engine
APS 546-3000-16-0 3.74 Engine
Figure 8-4: Additional Booster Pump Maintenance Kits, Level 3
Silencer Series Booster Pump, p/n: 029-0020-83-0
Appendix A Glossary/Measurements ❑
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.
Appendix A/A-1: Glossary/Measurements
95
❑ Appendix A Glossary/Measurements
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.
96
Appendix A/A-1: Glossary/Measurements
Appendix A Glossary/Measurements ❑
Positive ...............A pump with a fixed flow delivered to the discharge with each revolution.
Displacement Pump
Positive ..............Pressure above atmospheric.
Pressure
Power Valve........A valve that uses hydraulic pressure to transfer two-stage pump operation from volume
mode to pressure mode, and vice versa.
Pressure .............Force per unit area.
Pressure ............The pressure gauge is usually graduated in pounds per square inch (PSI) only. It
Gauge is connected to the pump discharge manifold, thus indicating pump discharge ressure.
Priming ...............Priming evacuates the air from the main pump and suction hose, thus creating a vacuum.
This allows atmospheric pressure on the source of the fluid to push the fluid up into the
suction hose and pump.
Priming Pump ....An auxiliary positive displacement pump which pumps air out of the booster pump that
creates a vacuum to prime the main pump. The priming pump is a rotary vane type,
electric motor driven. Once the main pump is primed and pumping, the priming pump
is shut off.
Priming Pump ...A valve located in the priming line between the priming pump and the main pump.
Valve It remains closed at all times except when priming. The control is normally located on
the pump panel.
Pump Shift..........A midship pump is usually mounted with a split gearbox installed in the drive shaft.The
pump shift moves a sliding gear in the gearbox that transmits power either to the pump
or the rear axle. In ROAD position, power is shifted to the rear axle for driving; in PUMP
position, the rear axle is disconnected, and power is shifted to the pump shaft.
Relay ...................Movement of water from an apparatus at a water source to additional apparatus until
water reaches the fire ground.
Relief Valve.........An automatic valve which, when activated by the relief valve control, 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.
Appendix A/A-1: Glossary/Measurements
97
❑ Appendix A Glossary/Measurements
Slinger Ring........Prevents fluid from continuing to travel down a shaft to the gears and ball bearings.
Stages .................The number of impellers in a pump that are used in series; that is, one following another
in terms of flow. Each impeller develops part of the total pump pressure.
Tachometer ........Indicates the speed of the engine crankshaft in revolutions per minute.
Torque.................The force that acts to produce rotation.
Transfer Valve ...A two-position valve in a pump that changes the operation from parallel (volume) to
series (pressure) operation and vice versa (not used on single stage pumps).
Vanes ..................Guides inside an impeller that direct fluid to the volute (pump body).
Volute..................A gradually increasing discharge waterway. Its function is to collect the water from the
impeller and, depending on its design, it either increases pressure and decreases
velocity or increases velocity and decreases pressure.
Water...................Amount of energy in the water stream.
Horsepower
Wear Rings .........See Clearance rings.
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Appendix A/A-1: Glossary/Measurements
Appendix A Glossary/Measurements ❑
Appendix A-1: 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 C o nv e rt 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
Appendix A/A-1: Glossary/Measurements
99
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