Hale MG User Manual

Download

OPEROPER

OPER

OPEROPER

TING ANDTING AND

TING AND

TING ANDTING AND

MAINTENANCE MANUMAINTENANCE MANU

MAINTENANCE MANU

MAINTENANCE MANUMAINTENANCE MANU

MODEL: MGMODEL: MG

MODEL: MG

MODEL: MGMODEL: MG

SERIAL NO._______________SERIAL NO._______________

SERIAL NO._______________

SERIAL NO._______________SERIAL NO._______________

ALAL

Failure to follow the operating, lubrication, and maintenance requirements set forth in the operating and instruction manual may result in serious personal injury and/or damage to equipment.

A Hale pump is a quality product; ruggedly designed, accurately machined, carefully assembled and thoroughly tested. In order to maintain the high quality of your pump 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 pump.

ALAL

YS INCLYS INCL

YS INCL

YS INCLYS INCL

UDE THE PUMP SERIAL NUMBER IN CORRESPONDENCEUDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE

UDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE

UDE THE PUMP SERIAL NUMBER IN CORRESPONDENCEUDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE



HALE PRODUCTS INC. A Unit of IDEX Corporation 700 Spring Mill Avenue 610/825-6300 www.haleproducts.com



Fax: 610/825-6440

Fire Suppression Division



Conshohocken, PA 19428

Muscle Pumps

TABLE OF CONTENTS

SECTION PAGE

1 INTRODUCTION........................................................................................................1-1

A. Description .............................................................................................................1-1

B. Principles of Operation ............................................................................................1-1

Centrifugal Force ....................................................................................................1-1

Pump Stages...........................................................................................................1-1

Single-Stage Pump.................................................................................................. 1-3

Single-Stage Pump Operation ................................................................................... 1-3

Two-Stage Pump.....................................................................................................1-3

Two-Stage Pump Operation .....................................................................................1-5

Vol ume (Parallel) Operation ....................................................................................1-5

Pressure (Series) Operation......................................................................................1-5

Volume Versus Pressure Operation...........................................................................1-5

Transfer Valve ........................................................................................................1-6

Choosing Between Volume and Pressure Operation ................................................... 1-6

Transferring Between Volume and Pressure Operation ..............................................1-6

Cavitation ...............................................................................................................1-7

C. Parts of Pump..........................................................................................................1-8

Basic Parts of Hale Midship Centrifugal Pump..........................................................1-8

Pump Body........................................................................................................1-8

Qmax and Qtwo Pumps ......................................................................................1-8

Qpak and Qflo Pumps ......................................................................................... 1-9

Impeller.............................................................................................................1-9

Clearance Rings .................................................................................................1-9

Bearings ...........................................................................................................1-10

Pump Seals .......................................................................................................1-10

Packing.............................................................................................................1-10

Mechanical Seal................................................................................................1-11

Auto Lube ®.....................................................................................................1-11

D. Pump Drives..........................................................................................................1-12

Pump Mounting Options .........................................................................................1-12

G-Series Gearbox...................................................................................................1-12

Principle of Operation ............................................................................................. 1-12

LP and XP Gearbox................................................................................................1-12

Shifting..................................................................................................................1-12

J Series Gearbox.....................................................................................................1-14

E. Accessories............................................................................................................ 1-14

Priming Pump ........................................................................................................1-14

Priming Valves ......................................................................................................1-15

Pressure Control Devices........................................................................................1-15

Relief Valve System ............................................................................................... 1-15

Hale Total Pressure Master (TPM) Relief Valve System ........................................... 1-17

Cooling Options .....................................................................................................1-22

Model K Auxiliary Heat Exchanger/Cooler.........................................................1-22

Thermal Relief Valve (TRV)..............................................................................1-23

Valves...................................................................................................................1-24

Suction Valves..................................................................................................1-24

- i -

Muscle Pumps

TABLE OF CONTENTS (CONTINUED)

SECTION PAGE 1 INTRODUCTION (Continued)

Discharge Valves ..............................................................................................1-24

Tank Suction Valves..........................................................................................1-25

In-line Valves ...................................................................................................1-25

Drain Valves ..................................................................................................... 1-26

Anodes..................................................................................................................1-26

Booster Pump ........................................................................................................1-27

2 OPERATING PROCEDURES......................................................................................2-1

A. Overview................................................................................................................2-1

B. Operating Procedures..............................................................................................2-1

Pumping From a Hydrant, General Operation............................................................2-1

TPM Operation from a Hydrant................................................................................2-2

Pumping From Draft, General Operation ................................................................... 2-2

Pumping From the Onboard Water Tank...................................................................2-4

Pumping In Relay....................................................................................................2-5

Tandem Pumping Operation From a Hydrant............................................................2-6

Pump to Road Shift Procedures ................................................................................ 2-7

Standard Relief Valve Procedures.............................................................................2-7

TPM Relief Valve Procedures .................................................................................. 2-7

TPM System with Engine Governor ......................................................................... 2-7

Emergency Pump Shift Procedures...........................................................................2-8

Post Operation Procedures .......................................................................................2-9

3 PREVENTATIVE MAINTENANCE.............................................................................3-1

A. Overview................................................................................................................3-1

B. Procedures..............................................................................................................3-1

Post Operation Maintenance.....................................................................................3-1

Extreme Conditions Maintenance Guidelines ............................................................3-1

During Freezing Weather....................................................................................3-1

After Pumping from Salt Water, Contaminated Water, or with Foam Solution........3-1

Weekly Maintenance...............................................................................................3-1

Relief Valve and TPM Test.................................................................................3-2

Governor Test....................................................................................................3-2

Transfer Valve Test ............................................................................................ 3-2

Priming System Test...........................................................................................3-2

Pump Shift Warning Indicator Lights...................................................................3-2

Valve Lubrication ............................................................................................... 3-3

Monthly Maintenance .............................................................................................. 3-3

Suction Check Valve Test...................................................................................3-3

Lubrication ........................................................................................................3-3

Packing Gland Adjustment ..................................................................................3-3

Drive Line and Flange Bolts ................................................................................ 3-4

- ii -

Muscle Pumps

TABLE OF CONTENTS (CONTINUED)

SECTION PAGE

3 PREVENTATIVE MAINTENANCE (Continued)

Pump Mounting Bolts ......................................................................................... 3-4

Priming System Test (Dry Vacuum Test).............................................................3-4

Relief Valve System Check.................................................................................3-4

Indicator Light Test............................................................................................3-5

Annual Maintenance................................................................................................3-5

Performance Testing Overview ................................................................................3-5

Performance Testing Equipment and Materials..........................................................3-5

Performance Testing .......................................................................................... 3-10

Repacking.........................................................................................................3-11

Annual MIV and 40BD Relief Valve Test and Adjustment ................................... 3-11

Worn Clearance Rings and Impeller Hubs...........................................................3-12

Anode Check .................................................................................................... 3-13

TRV Test..........................................................................................................3-13

4 TROUBLESHOOTING................................................................................................4-1

5 CORRECTIVE MAINTENANCE ................................................................................. 5-1

A. Midship Pump ......................................................................................................... 5-1

Removal............................................................................................................5-1

Installation.........................................................................................................5-1

B. Gearbox..................................................................................................................5-3

G-Series..................................................................................................................5-3

Removal............................................................................................................5-3

Installation.........................................................................................................5-3

J-Series...................................................................................................................5-6

Removal............................................................................................................5-6

Installation.........................................................................................................5-6

C. Packing Replacement ..............................................................................................5-7

D. Mechanical Seal Replacement .................................................................................. 5-7

Qmax and Qtwo Pump Mechanical Seal...................................................................5-7

Removal............................................................................................................5-7

Installation.........................................................................................................5-9

Qflo and Qpak Pump Mechanical Seal and Clearance Rings ...................................... 5-10

Removal...........................................................................................................5-10

Installation........................................................................................................5-12

E. AutoLube® Service (Qmax/Qtwo) .......................................................................... 5-13

F. Impeller Assembly .................................................................................................5-15

Impeller and Clearance Rings Removal...............................................................5-15

Disassembly (Single-Stage Pump) ......................................................................5-16

Assembly (Single-Stage Pump) ..........................................................................5-16

Disassembly (Two-Stage Pump).........................................................................5-17

Assembly (Two-Stage Pump).............................................................................5-18

Installation (Impeller and Clearance Rings) ......................................................... 5-18

G. Relief Valve System............................................................................................... 5-20

- iii -

Muscle Pumps

TABLE OF CONTENTS (CONTINUED)

SECTION PAGE

5 CORRECTIVE MAINTENANCE (Continued)

PM/PMD Control Valve ....................................................................................5-20

QD Relief Valve ................................................................................................ 5-21

QG Relief Valve ................................................................................................ 5-23

PG30 Relief Valve ............................................................................................5-24

Sensing Valve ...................................................................................................5-25

H. TRV Service .......................................................................................................... 5-26

I. Anode Replacement................................................................................................5-26

J. Qtwo Transfer Valve ..............................................................................................5-27

K. Qtwo Check Valves (Two-Stage Only) ....................................................................5-28

L. Tank To Pump Check Valve ...................................................................................5-29

M. Suction Extension and Suction Tube ........................................................................ 5-29

N. Gearbox Disassembly and Assembly ....................................................................... 5-30

G-Series.................................................................................................................5-30

Removal and Disassembly ................................................................................. 5-30

Assembly and Installation ..................................................................................5-33

J-Series..................................................................................................................5-35

Removal and Disassembly ................................................................................. 5-35

Assembly and installation ..................................................................................5-36

O. Primers..................................................................................................................5-37

ESP Priming Pump............................................................................................5-37

SPV Priming Valve ...........................................................................................5-38

PVG Priming Valve...........................................................................................5-38

P. Accessories............................................................................................................5-39

Valves..............................................................................................................5-39

40BD Series Valve Maintenance........................................................................5-40

40BD Valve Seat Replacement ..........................................................................5-41

Valve Stem Seal Replacement............................................................................5-42

Drain Valve Repair Procedures..........................................................................5-42

6 PARTS LISTS..............................................................................................................6-1

GLOSSARY .................................................................................................................G-1

APPENDICES

Data for Practical Use A

Parts and Service Centers B

Warranty C

- iv -

Muscle Pumps

1. INTRODUCTION

A. Description

Hale single-stage and two-stage midship pumps are favorites of firefighters throughout the world. Covering a range of capacities from 750 Gallons Per Minute (GPM) (2,838 Liters Per Minute, LPM) to 2,250 GPM (8,516 LPM), Hale pumps offer the versatility, dependability, reliability, and ease of operations necessary for effective fire fighting. This section reviews the principles of operation of Hale’s single-stage and two -stage midship pumps.

B. Principles of Operation

Centrifugal Force

A centrifugal pump operates on the principle that centrifugal force is created by a rapidly spinning disk. Figure 1-1 shows that an amount of water has been placed at the center of a disk. The disk is rotated at some speed, and the water is thrown from the center toward the outer circumference of the disk. The distance that 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 pump body), its pressure rises to a level that depends on the speed of rotation. There are three interrelated factors that regulate the performance of a centrifugal pump:

q SPEED (RPM). If the speed of rotation

increases with flow held constant, the water pressure increases.

q PRESSURE. Pressure is usually measured in

Pounds Per Square Inch (PSI) (BAR). If pressure changes with speed held constant, the flow (measured in GPM) (LPM) will change inversely, that is, if pressure increases, flow decreases.

q FLOW. Flow is usually measured in the

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

Figure 1-1. Centrifugal Force From a Rotating Disk

The 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 BAR), and the inlet pressure is 45 PSI (3 BAR), the pump must only produce the difference in pressures of 75 PSI (5 BAR). This contributes to low engine and pump speeds with reduced maintenance. Decreased maintenance is aided by the fact a centrifugal pump has basically only two moving parts the impeller and the shaft.

Pump Stages

The number of impellers on a common shaft determines the number of pump stages. The Hale series of single-stage pumps provides the same normal operating and rating test pressures as the Hale series of two-stage pumps. The two-stage pump provides an additional level of operating pressures if required, but adds some operating complexity.

1-1

Muscle Pumps

1-2

Muscle Pumps

Single-Stage Pump

There are three series of single-stage pumps.

q Qpak – 500 GPM to 1000 GPM

(1,892 LPM to 3,785 LPM)

q Qflo - 750 GPM to 1,250 GPM

(2,838 LPM to 4,731 LPM)

q Qmax - 1,000 GPM to 2,250 GPM

(3,785 LPM to 8,516 LPM) (See figure 1-2)

Hale single-stage pumps are of a size and design to attach to the chassis rails of commercial and custom chassis. The pump is driven from the truck’s main driveline. Generally, the pump consists of the following major components:

q Pump body q Impeller and Shaft Components q Gearbox q Priming System q Pressure Control Device q Valves

Single-Stage Pump Operation

Hale single -stage pumps use a single impeller to develop the required volume and pressure. Figure 1-3 shows the flow of water through the Hale Qmax single -stage pump. Water enters the suction channels on both sides of the impeller, thereby maintaining axial balance. Dual cutwaters on the Qmax strip water from the rotating impeller and direct it to the discharge path. The Qflo and Qpak

pumps utilize an impeller with a single suction channel where water enters. The impeller develops discharge pressure and directs the water to a single cutwater and then to the discharge valves. The impellers are radially and axially balanced. Radial hydraulic balance in the Qmax and Qtwo is maintained by the opposed discharge volute cutwaters. The cutwaters are wedge shaped and divide the water between the volute and the pump discharge.

Two-Stage Pump

There is one series of two-stage pump:

q Qtwo - 1,000 to 2,000 GPM

(3,785 LPM to 7,570 LPM) (See figure 1-4)

Hale two-stage pumps are of a size and desig n to mount on the chassis rails of commercial and custom chassis. The pump is driven from the truck’s main driveline. Generally, the pump consists of the following major components:

q Pump Body q Impeller and Shaft Components q Gearbox q Priming System q Pressure Control Device q Transfer Valve System q Valves

1-3

Muscle Pumps

1-4

Muscle Pumps

Two-Stage Pump Operation

The primary difference between a single-stage and a two-stage pump is that the former has only one impeller and no transfer valve to switch between volume and pressure operation. A transfer valve is a two-position valve that permits the impellers in a two-stage pump to be operated in parallel (volume) or series (pressure). Both types of operation are explained in the following paragraphs.

Volume (Parallel) Operation

Volume operation (figure 1-5), results in the pressure at the pump intake being added to the pressure developed by both impellers, and the amount of water delivered to the discharge being the sum of the flows of the two impellers. For example, if the inlet pressure is 30 PSI (2 BAR) and the flow of each impeller is 500 GPM (1,892 LPM) at 150 PSI (10 BAR), the pressure and volume at the discharge is:

Flow/Impeller x # Impellers

1,000 GPM (3,785 LPM) at 180 PSI (12 BAR): 500 GPM per Impeller X 2 Impellers = 1,000

GPM (1,892 LPM per Impeller X 2 Impellers = 3,785 LPM) 30 PSI Inlet Pressure + 150 PSI Pump Pressure = 180 PSI

(2 BAR Inlet Pressure + 10 BAR Pump Pressure = 12 BAR)

Pressure (Series) Operation

Pressure operation (figure 1-6), finds the impellers connected in series. That is, the output of the impeller supplied from the pump intake is supplied to the input of the next impeller. The pressure at the pump discharge is the sum of the pressure of the two impellers plus the pressure of the intake. The amount of water delivered to the discharge is the same amount that entered the first impeller. Using the example above when in series operation, the discharge pressure will be 330 PSI, (22 BAR) and the discharge volume will be 500 GPM (1,892 LPM).

Volume Versus Pressure Operation

Selection of volume versus pressure operation is determined by three factors:

q Generally, the pump should be operated so

that the pump gives the desired performance at the lowest engine speed.

q Transfer to volume (parallel) operation for

higher flows (see figure 1-5).

q Transfer to pressure (series) operation

when higher water pressures are required (see figure 1-6).

1-5

Muscle Pumps

Transfer Valve

A transfer valve, which is controlled from the apparatus pump control panel, allows the operator of a two-stage pump to select volume or pressure operations. This valve is an all-bronze waterway device that can transfer between pumping modes with two and one-half turns of its control hand wheel. The position of the valve is indicated on the apparatus pump control panel via a positive mechanical indicator. An optional power transfer valve is available.

operations. If your fire department does not have a policy to follow, here are general guidelines:

1. Hale pumps are designed to pump up to 200 PSI (13 BAR) net pressure in volume operation at reasonable engine speeds.

2. Generally, volume operation should be used at any net pump pressure under 150 PSI (10 BAR), especially when pumping from a hydrant.

Choosing Between Volume and Pressure Operation

In deciding which range to pump (pressure or volume), choose the one that gives the desired flow and pressure at the lowest engine speed. When a change of range is desired, slow down to idle speed, and shift the transfer valve to the desired range. When shifting the transfer valve from volume to pressure operation, the pressure will be doubled. You may hear a metallic click or two clicks, which will be the check valves closing. If the clicks sound too harshly, you are changing the transfer valve while the pressure is too high. This happens when the truck engine is running at high speed.

Refer to your fire department policy for when to use volume operation and when to use pressure

1-6

3. When pumping from draft or a water tank, pressure operation may be used when the volume is less that one -half the pump capacity and when the desired pressure is over 150 PSI (10 BAR).

4. Be certain to warn everyone involved before changing pump range.

Transferring Between Volume and Pressure Operation

Transferring between volume and pressure operation is evidenced by a metallic click, which results from the check valves closing. If the click is too loud or, perhaps, somewhat violent, the pumping pressure is too high for switching. In this case, you should ease back on the engine thrott le.

Muscle Pumps

Switching between volume and pressure operation is generally governed by prevailing fire department policy. However, here are some general guidelines if our fire department does not have an established policy:

1. The pump should be operated so that engine speed is within its best operating range.

2. Transfer to volume (parallel) operation if the pump has to discharge more than 50 percent of its rated capacity. Be certain to warn everyone involved before switching between volume and pressure operation.

3. Reduce the pump pressure to 50 to 60 PSI (3 to 4 BAR) before switching. The engine speed should especially be reduced when switching from volume to pressure operation with hand held hoses in use.

Cavitation

Cavitation occurs when a centrifugal pump is attempting to discharge more water than it is receiving. When cavitation occurs, a vacuum is created near the eye of the impeller. As the vacuum increases, the boiling point of the water is lowered until it reaches a point near the impeller eye where it flashes into vapor and enters the impeller. Once the vapor pockets, or 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, which condenses the va por back to a liquid. The sudden change from vapor pockets to a liquid generates a shock effect which causes a significant noise that is characteristic of cavitation. This shock damages the impeller and pump housing. This may happen while pumping from draft or a hydrant. The problem in either case is the pump running away from the supply and this causes a vacuum to occur. Cavitation is often referred to as “the pump running away from the water supply”. This means that the operator is trying to pump more water out of the pump than is going into the pump. To eliminate cavitation, the operator must be aware of the warning signs and correct the situation, or serious damage to the pump and impeller will occur. The most reliable indication that a pump is approachi ng cavitation is when an increase in engine RPM does not cause an increase in the pump discharge pressure. The operator must not depend entirely on the vacuum gage to indicate when a pump is nearing cavitation. This is because the vacuum gage is usually tapped into the intake chamber several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The most common way to eliminate cavitation is to decrease the amount of water being discharged. This is accomplished by decreasing engine speed or closing discharge valves. This will allow pressure to increase but this will result in a reduction of flow.

1-7

Muscle Pumps

C. Parts of Pump

Basic Parts of Hale Midship Centrifugal Pump

Figure 1-7 shows the basic parts of a Hale midship centrifugal pump. These parts are briefly described in the following text.

Pump Body

The standard pump body and related parts are constructed from fine grain alloy cast iron, with a minimum tensile strength of 30,000 PSI (207 N/mm2). All moving parts subject to water contact. The pumps are also available with a bronze body for use with saltwater or harsh water applications.

Qmax and Qtwo Pumps

The Qmax and Qtwo pump body is split horizontally on a single plane in two sections for easy removal of the entire impeller assembly, including clearance rings and bearings. The impeller assembly is removed from the bottom of the pump to avoid interference with the surrounding piping and pump mounting on the apparatus chassis.

Two tank suction valve locations are available to allow higher flows from the booster tank. Optional built-in check valves are available to prevent tank over-pressurization.

The Qmax and Qtwo pumps have two large suction inlets, on the left and right side. Additional front and rear inlets may be added as requested by the customer.

CLEARANCE RINGS

AUTO LUBE

PUMP BODY

BALL BEARINGS

REAR BEARING HOUSING

PUMP GEAR

GEARBOX

OIL SEAL

SLINGER RING

PACKING OR MECHANICAL SEAL

PUMP SHAFT

1-8

SLEEVE BEARING

Figure 1-7. Midship Two-Stage Centrifugal Pump

IMPELLERS (2 Stage)

Muscle Pumps

Impeller inlets are on opposite sides of the pump to balance axial forces; discharges are on opposite sides to balance radial forces.

Qpak and Qflo Pumps

The Hale Qpak and Qflo pump body is a single piece. Service of the impeller, clearance rings and mechanical seal is accomplished by removing the gearbox and rear pump head/bearing housing from the pump. This can be accomplished without disturbing discharge or suction piping attached to the pump.

The Qpak and Qflo pump has two large suction inlets on the left and right sides. The incoming water is directed to the impeller through the suction passages.

A tank suction valve opening, located on the rear of the Qpak and Qflo pump allows for high flows from the booster tank. An optional built-in check valve is available to prevent tank overpressurization.

Hale muscle pumps are “manifolded” type pumps meaning the pump volute, suction manifolding, and discharge manifolding are cast as one piece. This one -piece pump design simplifies installation of the pump and plumbing of the discharge piping.

Discharge valves in the basic pump configuration can be mounted at either side of the pump body. However, the manifolded pump body provides several additional discharge locations (facing front, back, or up) that can accommodate additional discharge valves.

Impeller

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

Figure 1-8 traces a drop of water from the intake of the impeller to the discharge outlet. The impeller is mounted so that the discharging tube is widest at the pump outlet. The increasing discharge path, known as the volute, collects the water at a constant velocity. A further increase in pressure and a decrease in velocity take place in the diffuser.

Clearance Rings

Clearance rings prevent the water that is pressurized and leaving the pump volute from returning to the intake of the impeller. Centrifugal pumps have clearance rings at the impeller intake to prevent leakage. This is accomplished by limiting the radial clearance between the spinning impeller and the stationary clearance ring. Refer to figure 1 -7.

DISCHARGE

INTAKE

1-9

CUT WATER

VANES

EYE

DIFFUSER

Figure 1-8. Impeller Operation

PACKING RINGS

PUMP SHAFT

Muscle Pumps

A clearance ring usually has a radial clearance of about 0.0075-inch or a 0.015-inch diameter. However, the clearance will increase over time as the pump is operated. Wear is due to foreign material found in the water. Clearance rings are designed for replacement as the clearance increases from usage and wear.

If a pump is operated without water for extended periods or without discharging water, it may overheat. This may damage the pump and the drive mechanism.

Bearings

Bearings support and align the impeller shaft for smooth operation (see figure 1-7).

Pump Seals

There are two types of seals available for Hale midship pumps, packing and mechanical.

Packing

Packing available on Qmax and Qtwo pumps forms a nearly watertight seal at the point where the shaft passes from the inside to the outside of the pump (see figure 1-9). Packing material is cooled with pump water. The packing gland should not be excessively tightened, or the material will lose its built -in lubrication and dry out, which may result in damage to the pump. The single packing gland is located on the low-pressure side of the pump. Its split design promotes ease of repacking. The packing nut is full circle threaded type to exert a uniform pressure on packing and to prevent cocking and uneven packing load. The packing is easily adjusted with a rod or screwdriver. The packing rings are made of a combination of unique materials and have sacrificial zinc separators to protect the pump shaft from galvanic corrosion. Packing material may also deteriorate if the pump is kept dry for long periods of time during winter months (for example, to prevent freezing). In this case, charging the pump with water at least once weekly will prevent deterioration. See the Maintenance Instructions in Section 3 for details.

1-10

PACKING LANTERN

(4) 7/16 SQUARE

PACKING HOUSING

IMPELLER END

(3) .005 THK FOIL PACKING SEPARATORS PER JOINT (TOTAL 12 REQUIRED)

PACKING COOLING PASSAGE

SPLIT PACKING GLAND

SLOTTED PACKING NUT

PACKING GLAND LOCK

Figure 1-9. Pump Packing

RESERVOIR

Muscle Pumps

Mechanical Seal

The mechanical seal is standard on the Qpak and Qflo pumps and is available as an option on the Qmax and Qtwo pumps. As shown in figure 1-10, a stationary seal seat is in constant contact with a rotating carbon face to prevent leakage. The sealing boot is made of a rubber elastomer that is specifically designed for high temperature operations.

Auto Lube ®

A miniature centrifugal pump is built into the shaft of Hale Qmax and Qtwo model pumps (see figure 1-11). This miniature pump continuously forces oil from the reservoir, through the bearing, and back again. A balancing chamber behind the oil reservoir is connected by a passage to the inlet side of the pump. This chamber always keeps the pressure in the oil reservoir equal to water pressure – whether you are pumping at high inlet pressure or pulling vacuum.

The miniature pump adds enough extra pressure to constantly keep the flowing oil a few PSI higher than water pressure. Thus, oil pressure inside the

MINIATURE CENTRIFUGAL PUMP

double lip-type seal is always slightly higher than water pressure outside. Dirt and water are repelled by this higher pressure.

Auto-Lube® does more than just fight off dirt. It

DOUBLE LIP OIL SEAL

ensures continuous lubrication, even when you are pumping dry. It permits the use of a compact, double lip-type oil seal, and maintains a constant film of oil under this seal to prevent shaft wear.

OIL

BEARING

Because it is built into the main pump body, it completely eliminates the need for a second set of packing, or a second mechanical seal.

BALANCING CHAMBER

Figure 1-11. AutoLube

1-11

Muscle Pumps

D. Pump Drives

Pump Mounting Options

There are four common types of centrifugal pump drives used with fire fighting apparatus:

q Operation from the truck chassis drive

shaft (split -shaft gearbox).

q Operation from a separate engine.

q Operation from the front of the truck

chassis engine (front engine PTO) crankshaft.

q Operation from a PTO from the truck

transmission, a PTO before the engine drive transmission or a PTO from the four-wheel drive transfer case.

G-Series Gearbox

The most common pump drive is the split-shaft gearbox.

The Hale G-Series split-shaft gearbox is available as a short (S), long (L), or extra long (X) model. The model designation S, L, or X, provides for different distances from the pump centerline/mount location to the center of the drive shaft for proper drive line angles. The location, pump and drive line angle determine the optimum gearbox length selection.

Hale offers a variety of pump gear ratios to accommodate a wide range of apparatus manufacturer requirements based on engine speed and available horsepower. The gearbox (figure 1-12) consists

of the gearbox, gear set, and input and shafts thatare both made of heat-treated nickel steel. This unit can withstand the full torque of the engine in road operating conditions up to 16,000 pounds -feet (21,693 N-m).

Principle of Operation

Midship pumps are so named because of their location on the fire apparatus. They are normally driven through an integral transmission that has a sliding gear shaft and sliding gear that selectively directs the engine power to the pump or the rear axle. Figure 1-13 shows the typical midship pump split shaft arrangement on a typical chassis.

The midship transmission is capable of handling full engine horsepower, enabling the pump to meet optimum performance levels as well as all torque requirements for over the road applications.

LP and XP Gearbox

In addition to the standard Hale gearboxes there is also available a “P” series gearbox. The “P” series gearbox contains a third stage “power take-off” that permits the mounting of an air compressor or other auxiliary drive component.

Shifting

If the gearbox is equipped with a power shift system, an in-cab control valve is provided for mode selection. This control locks in place for pump operation. Indicator lights are provided to alert the operator when the gearbox has fully shifted from road to pump position. Additionally, provision is provided for manual shift due to failure of the power shift system.

1-12

Muscle Pumps

1-13

Muscle Pumps

J-Series Gearbox

The Hale J-Series Gearbox, available for the Qpak pump, is a heavy duty gearbox that is driven from a transmission-mounted PTO allowing for pump and roll applications. This gearbox has a wide range of ratios available to allow for use on different engine and transmission combinations.

E. Accessories

Priming Pump

Priming pumps are used to create a vacuum: they are designed to evacuate air in the suction hose and the pump. The vacuum created allows atmospheric pressure to push water from the open source through the suction hose and into the pump. Hale centrifugal midship pumps use Rotary Vane Positive Displacement pumps for priming. A positive displacement pump moves a specified amount of air or fluid with each revolution. As shown in figure 1-14, the priming pump has a single rotor mounted off-center (eccentric) to the pump body housing.The vanes in the rotor slide in groves and are held against the body housing by centrifugal force. As a vane

turns toward the discharge, it recedes into the rotor. As the rotor continues past the discharge, the vane advances outward from its groove and against the body housing. During this cycle, the space between the rotor and housing cases fills with air, and the vanes, acting as wipers, force air out of the discharge, creating a vacuum in the main pump allowing atmospheric pressure to push water into the hose and into the suction side of the main pump.

A Ha le priming pump has a single control that both opens the priming valve between the midship pump and the priming pump and starts the priming motor.

1-14

Muscle Pumps

Priming Valves

Hale priming valves open when the primer is operated, to allow the primer to eva cuate air in the pump. There are two priming valves available.

The Hale Semi-Automatic Priming Valve (SPV) can be mounted directly to the priming connection on the midship pump, or can be remotely mounted using a universal mounting adapter. When the SPV i s installed, a single electric push-button on the operator’s panel starts the priming pump motor. When the primer motor starts and produces a vacuum, the SPV opens. Releasing the push-button stops the priming pump and the SPV closes.

The Hale PVG Priming Valve is mounted on the operator’s panel. The PVG is a combination valve and switch. When the panel handle on the PVG is pulled out the valve opens and the switch energizes the primer motor. Pushing the handle de -energizes the motor and closes the valve.

Pressure Control Devices

Two basic types of pressure control devices are used with Hale Midship pumps:

q Relief valve system (standard). q Hale Total Pressure Master Relief Valve

System (optional).

Relief Valve System

The Hale Standard Relief Valve System is shown in figure 1-15. The relief valve system consists of a panel mounted control valve (PM) and an internal relief valve, either a QG as shown or a QD.

The relief valve system works as follows: The strainer 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 spring tension on the diaphragm. The seat of the QD or QG relief valve is kept closed by pump discharge pressure.

As 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 will move off it’s seat, allowing pump pressure to push on the piston in the relief valve. The pressure on the piston will cause the relief valve seat to lift allowing excess discharge pressure to dump back to the pump suction.

The amber indicator light on the PM control illuminates when the relief valve is open.

1-15

Muscle Pumps

1-16

Muscle Pumps

Hale Total Pressure Master (TPM) Relief Valve System

This system, figure 1-16, includes a sensing valve connected to the inlet side of the pump that works in conjunction with a Pressure Master Control on the pump panel to give complete control over the entire system. The operating point is set by the Pressure Master Control. Small changes in pump pressure are normally handled internally by the recirculating relief valve (QG). Large changes on either the inlet or discharge side of the pump are controlled by dumping excess pressure to the atmosphere from the discharge side of the pump through the PG30 Relief Valve.

The Hale TPM Relief Valve System is designed to automatically relieve excess pump pressure when operating from draft or positive incoming flows.

The system self-restores to the non-relieving position when excessive pressure is no longer present.

The TPM relief valve system is a mechanical system, consisting of an internal relief valve (QG) which bypasses water to the suction side of the pump, an external relief (dump) valve (PG30, with sensing valve attached) to discharge water to the atmosphere, and a single panel mounted control valve (PMD) to provide control of pump pressure, within NFPA required limits, to the pump operator.

The PMD control permits the pump operator to “set” a de sired relief pressure for both internal and external relief valves. The panel control has an easy to read and easy to set adjustment with an approximate indication of pressure setting.

1-17

Muscle Pumps

During normal operation, both the QG relief valve and PG30 relief valve are closed (as shown in figure 1-17).

The TPM system functions by monitoring and controlling pump pressure and relieves excessive pressure by first utilizing the internal relief valve (QG) (returning flow to the pump suction, see figure 1-18). If excessive pressure remains and there is positive pressure on the suction, a secondary external relief valve (PG30) responds by discharging excessive pressure to the atmosphere (shown in figure 1-19). The staging of the internal and external relief valves to operate in series ensures maximum protection against over pressure and eliminates the indiscriminate discharging of water to the ground.

The external relief valve (PG30) is mounted on the discharge side of the pump where discharged water flowing through the valve provides a self -cleaning process and virtually eliminates the possibility of the valve remaining in an open position due to contamination.

The amber light on the PMD control illuminates when the QG relief valve is open. The same light flashes when both the QG and PG30 valves are open.

1-18

Muscle Pumps

1-19

Muscle Pumps

1-20

Muscle Pumps

1-21

Muscle Pumps

Cooling Options

Model K Auxiliary Heat Exchanger/Cooler

NFPA 1901 requires a supplementary heat exchanger cooling system for the pump drive engine during pumping operations. Hale model “K” heat exchangers, figure 1-20, meet NFPA 1901 requirements. The units can be used with any size radiator and use water from the pump to help maintain the proper temperature of the engine coolant during pumping. The cast-iron housing and copper-tubing coil keeps the water and coolant from contaminating each other. A valve is normally supplied on the operator’s panel to allow the operator to control the amount of water supplied to the model “K” heat exchanger.

1-22

Muscle Pumps

Thermal Relief Valve (TRV)

An optional Thermal Relief Valve (TRV), figure 121, can be attached to the main pump body. This valve prevents the overheating of the pump under certain operating conditions. The valve monitors and controls the temperature of the water in the pump. When the temperature exceeds 120°F, the valve automatically opens and discharges a small amount of water either to the ground or into the water tank, allowing cooler water to enter the pump. After the temperature reduces to a safe level, the valve closes until the temperature is exceeded again.

POWER CONNECTION THRU 10 AMP 12V FUSE

The TRV-L model includes a chrome panel placard with warning lamp and lamp test button, and a preassembled wiring harness. The light illuminates whenever the TRV is open and discharging water. An optional buzzer provides audible warning. The buzzer mounts in a 1-1/8 inch opening on pump panel.

INSTALLER SUPPLIED WIRING FOR AUDIBLE ALARM OPTION ONLY. (14 GA. SXL OR GXL SAE J1128)

ALARM-AUDIBLE

TO CHASSIS GROUND

INSTALLER SUPPLIED WIRE (14 GA. SXL OR GXL SAE J1128)

PRESSURE SWITCH

ELBOW-1/8 NPT X 1/4 FNPT REDUCING STREET

BODY-INDICATOR LIGHT BULB LENS

SWITCH-PUSH BUTTON

NAME PLATE, TEST SWITCH, AND LIGHT

WIRING HARNESS

CONNECTION FOR RELIEF VALVE DISCHARGE LINE

FITTING-1/8 NPT X 1/8 FNPT

Figure 1-21. Thermal Relief Valve (With Light Kit Installed)

1-23

TRV

HANDWHEEL

NITRILE RUBBER COATED DISK

PANEL PLACARD

SUCTION EXTENSION

BLEED CONNECTION

ELECTRICALLY

HALE TYPE "115" SERIES

Muscle Pumps

Valves

Suction Valves

Hale has available valves that mount in the suction of the midship pump.

The Hale Master Intake Valve (MIV) becomes an integral part of the fire pump. When the valve is ordered as part of a Hale Midship fire pump, the pump will pass UL requirements up to 1500 GPM (5678 LPM) from draft through a single 6 inch NST suction hose with the valve in place. When two valves are mounted to the fire pump the pump can achieve NFPA Performance Point flows of 2000 GPM (7580 LPM) from draft with dual 6 inch NST suction hoses. NFPA Performance Point flows of 2250 GPM (8516 LPM) is achieved with two MIVs and three 6 inch NST suction hoses. The Hale MIV meets NFPA requirements for operations using a large diameter supply hose. See

figure 1-22 for Master Intake Valve. Further information on the MIV can be found in manual P/N 029-0020-35-0.

At least one full flow suction valve with locking handle is normally mounted on the pump. The body of each suction valve connects into the pump suction with a maximum of one long sweep 90° elbow between the valve and the pump suction.

Discharge Valves

Discharge valves regulate the amount of water leaving a pump. Each valve includes a locking device that permits operation in any position from fully opened to fully closed. The 2-1/2-inch discharge valves are quarter-turn ball-type with a locking handle. As the valve handle is moved the ball can rotate from being in-line with the waterway to a position 90° to the waterway, or any position in between, thus reducing or stopping the flow of water. In-line valves are also quarter-turn ball-type valves.

AND INDICATORS

12 VOLT DC MOTOR

SEAL GEAR ACTUATORS

MANUALLY OPERATED

OPERATED

3/4 NPT (FEMALE)

MIV VALVE

PANEL PLACARD AND INDICATORS

HANDWHEEL

3/4 NPT (FEMALE) PRIMING CONNECTION

FLANGE WITH 2 1/2 NPT(FEMALE) THREAD FOR REMOTE MOUNTING

DRAIN CONNECTION

SUCTION TUBE

MANUAL OVERRIDE

1-24

Figure 1-22. MIV Valve

Muscle Pumps

These valves can be used in either suction or discharge lines.

Each discharge valve on a Hale pump may be equipped with a drain. Opening the drain before uncoupling the hose relieves the pressure in the line. Also, water must be drained from the pump during freezing conditions through the main drain valve.

q Manual gear operator (see figure 1-24). q Electric gear operator with optional

manual override (see figure 1-25).

Tank Suction Valves

There are two different Hale valves that can be used as tank suction.

The first valve is the Hale 30BPF, this valve is an integral flanged valve that mounts to the 8-bolt flange pattern at the tank suction port of the midship pump. The valve is a lever operated 3-inch full flow ball valve and can be connected to the tank using a 4-inch Victualic™ coupling or 3 inch NPT pipefitting or a 4 inch hose.

Another option for the tank suction valve, is the 40BDS Model valve. The 40BDS valve is a 4-inch full flow ball valve that is available lever operated or can be equipped with an electric motor gear operator. The nature of the 40BDS permits mounting to the tank suction opening on the pump using an 8-bolt 3.5° angled flange or an 8-bolt straight flange. Tank connection is by use of 4 inch NPT threaded pipe fittings or 4 inch or 5 inch Victualic™ clamps.

The 30BPF and 40BDS valves are provided with an optional check valve flapper to prevent pressurization of the water tank.

In-line Valves

Hale has several types, sizes, manual, and electrically operated in-line valves. The BP seriesbronze valves range in size from one inch to three inch in half -inch increments.

Hale type 40BD 4 inch in-line valves have many options:

q Inlet and outlet sizes. q Lever operated for tank and suction line

(see figure 1-23).

q Direct mount (Deck Gun) valve.

1-25

Muscle Pumps

An odes

The Hale Anode System helps prevent damage caused by galvanic corrosion within the pump. Galvanic action pits the pump and pump shaft material through the electrolysis of water in the pump. The popularity of non-corrosive water tanks and piping has increased the incidences of this type of corrosion in today’s fire pumps. The Hale Anode System provides a sacrificial metal, which helps to diminish or prevent pump and pump shaft galvanic corrosion. The Hale Anode will fit on any Hale truck mounted pump, regardless of age or model. It is designed to be easily installed requiring just four bolts and a gasket. Total time to

Drain Valves

There are two types of drain valves available from Hale. They are either the sliding plug type (HD, DV5) or a screw knob style (DV7).

The sliding plug type valves have a pull handle mounted on the operator’s panel. Pulling the handle out opens the valve allowing the component to drain. The Model DV5 has connections for up to five drain lines. When the DV5 is either open or closed, the possibility for “cross talk” exists. This drain valve cannot be used with either relief valves or other pilot pressure valves. The screw knob style drain valve (DV7) has facilities to connect up to seven in dividual drain lines. Each connection to the DV7 is individual and the possibility for “cross talk” does not exist. The control knob is located on the operator’s panel. Turning the control knob counterclockwise will open the drain valve.

install is just fifteen minutes, yet it will provide years of protection for your pump. The Anode kit (figure 1-26) is designed for installation in the standard Hale 115 series flange openings. On fabricated manifolds and similar applications, the installer is to provide 1-1/4 NPT openings and install anodes directly. It is recommended that one anode is installed on the suction side and one is installed on the discharge side. Anodes can be mounted in any position (horizontal or vertical).

HALE 115 SERIES FLANGE GASKET

HALE 115 SERIES FLANGE

ZINC ANODE

PUMP BODY, SUCTION TUBE, ETC.

Figure 1-26.

Hale Anti-Corrosion Anode

1-26

Muscle Pumps

Booster Pump

Hale booster pumps offer the added dimension of low volume and high pressure for use with the midship pumps. The booster is ideal for high pressure, hose reel operation.

As shown in figure 1-27, the booster pump is designed for direct mounting at the accessory port of the Hale "L" series gearbox. The booster pump is driven by the gearbox intermediate gear to provide a positive drive. Water is directed to the booster pump through a pre-piped supply hose.

1-27

Muscle Pumps

2. OPERATING PROCEDURES A. Overview

This section supplies information and procedures for the operation of Hale single-stage and twostage pumps. Included in this section are procedures for pumping from a hydrant, pumping from draft, pumping from a booster tank, pumping in relay, tandem pumping from a hydrant, and post-operation proc edures.

B. Operating Procedures

THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES AND POLICIES ESTABLISHED BY YOUR FIRE DEPARTMENT, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROC EDURES PROVIDED BY THE FIRE TRUCK MANUAL.

Pumping From a Hydrant, General Operation

1. Position the truck for the best hydrant hookup and discharge hose layout.

REFER TO THE FIRE DEPARTMENT PROCEDURES ON SETTING WHEEL CHOCKS AS WELL AS LAY OUT AND CONNECTION OF SUCTION AND DISCHARGE HOSES.

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

NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS “0” BEFORE MAKING PUMP TRANSMISSION SHIFT.

2. Bring the truck to a complete stop before you attempt to shift from road to pump.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRAL position.

5. Move the in-cab pump shift control valve from the ROAD position to the PUMP position. The shift warning lights should come on in a second or two, indicating a complete shift.

If the truck manufacturer has used another in -

cab valve to achieve pump shift or has an electric switch, follow the instructions supplied with that valve.

6. After pump shift is completed, put the truck transmission in the proper pump operating range or gear. For most pumpers this will be direct drive (1:1) ratio. In addition, the speedometer should read 5 to 15 MPH after the shift has been completed. If the shift does not seem to be completed, shift truck transmission to “N” and repeat the entire procedure. Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the pump position. See the chassis manual for details.

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

7. Exit the driving compartment only after all the above steps are completed and you are sure that the shift completed lights in the cab and panel are on.

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

2-1

Muscle Pumps

8. Verify that the pump panel shift indicator green "OK TO PUMP" light is on.

9. Open the hydrant.

10. If necessary, open the suction valve.

11. If applicable, set the transfer valve to either vol ume or pressure, as required.

12. If necessary to eliminate air pockets open valve to let air out or prime the pump: see “Pumping From Draft” for instructions.

13. Note the intake and discharge pressures then open the engine throttle gradually until the master discharge gauge indicates the desired pressure.

14. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy to follow, see the “Relief Valve or TPM Procedures” later in this section

DO NOT REDUCE THE PRESSURE ON THE INTAKE GAUGE TO ZERO; SERIOUS DAMAGE TO THE WATER MAIN COULD RESULT.

If the master intake gauge shows a vacuum before the desired discharge pressure or flow is reached, this is an indication that you are getting all the water that the hydrant will supply. To increase the pressure when this occurs, reduce the pump flow. The master intake gauge reading must be maintained at 5 PSI (.5 BAR), minimum.

As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. In this case, close the throttle slowly until the pressure begins to drop, and the engine returns to an idle. If this does not correct the problem you are trying to pump more capacity than is available from the hydrant.

15. Open the discharge valves.

16. If the pump overheats and is not equipped with the Hale TRV valve, open the valve to access

the pump auxiliary cooling system, or slightly

open the tank fill line.

17. After completion of pumping procedures, gradually reduce the pump pressure until the engine is at an idle speed. Use the “Pump to Road Shift Procedure” and “Post Operation Procedure” provided later in this section.

TPM Operation from a Hydrant

When operating from a positive inlet pressure, during some operational conditions, it may be necessary to adjust the TPM Relief Valve to a point where water is dumping to the ground. The internal relief valve will always open first, and if it cannot handle the pressure rise, the external relief valve will dump water on the ground. When the internal relief valve opens, the panel light will be on, and when the external dump valve opens, the pilot light on the panel will flash.

Pumping From Draft, General Operation.

1. Get as close to the water source as possible. The pump can do better than its rated capacity with less than a 10-foot vertical lift. As the vertical lift increases to above 10 feet, the maximum pump capacity will be reduced.

REFER TO THE FIRE DEPARTMENT PROCEDURES IN SETTING WHEEL CHOCKS AS WELL A S LAY OUT AND CONNECTION OF SUCTION AND DISCHARGE HOSES.

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

2-2

Muscle Pumps

2. Bring the truck to a complete stop before you attempt to connect suction hoses or shift from road to pump.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRAL position.

5. Move the in-cab pump shift control valve from the ROAD to the PUMP position. The shift warning light should come on in a second or two, indicating a completed shift. If the truck manufacturer has used another in -cab valve to achieve pump shift, follow the instructions supplied with that valve

6. After pump shift is complete, put the truck transmission in the proper pump operating range or gear. For most pumpers this will be direct drive (1:1) ratio. In addition, the speedometer should read 5 to 15 MPH after the shift has been completed. If the shift does not seem to be completed, shift truck transmission to “N” and repeat the entire procedure. Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the pump position. See the chassis manual for details.

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

7. Exit the driving compartment only after all the above steps are completed and you are sure that the shift completed lights in the cab and panel are on.

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

8. Verify that the pump shift indicator light is on.

9. Activate the priming pump by pulling the control handle located on the pump panel or depressing the push button.

The departmental manual for pumping should

specify the correct RPM for priming, but in general, for priming the pump should be operated at idle with an engine speed of about 1,000 to 1,200 RPM.

10. Watch the intake and discharge master gauges. When the pump is primed, the intake indication reading falls below zero, and the discharge pressure starts to increase. You may also hear water discharging on the ground, indicating that the pump is primed.

Running the engine at speeds higher than

1,200 RPM during priming is not recommended, because it will not improve priming operation. Running the pump at higher RPM will increase wear.

IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO, OR THE PRIMING PUMP DOES NOT DISCHARGE WATER ON THE GROUND IN 30 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP. STOP THE PUMP, AND CHECK FOR AIR LEAKS OR POSSIBLE PUMP TROUBLE.

11. After priming, select the desired transfer valve position (for two-stage pumps).

12. Gradually open the discharge valve until the water emerges as a steady stream. Then open the other discharge valves to the desired setting.

13. Open the engine throttle gradually until the desired pressure or flow is reached.

2-3

Muscle Pumps

DO NOT PUMP ENOUGH WATER TO CAUSE A WHIRLPOOL AT THE STRAINER. THIS ALLOWS AIR INTO THE PUMP, RESULTING IN ROUGH OPERATION AND PULSATION. REPOSITION THE STRAINER OR REDUCE FLOW TO CORRECT THE SITUATION.

As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating.

If the pump is cavitating, warn personnel that the pressure is being dropped. In this case, close the throttle slowly until the pressure begins to drop, and the engine returns to an idle. If this does not correct the problem, here are two possibilities that can also lead to this condition:

a. Cavitation can occur with large nozzle

tips. Solve this problem by reducing flow.

b. Cavitation can also occur when you are

pumping if air enters with the water. Even though the pump may be primed, 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, discontinue pumping and refer to Section 4 for maintenance.

14. 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. If the pump overheats from continued churning without water flow, open the discharge valves peri odically to release hot water.

15. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy to follow, see the “TPM or Relief Valve Procedures” later in this section.

16. If the pump overheats and is not equipped with the Hale TRV valve, open the valve to access the pump auxiliary cooling sys tem, or slightly open the tank fill line.

2-4

17. After completion of pumping procedures, gradually reduce the engine RPM until it is at an idle speed. Use the “Pump to Road Shift Procedure” and “Post Operation Procedure” provided later in this section.

Pumping From the Onboard Water Tank

1. Position the truck for convenient discharge hose layout, and bring the truck to a complete stop.

REFER TO THE FIRE DEPARTMENT PROCEDURES ON SETTING WHEEL CHOCKS AS WELL AS LAY OUT AND CONNECTION OF SUCTION AND DISCHA RGE HOSES.

2. Bring the truck to a complete stop before you attempt to shift from road to pump.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRAL position.

5. Move the in-cab pump shift control valve from the ROAD position to the PUMP position. The shift warning light should come on in a second or two, indicating a completed shift. If the truck manufacturer has used another in-cab valve to achieve pump shift, follow the instructions supplied with that valve.

6. After pump shift is complete, put the truck transmission in the proper pump operating range or gear. For most pumpers this will be direct drive (1:1) ratio. In addition, the speedometer should read 5 to 15 MPH after the shift has been completed. If the shift does no t seem to be completed, shift truck transmission to “N” and repeat the entire procedure. Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the pump position. See the chassis manual for details.

Muscle Pumps

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

7. Exit the driving compartment only after all the above steps are completed and you are sure that the shift completed warning lights in the cab and panel are on.

12. 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 may be cavitating.

If the pump is cavitating, warn personnel that the

pressure is being dropped. In this case, close the throttle slowly until the pressure begins to drop, and the engine returns to an idle. If this does not correct the problem, reduce flow.

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

8. Verify that the pump panel shift indicator light is on.

9. Open the tank suction valve.

10. For two-stage pumps, select the desired transfer valve position.

11. Check the master discharge gauge to see if priming is necessary. If necessary, start the priming pump by pulling the control handle located on the pump panel or depressing the prime push button or just crack the tank fill valve.

Watch the intake and discharge pressure gauges. When the pump is primed, the compound gauge i ndication falls below zero, and the pressure starts to increase. You may also hear water splashing on the ground, indicating that the pump is primed.

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

13. Gradually open the discharge valves until the water emerges as a steady stream. Then open the discharge valves to the desired setting.

14. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy to follow, see the “TPM or Relief Valve Procedures” later in this section.

15. If the pump overheats and is not equipped with the Hale TRV valve, open the valve to access the pump auxiliary cooling system, or slightly open the tank fill line.

16. After completion of pumping procedures, gradually reduce the engine RPM until it is at an idle speed. Use the “Pump to Road Shift Procedure” and “Post Operation Procedure” provided later in this section.

Pumping In Relay

Relay operations are necessary when the water source is too far away from the fire to be pumped efficiently by one pumper. Relay pumping is the movement of water through a number of consecutive pumpers, from suction to discharge. The number of pumpers is determined by how far the water source is from the fire.

In some cases, when you are on the receiving end of a relay, it may help to set the suction dump or

2-5

Muscle Pumps

TPM (if available) very low in order to limit the incoming pump pressure by dumping water on the ground before you have discharge hose lines connected and are flowing water. Then, as you are able to use the incoming water, the relief valve control can be moved up to the desired operating pressure and set as instructed. This technique will also help you to purge the air from the incoming hose and the pump before it can get to a dangerously high pressure.

Use this procedure after the hose is laid, the apparatus are in position, and the pumps are engaged. See the “Pumping from a Hydrant” procedure for setup and engagement instructions for apparatus receiving pressurized water.

1. Open two discharge gates on all pumps, except on the pump at the source, to get rid of air from hose lines and pumps.

2. On each pump, attach the hose lines to one of the discharges, and leave the other discharge uncapped (only for trucks without a relay valve).

3. Watch the intake gauge for a high-pressure reading. If this is reached, open the gate controlling the uncapped discharge to remove excess water.

4. Supply the pump at the water source with water; prime if necessary. The discharge pressure must not be over 150 PSI (10 BAR) or the maximum pressure rating of the relay hose to start water moving. Use either the “Pumping From Hydrant” or “Pumping From Draft” procedures that appear earlier in this section.

5. When the water reaches the second pump, close the uncapped discharge gate. Repeat this step for all pumps until the water reaches the fire ground.

6. Adjust the throttle on the pump at the water source for the required operating pressure. Watch the gauges to avoid cavitation. (The pump operator at the fire scene will advise all other pump operators of the amount of water needed at the fire ground).

7. Adjust the discharge pressure or flow at the fire scene to supply the lines being used.

8. Observe the gauges carefully, and adjust the pressure or flow as needed.

9. Shutdown starts from the fire ground pump and works toward the water source. Gradually reduce pressure at the fire ground pump until you can disengage it. Follow this procedure for every pump in the relay until the pump at the water source is shut down.

LOCAL TRAINING PROCEDURES MAY VARY SLIGHTLY FROM ABOVE.

Tandem Pumping Operation From a Hydrant

1. Using the large intake hose, connect the first pumper to the hydrant steamer. Open the hydrant until the pump is primed, then partially close the hydrant.

2. Position the second pumper intake-to-intake with the first pumper.

3. Open a discharge to flow water.

4. With the hydrant partially closed, adjust the throttle on the first pumper until the intake gauge reads about 5 PSI (.5 BAR)

5. Remove the unused intake cap.

6. Connect the second pumper to the unused steamer intake of the first pumper, using a large intake hose.

7. Open the hydrant completely. Both pumpers pump water to the fire, (refer to the procedure on “Pumping From a Hydrant”).

LOCAL TRAINING PROCEDURES MAY VARY FROM ABOVE.

2-6

Muscle Pumps

Pump To Road Shift Procedures

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

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

3. Moving pump shift control valve lever to the ROAD position. The in-cab and panel pump i ndicator lights should go out when the pump transmission starts to shift into the ROAD position.

REFER TO THE FIRE DEPARTMENT PROCE DURES ON REMOVING WHEEL CHOCKS AS WELL AS LAY OUT AND CONN ECTION OF SUCTION AND DISCHARGE HOSES.

Standard Relief Valve Procedures

These procedures are for setting the operating point of the standard relief valve.

1. Increase the engine RPM to reach the desired pump operating pressure while reading the di scharge pressure gauge.

2. Turn the hand wheel slowly counterclockwise until the relief valve opens, the pilot light comes on, and the master pressure gauge drops a couple of PSI (BAR).

3. Turn the hand wheel slowly clockwise until the master pressure gauge rises to the desired pressure and pilot light goes out. The relief valve will now operate at the set pressure.

4. When the pump is not in operation, turn the hand wheel clockwise so that the control is set slightly above the normal operating pressure. When the pump is put into operation again, reset the control valve to the desired operating pressure.

2-7

TPM Relief Valve Procedures

These procedures cover the Hale TPM Relief Valve System. Be sure to select the correct procedure, according to relief valv e.

TPM System (only)

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 and with the pump discharging water), slowly move the adjusting handwheel counterclockwise until the relief valve opens, the amber pilot light comes on, and the master pressure gauge reading drops a couple of PSI (BAR).

3. Turn the handwheel slowly clockwise until the master pressure gauge reading is at the correct operating pressure and the pilot light goes out. The relief valve will operate at the set pressure.

THE INDICATOR ON THE PANEL IS ONLY A ROUGH INDICATION OF TPM SETTING. ALWAYS USE THE ABOVE PROCEDURE TO PROPERLY SET THE TPM RELIEF VALVE SYSTEM.

TPM System with Engine Governor

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. Power on the governor control.

3. Set the discharge pressure using the RPM mode of the pressure governor control.

4. Move the TPM handwheel counterclockwise until the relief valve opens and the amber pilot light comes on.

Muscle Pumps

5. Turn the hand wheel slowly clockwise, until the amber light just goes out. Then turn the hand wheel one additional full turn clockwise for proper operation.

THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.

6. Put the governor control in the Pressure Governor mode; the system is now set.

7. Use the following procedures to change the set pressure while running:

Increasing Pressure

a. Set the TPM to a pressure (by the

indicator) slightly higher than the desired new pressure.

b. Put the governor control in the RPM

mode, and increase the speed to the new pressure.

c. Move the TPM handwheel counterclockwise

until the relief valve opens and the amber pilot light comes on.

d. Turn the handwheel slowly clockwise,

until the amber light just goes out. Then turn the handwheel one additional full turn clockwise for proper operation.

THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.

e. Put the governor control in the Pressure

Governor mode; the system is now set.

Decreasing Pressure

a. Put the governor control in the RPM

mode, and reduce the speed to the new pressure.

b. Move the TPM handwheel counterclockwise

until the relief valve opens and the amber pi lot light comes on.

c. Turn the handwheel slowly clockwise,

until the amber light just goes out. Then turn the handwheel one additional full turn clockwise for proper operation.

THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.

d. Put the governor control in the Pressure

Governor mode; the system is now set.

Emergency Pump Shift Procedures

Before implementing manual override shift procedures, repeat recommended procedures. If the shift fails to take place, follow these procedures.

1. Bring the truck to a complete stop.

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

3. Shift the truck transmission to the NEUTRAL position.

4. For Pump or Road position, put the in -cab shift control in the Neutral position. (Neutral position is exactly in the middle of the road and pump position.

5. Shut down the engine.

2-8

Muscle Pumps

a. Open discharge valves, remove suction

tube caps, and discharge valve caps.

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

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

An eyebolt is provided in the shift shaft to accept a drift punch or screwdriver. By inserting this tool into the hole provided, it will enable you to pull or push the shaft manually. Pull the shift shaft Out for Pump Position (after in-cab control valve selection), or push shift shaft for Road Position (after in-cab control valve selection). If the shift stroke cannot be completed manually, turn the driveshaft slightly by hand to realign the internal gears and repeat the manual shift effort.

b. 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.

c. On two-stage pumps, move the transfer

valve back and fourth to both the volume and pressure positions.

d. If installed, drain the gearbox cooler.

e. After the pump is completely drained,

replace all caps and close all valves.

3. Fill out the pump run log, indicating total pumping time and total out-of-station time.

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

Post Operation Procedures

1. If you have been pumping seawater, dirty water, alkaline water, or using an around the pump proportioner, flush the pump with clean water.

2. After using the pump, drain the pump as follows (especially important in freezing weather):

2-9

Muscle Pumps

3. PREVENTATIVE

MAINTENANCE A. Overview

Hale Midship Pumps require very little care and maintenance. However, the little required is extremely important. Preventive maintenance tasks require very little time to accomplish and consist mainly of testing for leaks, lubrication, and cleaning.

The procedures supplied in this section are for normal use and conditions. Extreme conditions may indicate a need for increased maintenance. The procedures in this section identify some extreme conditions and the additional measures needed to ensure lengthened pump life and continuing dependability.

The first part of this section includes some extreme condition maintenance guidelines. Sections with recommended activities to be accomplished on a weekly, a monthly, and an annual basis follow this. A separate maintenance checklist is provided to record completed maintenance actions.

B. Procedures

Post Operation Maintenance

1. If necessary, follow the procedures in the Extreme Maintenance Conditions paragraph.

2. On two-stage pumps, remove the suction tube strainers, and reach in to ensure that check valves are free to swing. Also, verify that no foreign matter is caught between the valve and the seat.

3. Inspect the suction hose rubber washers and washers in the suction tube caps. Remove foreign matter from under these washers. Replace worn, damaged, or dry washers.

4. Verify that all discharge valves, booster line valves, drain valves, and cocks are closed.

5. Tighten suction caps.

Extreme Conditions Maintenance Guidelines

Extreme conditions occur when the pump has been operated during freezing weather and as a result of pumping from a water source that contains material that will be harmful to the pump if not purged.

During Freezing Weather

In freezing weathe r, 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. On two-stage pumps, move the transfer valve back and forth to both the volume and the pressure positions.

4. After the pump is completely drained, replace all caps and close all valves.

After Pumping from Salt Water, Contaminated Water, or With Foam Solution

After drafting from sea water, contaminated, sandy or dirty water, flush the pump and suction hoses by using water from a hydrant or other clean water source. After pumping foam through the pump, flush as above until all residues of foam have gone.

Weekly Maintenance

Weekly maintenance consists of testing the relief valve system or governor, the transfer valve on two-stage pumps, the priming system, and the pump shift warning indicator lights. If testing criteria is not met, refer to Section 4 for corrective maintenance.

3-1

Muscle Pumps

Relief Valve and TPM Test

When the relief valve is not in operation, maintain a setting above the normal operating pressure.

1. Set up to pump from the onboard water tank with the discharge valve back to the water tank open less than 1/2 way. See the procedures in Section 2 for assistance.

2. Bring the pump pressure up to 150 PSI (10 BAR) per normal operating procedures.

3. Turn the control valve handwheel counterclockwise until the relief valve opens and the pilot light is lit. Master pressure gauge should drop at least 5 to 10 PSI (0.5 to 1 BAR).

4. Turn the control valve handwheel clockwise then counterclockwise a few times to ensure that the handwheel turns freely. Master pressure gauge should increase and pilot light should go out. This action also ensures proper valve operation.

5. Reset the relief valve to its normal operational setting.

Governor Test

If your apparatus is equipped with an electronic governor, follow the manufacturer’s instructions for weekly preventive maintenance.

Transfer Valve Test (Two Stage Pumps Only)

1. For manual transfer valves:

a. With the apparatus engine turned off, turn

the handwheel between the volume and pressure positions a few times to verify that the valve operates freely.

b. Set the truck up for pumping per the

procedure in Section 2, with the transfer valve in the volume position.

c. Leave the engine at idle speed, and move

the transfer valve to the pressure position.

d. Verify that the discharge pressure gauge

readings have approximately doubled.

2. For power transfer valv es:

a. With the apparatus engine turned off, use

either a 3/8-inch socket on the indicator hex nut or a rod in the hole in the indicator hex nut to manually transfer the valve to verify that the valve operates freely.

b. Set the truck up for pumping per the

procedures in Section 2, with the transfer valve in the volume position. Note the discharge gauge readings.

c. Leave the engine at idle speed, and move

the transfer valve to the pressure position.

d. Verify that the master intake gauge

readings have approximately doubled.

Priming System Test

1. Tighten all pump caps, and close all pump valves.

2. Pull the primer control while you watch for a below-zero reading on the master intake gauge.

3. Verify that the master intake gauge readings hold for approximately 5 minutes after you release the primer control. A drop of 10 inches hg in this 5 minute period is anticipated per NFPA 1901.

Pump Shift Warning Indicator Lights

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

1. Follow the operating procedures in Section 2 to engage the pump.

3-2

Muscle Pumps

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

3. Switch to non-pumping operations, and verify the warning indicators are off.

Valve Lubrication

1. Spray all moving parts of the suction, discharge, hose drain, and multi drain valves with a good grade of lithium base grease.

2. Lubricate all of the valve linkages.

Monthly Maintenance

Monthly maintenance includes the Weekly Maintenance procedures plus lubrication, the packing gland adjustment, dry vacuum testing, and checking the drive line bolts. The Weekly Maintenance includes testing the relie f valve system or governor, the transfer valve on two-stage pumps, the priming system, and pump shift warning indicator lights.

Suction Check Valve Testing

On two-stage pumps remove the suction tube strainers, and reach inside the pump to ensure that the check valves are free to swing. Also, verify that no foreign matter is caught between the valve and the seat.

Lubrication

1. On handwheel-type valves, including PM, PMD, and Transfer Valve Controls, if necessary, first remove old grease and paint, use a dry lubricating spray on gears.

2. Remove the gearbox oil fill plug (refer to the Hale Service Chart), and check the level of the oil in the gearbox. The level should be up to the plug hole. If necessary, add oil, using only a good grade of SAE EP 90 (oil should meet GL -5 requirements).

3. Lubricate suction threads with a light coat of grease.

Packing Gland Adjustment

The packing gland is adjusted for a leakage of about 8 to 10 drops per minute at 150 PSI (10 BAR). This slight leakage will lubricate and cool the shaft and packing to prevent burning and scoring the shaft. First, check the leakage rate, and adjust the packing gland only if necessary. If the leakage rate cannot be adjusted within satisfactory limits, replace the packing per the instructions under Repacking in this section, page 3-6. Packing should be replaced every three years. The packing gland is adjusted as follows.

1. Connect the pump to a hydrant or some other source of water of about 150 pounds of pressure. If this is not possible, operate the pump at about 150 pounds from draft or from the booster tank discharging through the booster line, another small nozzle, or circulating back to the tank. Count the drops per minute.

2. Shut down engine to make adjustments.

DO NOT RUN ENGINE WHILE MAKING PACKING ADJUSTMENTS.

3. Loosen the packing nut lock. The lock is either a spring-loaded pin or a screw and locknut. The end of the lock fits into a slot in the gland.

4. To loosen or tighten the packing gland:

a. Insert a screwdriver or rod into one of the

slots. Refer to the Hale Service Chart.

b. To loosen the nut, turn it in the direction

of engine rotation.

c. To tighten the nut, turn it in the direction

that is opposite to engine rotation.

5. Repeat step 1 and verify that leakage is correct. Tighten for less leakage, loosen for more leakage.

3-3

Muscle Pumps

Drive Line and Flange Bolts

Check all drive line and flange bolts to ensure:

1. No bolts are missing.

2. All bolts are tight.

3. Bolts used are “Grade 8” strength.

Pump Mounting Bolts

1. No bolts are missing.

2. All bolts are tight.

Priming System Test (Dry Vacuum Test)

IN THE FOLLOWING PRIMING SYSTEM TEST, IF LEAKS CANNOT BE DETECTED BY FOLLOWING THE PROCEDURE BELOW, IT IS ADVISABLE TO TEST THE PUMP HYDROSTATICALLY. TO DO THIS CONNECT THE PUMP TO A SOURCE OF WATER, AND LOOK FOR LEAKS.

1. Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if so equipped).

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 22 inches or more mercury vacuum.

4. Watch the gauge. If the vacuum falls more then 10 inches in 5 minutes, it is a certain indication of at least one air leak. Vacuum leaks may often be detected by ear if the apparatus engine is turned off. Correct leaks immediately to return the pump to a serviceable condition.

5. Test the suction hose as follows:

a. Attach the suction hose to the pump.

b. Place the 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 test 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 inches mercury.

f. Watch the gauge. If the vacuum falls more

then 10 inches in 5 minutes, it is a certain indication of at least one air leak. Vacuum leaks may often be detected by ear if the apparatus engine is turned off. Correct leaks immediately to return the pump to a serviceable condition.

Relief Valve System Check

1. Place apparatus out of service in accordance with departmental procedures.

2. Test relief valve system in accordance with Weekly Maintenance Check. If the relief valve is not working, clean the strainers as follows:

a. Open pump compartment panel and locate

the relief valve system strainer(s). (On all relief valve systems the strainer is located in one of the pump pressure taps. On TPM an additional strainer is located in one of the pump vacuum taps).

b. Disconnect tubing then remove strainer

from respective tap.

c. Clean any debris from strainer and check

strainer for damage.

d. Using a suitable thread sealant (Loctite

PST or equal) reinstall strainer.

e. Reconnect tubing.

3-4

Muscle Pumps

f. Test apparatus and check for leaks around

strainer fittings

3. Place apparatus back in service.

Indicator Light Test

1. Operate component with indicator lights and observe the respective indicator lights. If the indicator light fails to light replace the bulb and test again.

Annual Maintenance

Annual maintenance consists of post-operation, weekly, and monthly maintenance. Maintenance for extreme conditions ma y also apply. In addition, the annual maintenance includes the following tasks.

• Gauge calibration check.

• Autolube® assembly oil level check: fill or

replace with SAE EP 90 or 80W90 weight oil.

• Lubricating the power transfer cylinder, power shift cylinder, and shift control valve with air cylinder oil.

• Replacing the pump gearbox oil: use SAE EP 90 or 80W90 weight oil (GL -5 equivalent).

• Checking individual drain lines from the pump to the multi-drain to ensure proper drainage and protection from freezing.

• Running the yearly pump test to check performance levels. (See NFPA 1911 pamphlet for more details).

• Repacking the pump at three-year intervals.

Performance Testing Overview

The yearly standard performance test consists of checking the pumper, according to rating, at three capacities and comparing the results to when the pump was new. This provides some measure of performance deterioration, if any. For performance

testing criteria refer to the latest version of NFPA 1911 pamphlet. Pumpers are rated at capacities of 500, 750, 1000, 1250, 1500, 1750, 2000, or 2250 GPM (1892, 2839, 3785, 4731, 5678, 6624, 7570, or 8516 LPM). See Table 3-1.

Performance Testing Equipment and Materials

To accurately test pumper performance, you will require a pitot gauge, a pump master pressure gauge, and a master vacuum gauge or manometer. ALL gauges must be carefully tested for accuracy. Gauge testing is appropriately accomplished with a dead weight gauge tester, which is usually available at the local water works.

Pumpers should be tested from draft at not over a 10-foot lift with 20 feet of suction hose. Pumpers rated at 1500 GPM and over often require two separate 20-foot lengths of suction hose and a lower lift height.

Use smooth bore test nozzles of accurate size wit h the pitot gauge. The volume pumped is then determined by reference to discharge tables for smooth nozzles. Refer to Table 3-2 for Nozzle Flow Rates. Preferably, nozzles will be used on a Siamese deluge gun for greatest accuracy. A stream straightener, ju st upstream of the nozzle is advisable.

The amount of discharge hoses required for the service tests is dependent on the flow requirements and capacity test point. The most common discharge hose used is 2-1/2 inches in diameter 100 feet long. The number of hoses and length should be sufficient to reduce nozzle pressure to between 30 and 85 PSIG (2 and 6 BAR). In general refer to the hose friction loss chart in Table 3-3 for a determination as to the friction loss in 100 feet of hose. Refer to Table 3-4 for suggested nozzle sizes for service testing of common size pumps.

3-5

Muscle Pumps

TABLE 3-1.

PUMP RATING GPM (LPM)

CAPACITY

FULL 150 (10)

FULL 165 (11)

70% 200 (13)

50% 250 (17)

PRESSURE PSI (BAR)

500 750 1000 1250 1500 1750 2000 2250

500

(1892)

500

(1892)

350

(1325)

250

(946)

750

(2839)

750

(2839)

525

(1987

375

(1419)

1000

(3785)

1000

(3785)

700

(2650)

500

(1893)

1250

(4731)

1250

(4731)

875

(3312)

625

(2366)

1500

(5678)

1500

(5678)

1050

(3974)

750

(2839)

1750

(6624)

1750

(6624)

1225

(4637)

875

(3312)

2000

(7570

2000

(7570

1400

(5299)

1000

(3785)

TABLE 3-2.

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS ½” 5/8” ¾” 7/8” 1" 1 1/8" 1 ¼” 1 3/8”

30 41 64 92 125 163 206 254 308 35 44 69 99 135 176 222 275 332 40 47 73 106 144 188 238 294 355

2250

(8516)

2250

(8516)

1575

(5961)

1125

(4258)

45 50 78 112 153 199 252 311 377 50 53 82 118 161 210 266 328 397 55 55 86 124 169 220 279 344 417 60 58 90 130 176 230 291 360 435 62 58 91 132 179 234 296 366 442 64 59 93 134 182 238 301 371 449 66 60 94 136 185 241 305 377 456 68 61 96 138 188 245 310 383 463 70 62 97 140 190 248 315 388 470 72 63 99 142 193 252 319 394 477 74 64 100 144 196 255 323 399 483 76 65 101 146 198 259 328 405 490

3-6

Muscle Pumps

TABLE 3-2. (Continued)

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS ½” 5/8” ¾” 7/8” 1" 1 1/8" 1 ¼” 1 3/8”

78 66 103 148 201 262 332 410 496 80 66 104 150 203 266 36 415 502 85 68 107 154 210 274 347 428 518 90 70 110 159 216 282 357 440 533

95 72 113 163 222 289 366 452 547 100 74 116 167 228 297 376 464 562 105 76 119 171 233 304 385 476 575 110 78 122 175 239 311 394 487 589 115 80 125 179 244 319 403 498 602 120 81 127 183 249 325 412 509 615

NOZZLE

PRESS

30 366 430 498 572 651 824 1017 1464

35 395 464 538 618 703 890 1098 1581

40 423 496 575 660 751 951 1174 1691

45 448 525 610 700 797 1009 1245 1793

50 473 555 643 738 840 1063 1313 1890

55 496 582 675 774 881 1115 1377 1982

60 518 608 705 809 920 1165 1438 2071

1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3"

GPM AT VARIOUS NOZZLE SIZES

62 526 618 716 822 935 1184 1462 2105

64 535 628 728 835 950 1203 1485 2138

66 543 637 739 848 965 1222 1508 2172

68 551 647 750 861 980 1240 1531 2204

70 559 656 761 874 994 1258 1553 2236

3-7

Muscle Pumps

TABLE 3-2. (Continued)

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS 1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3"

72 567 666 772 886 1008 1276 1575 2268

74 575 675 783 898 1022 1293 1597 2299

76 583 684 793 910 1036 1311 1618 2330

78 590 693 803 922 1049 1328 1639 2361

80 598 702 814 934 1063 1345 1660 2391

85 616 723 839 963 1095 1386 1711 2465

90 634 744 863 991 1127 1427 1761 2536

95 651 765 887 1018 1158 1466 1809 2605 100 668 784 910 1044 1188 1504 1856 2673 105 685 804 932 1070 1217 1541 1902 2739 110 701 823 954 1095 1246 1577 1947 2803 115 717 841 976 1120 1274 1613 1991 2867 120 732 859 997 1144 1301 1647 2034 2928

3-8

Muscle Pumps

TABLE 3-3.

HOSE FRICTION LOSS (PSI PER 100 FEET)

GPM Flowing

10 13.5 3.5 95 14 8 500 9.5 3

20 44 6 125 24 13 750 20 11 5

30 99 14 150 35 18 1000 34 20 8

40 176 24 4 175 47 25 6 1250 53 31 13

50 38 7 200 62 32 8 1500 74 45 18

60 54 9 225 10 1750 61 25

70 12 250 13 5 4 2000 32

80 15 275 15

95 22 300 18

¾” Booster

1” Booster

1 1/2” Hose

GPM Flowing

1 ¾” Hose with

1 1/2” Couplings

2” Hose with

1 1/2” couplings

2 1/2” Hose

3" Hose with

2 1/2" Couplings

3" Hose

GPM Flowing

3 1/2" Hose

4" Hose

5" Hose

125 38 325 22 8

150 54 350 25 8

500 20 17

750 45 38

1000 80 68

NOTE: Add 5 PSI for each story of building and each wye or siamese. Friction Loss Calculations courtesy of IFSTA.

3-9

Muscle Pumps

TABLE 3-4.

SUGGESTED NOZZLE SIZE (INCHES)

PUMP RATING FULL CAPACITY 70% CAPACITY 50% CAPACITY

750 1-3/4 1-3/8 1-1/4 1000 2 1-5/8 1-3/8 1250 (2) 1-1/2 or 2-1/4 1-7/8 1-1/2 1500 (2) 1-3/4 or 2-1/4 2 1-3/4 1750 (2) 2 (2) 1-1/2 or 2-1/4 1-7/8 2000 (2) 2 (2) 1-3/4 or 2-1/4 2 2250 (2) 2-1/4 (2) 1-3/4 or 2-1/4 2

The following general guidelines should be used when testing the apparatus.

For 750 GPM (2839 LPM) test, two 2-1/2-inch lines should be laid from the pumper to the nozzle. For 1000 GPM (3785 LPM) test, three lines are required, and for the 1250 (4731 LPM) and 1500 GPM (5677 LPM) tests, four or more lines are required between the pumper and the nozzle. For 1750 (6624 LPM) and 2000 GPM (7570 LPM) tests four or more hose lines and two nozzles are required. For testing a 2250 GPM (8516 LPM) pumper up to six hose lines into two separate nozzles should be used.

Because deluge guns are not always available, other hose layouts may be used, such as one, 2 1/2inch line to a 1-3/8-inch nozzle for 500 GPM (1892 LPM). Generally, the nozzle used on one, 2 1/2-inch line should not be larger than 1 1/2 inches for accuracy in measuring GPM (LPM). Another alternative when a deluge gun is not available consists of a 1 1/4 inch nozzle on one and a 1 1/2 inch nozzle on the other to pass 1000 GPM (3785 LPM). The sum of the flow from both nozzles is the GPM (LPM) delivered by the pump. For good pilot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 5.8 BAR).

Because NFPA standards specify both GPM (LPM) 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. However, depending on line loss alone would require a large amount of hose for some tests. For example, testing a 500 GPM (1892 LPM) Class A pumper at 250 GPM (946 LPM) and 250 PSI (17.2

BAR) requires 72-PSI (5 BAR) nozzle pressure on a one-inch tip. To reduce the pressure from 250 PSI (17.2 BAR) at the pump to 72 PSI (5 BAR) at the nozzle would require approximately 1100 feet of 2 1/2-inch hose. Therefore, it is common practice to use 50 to 100 feet of hose and gate the discharge valves as required.

Performance Testing

Note that the NFPA standards require a 10 percent reserve in pressure at the capacity run when the apparatus is delivered.

1. Check the relief valve according to the Relief Valve Testing procedure under Weekly Maintenance.

2. Perform steps 1 and 2 of the Post Operation Maintenance procedures in this section.

3. Run the standard pump test in accordance with NFPA standards to check pump performance.

4. Run the engine for 20 to 30 minutes to stabilize the engine temperature. Then run the pump for 20 minutes at capacity, 10 minutes at 70 percent capacity, and 10 minutes at 50 percent capacity.

5. If the apparatus does not reach performance levels, refer to the Hale diagnostic/service chart (Section 4).

6. Compare the results of this test to those from when the apparatus was delivered. It maybe that the apparatus did not show the 10 percent reserve at delivery. If the apparatus

3-10

Muscle Pumps

performance has dropped appreciably

compared to its original performance, it needs to be serviced. (Apparatus test results should be on file with the delivery documents. If not, they may be obtained from the apparatus manufacturer or from the original certifying authority).

Repacking

Refer to figure 1-9 for a cross -section showing the packing arrangement and number of packing rings. The three rings adjacent to the packing gland can be replaced without disassembling the pump. The ring in front of the lantern does not need to be replaced. Repack the pump as follows.

joint one-third ofthe way around from the

firstjoint. Put a foil separator between each packing ring. The foil separator must be cut tofit the shaft. Install the other rings, again staggering the joints.

6. Replace the gland and adjust it according to the Packing Gland Adjustment procedure in this section.

7. Operate the pump normally for about 15 minutes at 130 PSI (9 BAR), and check the packing gland. If necessary, adjust the packing nut again according to the Packing Gland Adjustment procedure in this section.

Annual MIV and 40BD Relief Valve Test and Adjustment

DO NOT RUN ENGINE WHILE MAKING PACKING ADJUSTMENT.

1. Loosen the packing nut lock.

2. Loosen the packing gland. If necessary, soak the threads with penetrating oil and work the nut back and fourth to loosen it. Loosen the adjusting gland just eno ugh to remove the split glands. If the front part of the gland is of the split type, remove the two halves.

3. Remove the old packing rings with a packing hook. The hook can be made from a bent piece of stiff wire or small pointed rod. Another type of packing hook consists of a corkscrew on the end of a flexible shaft. Be sure to remove all shreds of old packing, and clean out the packing housing as much as possible.

4. Remove all old packing, dirt, and foreign matter from the bearing housing under the gl and.

5. Repack using the Hale packing kit recommended for your particular pump. For most pumps, the packing is 7/16 inch square cut to the proper length. Wrap one length of packing around the shaft to form a ring, and push the ring into the packing housing. Install the second ring the same way, but stagger the

NEVER SET RELIEF VALVE ABOVE HOSE MANUFACTURERS RATED WORKING PRESSURE. ALWAYS USE THE LOWEST POSSIBLE RELIEF VALVE SETTING TO ENHANCE OPERATOR AND EQUIPMENT SAFETY.

PER NFPA 1962 REQUIREMENTS, LARGE DIAMETER HOSE MARKED “SUPPLY HOSE” 3-1/2 TO 5 INCHES (89 TO 127 MM) DIAMETER SHALL NOT BE USED AT OPERATING PRESSURES EXCEEDING 185 PSI (13 BAR).

PER NFPA 1962 REQUIREMENTS, LARGE DIAMETER HOSE MARKED “SUPPLY HOSE” 6 INCHES (152 MM) DIAMETER SHALL NOT BE USED AT OPERATING PRESSURES EXCEEDING 135 PSI (9 BAR).

The 40BD MIV relief valve is factory set to open at 125 PSI (9 BAR). The relief valve can be adjusted to open from 75 to 250 PSI (5 to 17

3-11

Muscle Pumps

BAR). Test and set relief valve as necessary using the following procedures and figure 3-1.

1. Open operator panel and gain access to the relief valve adjustment cap screw.

2. Make sure the valve is closed and install a pressure test cap on the suction tube or discharge fitting.

8. Lock the pressure setting by turning the adjustment locking screw until tight. Lock screw in place with Loctite #290 or equivalent.

9. Turn off water source and relieve pressure through the air bleeder allowing relief valve to reset.

10. Reenergize water source and return the

3. Connect a pressurized water source or hydrostatic test pump and water supply to the pressure test cap fitting.

4. Open water supply valve and air bleed valve. Fill suction tube or discharge connection until water flows from air bleed. Close air bleed.

5. Pressurize to desired set pressure in accordance with the above warnings. Observe whether relief valve opens or remains closed at the desired pressured.

6. Using a 3/16 inch allen wrench loosen, BUT DO NOT REMOVE, the set screw that locks the pressure adjustment cap screw.

7. Using 7/8 inch open end wrench, turn pressure adjustment cap screw to set relief valve pressure (clockwise to increase opening pressure or counterclockwise to decrease opening pressure). Turn cap screw until relief valve just opens or closes.

Once relief valve opens or closes turn pressure

adjustment cap screw 1/4 turn in the clockwise (increase pressure) direction.

pressure to the relief valve set point to verif y valve-opening point. Repeat adjustment procedures as necessary to verify relief valve operation.

11. Open drain valve and drain water from suction tube or discharge connection.

12. Disconnect water supply and remove test cap from suction tube or discha rge connection.

13. Close operator panel and return apparatus to normal ready condition.

Worn Clearance Rings and Impeller Hubs

Because clearance ring replacement requires pump disassembly, it is advisable to thoroughly check other possible causes (see Table 4-1) of low performance before assuming that clearance ring wear is at fault.

Clearance (that is, sealing) rings limit the internal bypass of water from the discharge side of the pump back to the suction. The radial clearance between the impeller hub and the clearance rings is only a few thousandths of an inch when new, effectively preventing a large bypass.

3-12

Muscle Pumps

In clear water, the clearance rings continue to effectively seal for hundreds of hours of pumping. In dirty or sandy water, the impeller hub and clearance rings will wear faster than in clear water. The more the wear, the greater the bypass and the lower pump performance. Also, the greater the pressure at which each stage is operated, the larger will be the bypass and the more the performance will be lowered.

When new, the radial clearance between the impeller hubs and the clearance ring is from 0.005 to 0.007 inch per side. Any increase will allow more bypass and result in lower performance. But when the pump is adequately powered, it should not be necessary to replace clearance rings and impellers until the average radial clearance reaches

0.015 to 0.020 inch or more per side, as measured by a feeler gauge.

Often, replacement of the clearance rings is all that is necessary. This will largely reduce the bypass and restore the pump to near original performance. A complete restoration requires that oversize clearance rings be installed and the impeller turned or the impeller may also be replaced.

Anode Check

The zinc anodes should be inspected every 12 months. Replace when over 75% of the zinc has been consumed (Refer to figure 6-15 for original dimensions). Performance of the anode life will vary with water quality and pH. Anodes conform to MIL Spec A180001.

TRV Test

The TRV should be tested every 12 months. The following procedure should be used to test the TRV. Before testing, make sure a clear view is available to the TRV discharge.

DO NOT RUN PUMP FOR LONGER THAN IS SHOWN IN THE TABLE, AS OVERHEATING COULD OCCUR AND SERIOUS DAMAGE TO PUMP WILL RESULT.

1. Close all discharge valves including pump and engine coolers so there is no flow through the pump.

2. Use care that engine does not overheat, set the pump discharge pressure to one of the pressures listed.

Time in Minute s

PRESSURE

TRV120

TRVM120

TRV170

TRVM170 200 PSIG (13.8 Bar) 10 20 400 PSIG (27.6 Bar) 4 8 600 PSIG (41.4 Bar) 2 4

3. The thermal relief valve should discharge water through the 1/8 NPT or metric discharge line approximately within the time specified.

4. The table is for midship type pumps. The thermal relief valve will open faster on smaller pumps, dependent on how close it is to the impeller.

5. The table is based on 70°F (21°C) water and 70°F (21°C) air temperature. The thermal relief valve will open faster in hotter conditions and slower in cooler conditions.

6. Units equipped with TRV-L kit will flow up to 1-2 GPM (3-7 LPM) of water before lamp turns on.

If unit fails to open in time allotted, remove TRV in accordance with Procedures in Section 5.

Place TRV -120 on work area with inlet facing up. Pour water of 120°-130°F (66° to 72°C) into opening of TRV. Element should open allowing water to flow out, if valve does not open replace valve. For TRV 170, use water at 170o to 180

(77 o to 82 o C).

Refer to figure 3-2 for a service chart including recommended service points and intervals.

3-13

Muscle Pumps

3-14

Midship Pump Maintenance Check List

Truck Manufacturer ________________________

Pump Model & Serial Number ________________ Year __________ Unit# _____________________

RECOMMENDED WEEKLY PROCEDURES

q Test relief valve system or governor at 150, 200, 250 PSIG. q Test transfer valve (if applicable). q Test the priming system (check lubrication level in priming tank were installed). q Lubricate all valves, discharge, suction, hose, drain, and multi-drain. q Check pump shift warning indicator lights.

RECOMMENDED MONTHLY PROCEDURES

Complete weekly checks Lubricate threads on PM relief valve panel

control and check light Lubricate remote valve controls

Check controlled packing leakage and adjust if necessary (8 to 10 drops per minute) Perform dry vacuum test*

Check drive flange bolts to ensure tightness Lubricate suction tube threads Clean strainer Inspect gaskets Check oil level in pump gearbox; add oil if

necessary If necessary, replace oil with SAE EP 90 oil

*Per NFPA-1911, 22 inches Hg minimum vacuum: loss not to exceed 10 inches Hg vacuum in 5 minutes.

JAN

FEB

MAR

APR

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

RECOMMENDED ANNUAL PROCEDURES

q Complete all previous checks on all questions. q Check gauge calibration. q Check oil level in AutoLube® assembly (SAE -EP 90 or 80W -90); see operation and maintenance manual

for details.

q Lubricate power transfer cylinder, power shift cylinder, and shift control valve with vacuum cylinder oil, if

applicable.

q Change pump gearbox oil and refill (SAE-EP 90 oil or 80W -90). q Check individual drain lines from pump to multi-drain to ensure proper drainage and protection from

freezing.

q Lubricate transfer valve mechanism on two stage pumps. Dry moly spray is preferred. q Run yearly standard pump test (per NFPA-1911) to check pump performance levels – chart provided

below.

q Repacking of pump is recommended every two or three years.

NOTE: The above general recommendations are pr ovided for normal use and conditions. Extreme conditions or variables may indicate a need for increased maintenance. Good preventative maintenance lengthens pump life and ensures greater dependability. Consult service or diagnostic chart in operator’s manu al for detailed information.

ANNUAL PUMP TEST RESULTS

Hose Layout Nozzle Size Nozzle Pressure Gallons Per Minute Pump Pressure Current Engine Speed Engine Speed from Original Test Documents

Lift and Suction Hose Size and Number

Capacity @ 150 PSI 70% Capacity @ 200 PSI 50% Capacity @ 250 PSI

Muscle Pumps

4. TROUBLESHOOTING

Table 4-1 lists the symptoms of some common problems and possible corrective measures. Before calling Hale or a Hale authorized parts service center for assistance, eliminate problem causes using Table 4-1. If you cannot correct a problem, please have the following information ready prior to calling the Hale Customer Service Technician Department for assistance. Customer Service Number: 610-825-6300.

q Pump Model and Serial Number q Pump Configuration Information q Observed Symptoms and Under What Conditions The Symptoms Occur

TABLE 4-1. HALE MIDSHIP PUMP TROUBLE ANALYSIS

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION PUMP WILL NOT ENGAGE

Standard transmission with Manual Pump Shift

Automatic Transmission with Manual Pump Shift

Standard Transmission with Power Shift System

Automatic Transmission With Power Shift System

Clutch not fully disengaged or malfunction in shift linkage

Automatic transmission not in neutral position

Insufficient air supply in shift system

Clutch not fully engaged or malfunction in shift linkage.

Repeat recommended shift procedures with

Check clutch disengagement. Drive shaft must come to a complete stop before attempting pump shift

Repeat recommended shift procedures with transmission in neutral position

Repeat recommended shift procedures.

Check system for loss of air supply. Check clutch disengagement. Drive shaft

must come to a complete stop before attempting pump shift

Turn the engine off and employ shift override procedures as follows:

1. Hole is provided in shift shaft to accomplish emergency shifting.

2. Complete shift of control in cab to neutral and proceed to complete shift of lower control manually.

transmission in neutral position.

Release braking system momentarily. Then reset and repeat recommended shifting procedures.

4-1

Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

Automatic Transmission With Power Shift System (continued)

Insufficient air in shift system

Air leaks in shift system

Repeat recommended shift procedures.

Check system for loss of air. Check of leak in system. Employ manual override procedures if necessary. See Standard Transmission with Power Shift System.

Attempt to locate and repair leak(s). Leakage, if external, may be detected audibly. Leakage could be internal and not as easily detected.

DO NOT LEAVE THE CAB AFTER PUMP SHIFTING UNLESS THE SHIFT INDICATOR LIGHT

IS ON, OR A SPEEDOMETER READING IS NOTED.

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION PUMP LOSES PRIME OR IT WILL NOT PRIME

NOTE: Weekly priming pump operation is recommended to provide good operation.

Electric Priming System

Defective Priming System

Suction lifts too high

Blocked suction strainer

Suction connections

Primer not operated long enough.

No recommended engine speed is required to operate the electric primer, however, 1,000 engine RPM will maintain truck electrical system while providing enough speed for initial pumping operation

Check priming system by performing “Dry Vacuum Test” per NFPA standards. If pump is tight, but primer pulls less than 22 inches of vacuum, it could indicate excessive wear in the primer.

Do not attempt lifts exceeding 22 feet except at low elevation.

Remove obstruction from suction hose strainer.

Clean and tighten all suction connections. Check suction hose and hose gaskets for possible defects.

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 same.

NOTICE: Do not run the primer over 45 seconds. If prime is not achieved in 45 seconds, stop and look for causes (for example, air leaks or blocked suction).

4-2

Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION PUMP LOSES PRIME OR IT WILL NOT PRIME (CONTINUED)

Air Trap in Suction Line

Pump Pressure too low when nozzle is opened

Air Leaks

Avoid placing any part of the suction hose higher than the suc tion intake. Suction hose should be laid with continuous decline to water supply. If trap in hose is unavoidable, repeated priming may be necessary to eliminate air pocket in suction hose.

Prime the pump again and maintain higher pump pressure while opening discharge valve slowly.

Attempt to locate and correct air leaks using the following procedure.

1. Perform dry vacuum test on pump per NFPA standards with 22 inches minimum vacuum required with loss not to exceed 10 inches of vacuum in 5 minutes.

2. If a minimum of 22 inches 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). The loss of vacuum indicates leakage and could prevent priming or cause loss of prime .

3. Attempt above dry prime and shut off engine. Audible detection of a leak is often possible.

4. 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 (6.9 BAR) should be sufficient. Do not exceed pressure limitations of pump, pump accessories, or piping connections.

5. Check pump packing during attempt to locate leakage. If leakage is in excess of recommendations, adjust accordingly following instructions in Section 3.

6. The suction side relief valve can leak. Plug the valve outlet connection and retest.

4-3

Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION INSUFFICIENT PUMP CAPACITY

INSUFFICENT PRESSURE

Insufficient engine power

Transfer Valve not in prope r “Volume” position

Relief Valve improperly set

Engine Governor set incorrectly

Truck transmission in wrong gear or clutch is slipping

Air Leaks

Check similar causes for insufficient capacity

Transfer Valve not in “Pressure” position

Engine power check or tune up may be required for peak engine and pump performance.

TWO STAGE PUMPS ONLY. Place transfer valve in “Volume” position (parallel) when pumping more than 1/2 rated capacity. For pressure above 200 PSI (13.8 BAR), pump should be placed in “Pressure” (series) position.

If relief valve control is set for too low a pressure, it will allow relief valve to open and bypass water. Reset Relief Valve control per the procedures in Section 3. Other bypass lines (such as foam system or inline valves) may reduce pump capacity or pressure.

Engine governor, if set too low a pressure when on automatic, will decelerate engine speed before desired pressure is achieved. Reset the governor per manufacturer’s procedures.

Recheck the pumping procedure for the recommended transmission or gear range; see Section 3 for assistance.

Use mechanical speed counter on the pump panel to check speed against possible clutch or transmission slipping or inaccurate tachometer. (Check the truck manual for the proper speed counter ratio).

See air leaks under “PUMP LOSES PRIME OR WILL NOT PRIME”. Recheck pumping procedure for recommended transmission gear or range. Use mechanical speed counter on pump panel to

check actual speed against possible clutch or transmission slippage or inaccurate tachometer. (Check the truck manual for proper speed counter ratio).

TWO STAGE PUMPS ONLY. For desired pump pressure above 200 PSI (13.8 BAR), transfer valve should be in “Pressure” position.

4-4

Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION LEAK AT PUMP PACKING

REMOTE CONTROL DIFFICULT TO OPERATE

ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACTICTY OR PRESSURE

RELIEF VALVE DOES NOT RELIEVE PRESSURE WHEN VALVES ARE CLOSED

Packing out of adjustment or worn.

Lack of lubrication Lubricate the remote control linkages and

Truck transmission in wrong range or gear

Lift too high, suction hose too small

Defective suction hose

Blockage of suction hose entry

Worn pump impeller(s) and clearance rings

Impeller blockage

Incorrect setting of Control (Pilot) Valve

Relief Valve inoperative

Adjust the packing per the procedure in Section 3 of this manual (8 to 10 drops per minute leakage at 150 PSI (10 BAR) preferred).

Replace pump packing per Section 3 of this manual. Packing replacement is recommended every 2 or 3 years depending on usage.

collar with oil.

Check recommende d procedures for correct transmission selection; see Section 3 and truck manual.

Higher than normal lift (10 feet) will cause higher engine speeds, high vacuum and rough operation. Use larger suction hose.

Inner line of suction hose may collapse when drafting and is usually undetectable. Try a different suction hose on same pump; test for comparison against original hose.

Clean suction hose strainer of obstruction and follow recommended practices for laying suction hose. Keep off the bottom of the water supply but a least 2 feet below the surface of the water.

Installation of new parts required.

Blockage in the impeller can prevent loss of both capacity and pressure. Back flushing of pumps from discharge to suction may free blockage. Removal of one ha lf of the pump body may be required (this is considered a major repair).

Check and repeat proper procedures for setting relief valve system. (see Section 3)

Possibly in need of lubrication. Remove relief valve from pump; dismantle; clean and lubricate. Weekly use of the Relief Valve is recommended.

4-5

Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION RELIEF VALVE DOES NOT RECOVE R AND RETURN TO ORGINAL PRESSURE

SETTING AFTER OPENING VALVES RELIEF VALVE OPENS WHEN CONTROL VALVE IS LOCKED OUT UNABLE TO OBTAIN PROPER SETTING ON RELIEF VALVE

WATER IN PUMP GEARBOX

DISCHARGE VALVES DIFFICULT TO OPERATE

Dirt in system causing sticky or slow reaction

Drain hole in housing, piston, or sensing valve blocked

Wrong procedure

Blocked strainer

Foreign matter in the Control Valve

Hunting condition

Leak coming from above pump

Lack of lubrication

Valve in need of more clearance

Relief valve dirty or sticky. Follow instructions for disassembling, cleaning, and lubricating.

Blocked relief valve. Clean the valve with a small wire or straightened paper clip. Clean the hole with a small wire or straightened paper clip.

Dismantle and clean the sensing valve. Check instruction for setting the relief valve and reset.

Check and clean the strainer in the supply line from the pump discharge to the control valve. Check the truck manual for the exact location. Check and clean tubing lines related to the relief valve and control valve.

Remove the control valve and clean.

Insufficient water supply coming from the pump to the control valve. Check the strainer in the Relief Valve system.

Remove the control valve and clean. Check all piping connections and tank overflow for possible spillage falling directly on the pump gearbox.

Follow the procedures in Section 3 of this manual for adjustment or replacement of packing. Excess packing leakage permits the flushing of water over the gearbox casing to the input shaft area. Induction of this excessive water may occur through the oil seal or speedometer connection.

If mechanical seal is installed, there should be no leaks. Inspect the oil seal and replace if necessary. Recommended weekly lubrication of discharge and suction valve, use a good grade of petroleum base or silicone grease.

Add gasket to the valve cover per the truck manual. Multi-gasket design allows additional gaskets for more clearance and free operation. NOTE: Addition of too many gaskets to the valve will permit leakage.

4-6

Muscle Pumps

5. CORRECTIVE MAINTENANCE

A. Midship Pump

Tools Required

q Lifting gear-Lever hoist or chain hoist, and

short chokers.

q Ball peen hammer q Center punch q Allen Wrenches q Pry bars (2) q Ratchets and wrenches for disassembly q Torque wrench, with sockets for cap screws,

capable of 40, 65, and 135 ft-lb (54, 88, and 183 N-m)

q Pan (to catch drip oil). q Disposable-rags and oil dry.

NOTE: Due to the nature of a Hale Midship pump most service can be performed without removing the pump assembly from the apparatus.

If a catastrophic failure to the pump (cracked pump body) requires removal of the entire pump assembly from the apparatus use the following procedure.

THE MIDSHIP PUMP AND GEARBOX ASSEMBLY WITH ASSOCIATED COMPONENTS WEIGHS 1,500 LBS. (680 KG) TO 2,000 LBS. (909 KG). MAKE SURE PROPER CAPACITY LIFTING APPARATUS IS PROVIDED TO REMOVE PUMP AND GEARBOX FROM APPARATUS.

1. Removal a. Place apparatus out of service in

accordance with department procedures.

b. Remove body panels and framework

to gain access to the pump compartment and pump. Make sure there is sufficient clearance above the apparatus to lift the pump and gearbox assembly out of the apparatus.

5-1

c. Remove valve operators, discharge

piping suction piping and valves that would inte rfere with pump removal.

d. Disconnect drive shafts, airlines,

electrical wiring and cooling lines as necessary from the gearbox.

e. Install 1/2-13UNC eyebolts into

lifting holes on the pump body (see figure 5-1). Attach proper lifting gear to these ey ebolts.

f. Locate and remove fasteners that hold

the pump to the apparatus chassis frame.

g. Carefully lift pump and gearbox

assembly from apparatus. Place the entire assembly on a work stand of suitable capacity.

NOTE: Before beginning removal, you may want to make a sketch of plumbing and component configuration to aid in assembly.

2. Installation

a. Make sure the chassis mounting point

and area around the apparatus is clean and free of obstructions.

b. Attach suitable lifting device to the

pump and gearbox assembly.

c. Lift pump and gearbox assembly and

guide onto apparatus at proper mounting point.

d. Install and tighten fasteners that secure

pump assembly to chassis frame.

e. Once pump is secure remove lifting

device and eyebolts.

f. Connect all components to gearbox.

g. Attach valves, suction piping,

discharge piping and valve operators.

h. Reinstall apparatus frame work and

body pa nels.

Muscle Pumps

5-2

Muscle Pumps

i. Test operate apparatus and certify

pump perfor mance as required.

j. Return apparatus to service.

B. Gearbox

G-Series

(Refer to figures 5-2 and 5-3)

1. Removal

a. Place apparatus out of service in ac-

cordance with department procedures.

b. Drain oil, disconnect drive shafts,

shift switches, air connection, cooling lines, and tachometer from gearbox as necessary. Make sure to mark connections for reasse mbly.

THE GEARBOX WEIGHT IS ABOUT 500 LBS (228 KG) BEFORE BEGINNING DISASSEMBLY PROPERLY SUPPORT GEARBOX WITH LIFTING GEAR TO AID IN LOWERING GEARBOX AND TO PREVENT PERSONNEL INJURY.

c. Remove six 1/2-13 x 1-1/2 inch long

cap screws on the cover of the gearbox, remove the spacer plate if i nstalled.

NOTE: The number of cap screws that hold the rear bearing housing to the gearbox depends on the model gearbox. The short gearbox uses seven cap screws and the long gearbox uses eight cap screws.

d. Remove 7/16-14 x 1-1/4 inch long cap

screws that hold the rear bearing hous ing to the gearbox. Remove the gearbox cover.

e. Carefully lower the gearbox from the

apparatus. Place a temporary cover over the gearbox to prevent dirt and debris from entering the gearbox. Move gearbox to suitable work area.

f. After the gearbox is removed,

carefully inspect bearings and other parts for excessive wear or damage

Order new components from Hale if

replacement is required.

2. Installation

a. Install a new gasket onto the gearbox

seating surface of the rear bearing hous ing. Apply a light coat of grease to the ga sket to hold it on place.

b. Place a new gasket on the seating

surface of the gearbox and gearbox cover. Check the fit of the ga sket and carefully trim the gasket to match the contour of the gearbox.

c. Carefully lift the gearbox into place

around the rear bearing housing. Insert two or three 7/16-14 x 1-1/4 inch long cap screws through the rear bearing housing to help hold the gearbox in place.

d. Position the gearbox cover and insert

six 1/2-13 x 1-1/2 inch long cap screws. Tighten cap screws hand tight.

e. Insert the remainder of the 7/16-14 x

1-1/4 inch long cap screws through the rear bearing housing and gasket into the gearbox and cover. Tighten the 7/16-14 x 1-1/4 inch long cap screws. Torque the 7/16-14 x 1-1/4 inch long cap screws to 40 ft-lb (54 N-m). Tighten the 1/2-13 x 1-1/2 inch long cap screws to 65 ft-lb (88 N-m).

f. Connect drive shafts, cooling lines, air

hoses, and electrical connections to

gearbox. g. Fill gearbox with oil.

h. Test operate apparatus observing

packing or mechanical seal, oil seal,

and gaskets for leaks.

5-3

Muscle Pumps

5-4

Muscle Pumps

5-5

Muscle Pumps

J-Series Gearbox

(Refer to figure 6-6)

1. Removal

a. Place apparatus out of service in

accordance with department procedures.

b. Drain oil, disconnect drive shaft.

Make sure to mark connections for reassembly.

THE J-SERIES GEARBOX WEIGHS 350 LBS (159 KG) . BEFORE BEGINNING DISASSEMBLY, PROPERLY SUPPORT GEARBOX WITH LIFTING GEAR TO AID IN LOWERING GEARBOX AND TO PREVENT PERSONNEL INJURY.

c. Note the locations and remove eight

1/2-13 cap screws which hold the upper housing and lower housing together.

d. Carefully lower the lower gearbox

hous ing from the apparatus making sure the spacer (if installed) does not get damaged. Place a temporary cover over the gearbox to prevent dirt and debris from entering the gearbox. Move gearbox to suitable work area.

e. After the gearbox is removed,

carefully inspect dowel pins, bearings and other parts for visible signs of excessive wear or damage. Order new components from Hale if replacement is required.

2. Installation

a. Make sure the dowel pins are properly

seated and install new ones if

necessary.

b. Install new gaskets onto the seating

surface of the lower gearbox housing.

Apply a light coat of grease to the

gasket to hold it in place. c. Install the spacer, if required, and

i nstall a new gasket on the seating

surface of the spacer.

d. Carefully lift the gearbox into place

aligning the dowel pins with the holes

in the upper gearbox housing.

e. Insert the eight 1/2-13 cap screws.

Tighten cap screws to 65 ft-lb (88 N-

m). f. Connect drive shaft to gearbox.

g. Fill gearbox to proper level with oil.

h. Test operate apparatus observing

mechanical seal, oil seal, and ga skets

for leaks.

5-6

Muscle Pumps

C. Packing Replace ment

When the packing adjustment has been taken up, a single ring of packing can be added. However, it is usually more satisfactory to repack the pump. Refer to figures 1-9 and 5-3 for a cross-section showing the packing arrangement and number of packing rings. The three rings adjacent to the packing gland can be replaced without disassembling the pump. The ring in front of the lantern does not need to be replaced. Repack the pump as follows.

DO NOT RUN ENGINE WHILE MAKING PACKING ADJUSTMENT

1. Loosen the packing nut lock.

2. Loosen the packing nut. If necessary, soak the threads with penetrating oil and work the nut back and fourth to loosen it. Loosen the adjusting nut just enough to remove the split glands. If the front part of the gland is of the split type, remove the two halves.

3. Remove the old packing rings with a packing hook or blow the packing out. The hook can be made from a bent piece of stiff wire or small pointed rod. Another type of packing hook consists of a corkscrew on the end of a flexible shaft. Be sure to remove all shreds of old packing, and clean out the packing housing as much as possi ble.

4. Remove all old packing, dirt, and foreign matter from the bearing housing under the packing gland.

5. Repack using the Hale packing kit recommended for your particular pump. For most pumps, the packing is 7/16-inch square cut to the proper length. Wrap one length of packing around the shaft to form a ring, and push the ring into the packing housing. Install the second ring the same way, but sta gger the joint one -third of the way around from the first joint. Put foil

5-7

separators between each pac king ring. The

foil separators must be cut to fit the shaft. Install the other rings, again stagge ring the joints.

6. Replace the gland and adjust it according to the Packing Gland Adjustment procedure in this section.

7. Operate the pump normally for about 15 minutes, and check the packing gland. If necessary, adjust the packing nut according to the Packing Gland Adjustment pr ocedure in Section 3.

D. Mechanical Seal Replacement

NOTE: Before starting disassembly matchmark with a center punch the rear bearing housing, mechanical seal housing, and pump body for proper alignment during reasse mbly.

Qmax and Qtwo Pump Mechanical Seal

1. Removal (Refer to figure 5-4)

a. Remove gearbox in accordance with

paragraph B.1, this section.

b. Remove the 5/8-11 x 1-1/4 inch long

cap screw and bearing retainer washer from the end of the impeller shaft.

c. Remove twelve 1/2-13 x 1-3/4 inch

long cap screws that hold the rear bearing housing to the pump body.

d. Install two 1/2-13 x 2-1/2 inch long

cap screws into the 1/2-13UNC threaded holes on the rear bearing housing to use as jacking screws. Install a 1/2-13 x 2-1/2 inch long cap screw in to one of the holes on the rear bearing housing into the pump body to keep the mechanical seal housing from rotating while removing rear bearing housing.

NOTE: It may be necessary to use prybars to

loosen the back bearing and gear before attempting to remove the rear bearing housing.

Muscle Pumps

e. Slowly and evenly turn the jacking

screws clockwise to move the rear bearing hous ing away from the pump body.

f. As the rear bearing housing moves

back remove the gear and gear key from the impeller shaft and bearing housing as they clear the shaft. Do not allow the weight of the rear bearing hous ing to rest on the oil seal.

g. After the gear and key are removed,

carefully remove the rear bearing hous ing from the impeller shaft being careful not to da mage the oil seal.

h. Remove the slinger from the impeller

shaft.

i. Using a center punch, matchmark the

mechanical seal cover and mechanical seal housing. Remove four 7/16-14 x 1-1/4 inch long cap screws that secure the mechanical seal cover to the mechanical seal housing.

j. If necessary, use pry bars in the slots

provided to loosen the mechanical seal cover from the mechanical seal hous ing. Remove the mechanical seal cover from the impeller shaft.

k. Remove the old mechanical seal from

the mechanical seal housing and i mpeller shaft. Two small hooks will aid in removal of these components.

l. After all components are removed,

carefully inspect bearings and other parts for excessive wear or damage. Order new components from Hale if replacement is required.

5-8

Muscle Pumps

1. Installation

INSTALLATION NOTES:

q Apply a light coat of grease to the gaskets

to hold them in place during assembly. Use only lithium based grease with 1 to % molybdenum disulfide. Some examples of correct greases are: Dow Corning BR2PLUS, Lubriplate-Fiske #3000, Shell Super Duty Grease, Imperial #777, Mobil Mobil Grease Special and Sun Oil Sunoco MOLY #2EP.

q Apply a light coat of grease to the seal

rings before assembly.

q When installing the cap screws make sure

they are locked in place using a suitable thread locking compound such as Loctite #242 or equal.

q If cap screws require replacement they

shall be replaced with grade 5, zinc plated steel, nylon locking type.

q Oil and grease will damage the Ethylene-

Propylene (EPT) bellows on the mechanical seal. Use only Ethylene-Glycol (anti-freeze) or soapy water to lubricate the impeller shaft and bellows during assembly.

q Do not touch the sealing face of the carbon

seal ring or seat while handling or installing the mechanical seal.

a. Clean all oil, dirt, and grease from the

end of the impeller shaft. Make sure the impe ller shaft is smooth and free of burrs at the gear key slot and bearing journals.

OIL AND GREASE WILL DAMAGE THE ETHYLENE-PROPYLENE (EPT) BELLOWS ON THE MECHANICAL SEAL. USE ONLY ETHYLENE-GLYCOL (ANTI-FREEZE) OR SOAPY WATER TO LUBRICATE THE IMPELLER SHAFT AND BELLOWS DURING ASSEMBLY.

DO NOT TOUCH THE SEALING SURFACE OF THE CARBON SEAL RING OR THE METAL SEAT WHILE HANDLING OR INSTALLING THE MECHANICAL SEAL.

IMPORTANT: Always replace the entire mechanical seal with a complete new Hale mechanical seal assembly.

b. Lubricate the inside of the mechanical

seal bellows and impeller shaft using Ethyl ene-Glycol (anti-freeze) or soapy water solution.

c. Slide new mechanical seal bellows

end over the impeller shaft making sure the spring is oriented towards the impeller. Using a soft pusher tube (2 inch PVC pipe) and keeping fingers away from carbon seal ring, carefully push the mechanical seal assembly into the mechanical seal housing. If binding occurs apply more lubricant to the impe ller shaft and bellows.

d. Being careful not to touch the face of

the seat, install the cup and seat into the mechanical seal cover. Lubricate the cup and mechanical seal cover with Ethylene-Glycol or soapy water sol ution.

e. Replace the seal rings in the groves on

the mechanical seal cover. Apply a light coat of grease to the seal rings being careful not to get grease on the impeller shaft. Slide the mechanical seal cover over the impeller shaft making sure the mechanical seal remains seated in the bore of the cover. Make sure there is no oil or grease on the faces of the mechanical seal.

f. Screw a 7/16-14UNC stud into one of

the holes in the mechanical seal hous ing to aid in bolt hole alignment.

5-9

Muscle Pumps

g. Insert the mechanical seal cover in

mechanical seal housing making sure to line up the bolt holes and center punch marks.

h. Install four 7/16-14 x 1-1/4 inch long

cap screws into the holes. Tighten cap screws evenly and torque to 40 ft-lb (54 N-m). When installing the cap screws make sure they are locked in place using a suitable thread locking compound such as Loctite #242 or equal. If cap screws require replacement they shall be replaced with grade 5, zinc plated steel, nylon locking type.

i Slide the slinger onto the impeller

shaft.

j. Install new oil seal into the rear

bearing housing.

k. Place a new gasket over the mating

surface of the mechanical seal hous ing and rear bearing housing. Apply a light coating of grease to the gaskets to hold them in place during assembly. Use only lithium based grease with 1 to 3% molybdenum disulfide. Some examples of correct greases are: Mobile Grease Special and Sun Oil – Sunoco MOLY #2EP.

l. Install two 1/2-13UNC studs into

mechanical seal housing in pump body to aid in alignment of the rear bearing housing. Slide the rear bearing housing over the impeller shaft making sure the oil seal aligns properly. Do not allow the weight of the rear bearing housing to rest on the oil seal. Align the bolt holes and center punch marks.

m. Insert twelve 1/2-13 x 1-3/4 inch long

cap screws into the holes. Evenly tighten the cap screws to 65 ft-lb (88 N -m).

n. Install 310 bearing onto the impeller

shaft and properly seat into bearing housing.

o. Place the gear key into slot on

impeller shaft then install the gear onto the impeller shaft making sure the key lines up with the key way in the gear.

p. Install 409 bearing over the impeller

shaft and properly seat in bearing hous ing.

q. Install bearing retainer washer on

i mpeller shaft end and secure using 5/8-11 x 1-1/4 inch long cap screw. Tighten cap screw and torque to 135 ft-lb (183 N-m).

r. Install gearbox in accordance with

paragraph B.2, this section.

Qflo and Qpak Pump Mechanical Seal and Clearance Rings

1. Removal (Refer to figure 5-5)

a. Place apparatus out of service in

accordance with department pro-

cedures. b. Open drains and drain pump body.

c. Drain gearbox oil.

d. Tag and disconnect air lines and

electrical connections. e. Disconnect drive shafts.

GEARBOX AND IMPELLER ASSEMBLY WEIGHS ABOUT 500 LBS (228 KG). MAKE SURE PROPER LIFTING DEVICES ARE USED FOR REMOVAL AND INSTALLATION OF GEARBOX.

f. Attach proper lifting device to

gearbox. g, Remove the twelve 7/16-14UNC X 1-

1/4 inch long screws from the bearing

hous ing and pump body.

5-10

Muscle Pumps

h. Install 7/16-14UNC screws into

threaded holes on bearing housing to use as jacking screws.

i. Turn the jacking screws clockwise

evenly to back the bearing housing out of the pump body. Make sure the gearbox and bearing housing stay straight as the assembly is backed out.

j. Remove the gearbox and impeller

assembly to a suitable work area.

k. Remove cotter pin and nut from

i mpeller shaft.

l. Using a suitable puller remove the

impeller and impeller key from the shaft.

m. Use hooks that fit around the shaft

and seal then remove the spring and spring retainer then the remainder of the mechanical seal assembly.

n. Remove the cup and seat from the

bearing housing. o. Clean impeller shaft and all com-

ponents.

p. Measure the impeller wear surfaces

and the wear rings. The wear rings

should be replaced if the radial

clearance is 0.015 to 0.020 inch per

side or overall.

q. If necessary, remove and replace the

wear rings in the pump body and rear

bearing housing.

r. Inspect the oil seal in the rear bearing

hous ing and replace if necessary.

5-11

Muscle Pumps

2. Installation

WHEN APPLYING THE ETHYLENE GLYCOL OR SOAP AND WATER SOLUTION, MAKE SURE ALL SHAFT SURFACES AND THE INSIDE OF THE SEALING BOOT ARE COATED.

a. Being careful not to touch the sealing

surface of the mechanical seal seat, apply a solution of ethyl ene glycol (anti-freeze) or soap and water to l ubricate the pump shaft and inside of the seat assembly. Slide the cup and seat assembly over the impeller shaft. Using a soft clean pusher tube (a short length of 2 inch PVC pipe) make sure the cup and seat assembly are seated squarely in the rear bearing hous ing.

b. Keeping fingers away from the carbon

seal ring apply a solution of ethylene glycol (anti-freeze) or soap and water to lubr icate the shaft and inside of the seal bellows. Orient the carbon seal ring towards the seal and slide the bellows and spring over the impeller shaft. Use the pusher tube to make sure the assembly is pushed all the way in. If resistance is felt, add more ethylene glycol (anti-freeze) or soap and water to keep the shaft and bellows lubri cated.

c. Insert impeller key in the impeller

shaft and install the impeller on the shaft.

d. Install impeller nut and tighten to 135

ft-lb (183 N-m) Lock the impeller nut in place using a cotter pin.

e. Apply a light coating of grease to the

seal ring groove and install a new seal ring on the rear bea ring housing.

5-12

f. Install a new gasket on the rear

bearing hous ing, holding it in place

with a light coating of grease.

g. Thread two 7/16-14UNC studs in the

pump body to help guide the rear

bearing housing onto the pump body. h. Using proper lifting device lift

gearbox and impeller assembly into

place. Use studs to guide the rear

bearing housing into the pump body.

i. Insert the 7/16 –14UNC X 1-1/4 inch

long cap screws into the rear bearing

hous ing. Tighten screws to 40 ft-lb

(58 N-m) torque.

j. Reconnect drive shafts, electrical, and

air lines to gearbox.

k. Refill the gearbox with oil. l. Test operate apparatus and watch for

leaks.

Muscle Pumps

E. AutoLube® Service (Qmax/Qtwo)

1. Park the vehicle on a level surface. Shut down the engine. Set the parking brake and chock the front and rear wheels.

2. Drain water from the pump.

3. Remove the fill and drain plugs from the AutoLube® reservoir and drain oil.

4. Use a center punch to mark the AutoLube® cover and the front bearing cover housing (for proper alignment during assembly).

DO NOT USE A CHISEL TO SEPARATE THE AUTOLUBE® FROM THE PUMP BODY BECAUSE THE MATING SURFACES MAY BE SCRATCHED OR GOUGED, WHICH COULD RESULT IN A LEAK. ALSO, THE AUTOLUBE® IS MANUFACTURED FROM CAST METAL, BODY, PRY BETWEEN THE AUTOLUBE® AND THE PUMP BODY OR AT THE AND IF IT BECOMES NECESSARY TO PRY THE AUTOLUBE® APART FROM THE PUMP AUTOLUBE® “NOTCHES’

5. Remove the cap screws attaching the AutoLube®, figure 5-6, to the pump body and gently pry AutoLube® from the pump body and impeller shaft.

5-13

Muscle Pumps

6. Place the AutoLube® face down on a work bench and remove the two allenhead cap screws from the impeller side. Separate the two halves and remove the diaphragm.

7. Remove the oil seal lock ring.

8. Remove the oil seal from the inner half of the AutoLube®.

9. Check the impeller shaft bushing for wear.

10. Clean the inner and outer halves of the AutoLube®.

11. Clean the gasket surfaces of the AutoLube® and pump body.

12. Check for restrictions in the water passages to the rear half of the AutoLube®.

13. If it is necessary to replace the impeller shaft bushing, press the bushing from the inner side of the inner half of the AutoLube® (on the side opposite of the impeller). Install the bushing from the i mpeller side of the inner half of the AutoLube®. See figure 5-6.

THE IMPELLER SHAFT BUSHING SEATS AGAINST A SHOULDER IN THE INNER HALF OF THE AUTOLUBE® AND CAN ONLY BE REMOVED AND INSTALLED AS DIRECTED OR THE AUTOLUBE® MAY BE DAMAGED.

14. Install the new oil seal in the inner half of the AutoLube®.

15. Install the seal lock ring.

16. Position the diaphragm on the inner half of the AutoLube®.

17. Line up the marks, and place the outer half of the AutoLube® onto the inner half. Apply Loctite® 242 to the two allen-head cap screws. Tighten to 26 ft-lb (35 N-m).

18. Install the new gasket on the AutoLube®, and position the assembly (with the top up) onto the impeller shaft. Attach the AutoLube® with cap screws and tighten to 64 ft-lb (87 N-m).

DO NOT DAMAGE THE OIL SEAL. A DAMAGED OIL SEAL COULD RESULT IN DAMAGE TO THE AUTOLUBE® ASSEMBLY, AS WELL AS THE PUMP.

PURGE THE AIR FROM THE AUTOLUBE® WHILE FILLING IT WITH OIL OR A “FALSEFILL” SITUATION WILL DEVELOP, WHICH COULD CAUSE DAMAGE TO THE AUTOLUBE® AND OTHER COM PONENTS

19. To fill the AutoLube® with 90w oil, pump the oil in from the bottom plug opening until the oil spills from the top opening. This eliminates air pockets and false readings.

20. Add water to the pump.

21. Operate the fire pump and check the AutoLube® for water or oil leaks.

22. Remove the tire chocks.

23. Return apparatus to service.

5-14

Muscle Pumps

F. Impeller Assembly

1. Impeller and Clearance Rings Removal

(Qmax (refer to Figure 6-3 and Qtwo Pumps (Refer to Figure 6-4)

a. Park the vehicle on a level surface.

Shut down the engine. Set the parking rake and chock the front and rear wheels.

b. Drain the water from the pump.

THE GEARBOX ASSEMBLY WEIGHS 500 LBS (228 KG). SUPPORT THE LOWER GEARBOX ASSEMBLY WITH A LIFTING DEVICE. FAIL URE TO DO SO COULD RESULT IN THE ASSEMBLY FALLING, WHICH COULD RESULT IN PERSONAL INJURY OR PROPERTY DAM AGE.

c. Remove the gearbox, refer to para-

graph B.1, this section.

THE LOWER PUMP BODY WEIGHS 100 LBS (46 KG). SUPPORT THE LOWER PUMP BODY AND IMPELLER ASSEMBLY WITH A LIFTING DEVICE. FAIL URE TO DO SO COULD RESULT IN THE LOWER PUMP BODY AND IMPELLER ASSEMBLY FALLING, WHICH COULD RESULT IN PERSONAL INJURY, OR PROPERTY DAMAGE.

d. Remove the drain lines from the lower

pump body.

e. Mark lower pump body, Autolube®

housing, and rear bearing housing for reassembly.

f. Drain the oil from the AutoLube®,

and remove the 1/2-13UNC X2 inch long cap screws from the upper half of the AutoLube® and pump body.

5-15

g. Remove the 1/2-13UNC X 1-3/4 inch

long cap screws from the upper half of the rear bearing housing and pump body.

h. Remove the 1/2-13UNC X 1-1/4 inch

long cap screws, from the lower pump body.

DO NOT REMOVE THE FOUR CAP SCREWS, ONE IN EACH CORNER OF THE LOWER PUMP BODY, UNTIL THE LIFTING DEVICE IS IN POSITION. FAILURE TO DO SO COULD RESULT IN THE LOWER PUMP BODY AND IMPELLER ASSEMBLY FALLING, WHICH COULD RESULT IN PERSONNEL INJURY OR PROPERTY DAMAGE.

i. Position the lifting device into place

with the lower pump body-lifting adapter between the lif ting device and the lower pump body.

j. Remove the 5/8-11UNC X5 inch long

cap screws in each corner of the lower pump body.

k. Lower the lower pump body and

i mpeller assembly so that it does not tip from the lifting device. Remove the asse mbly to a suitable work area.

l. Remove the remaining cap screws

from the lower half of the AutoLube®, the rear bearing hous ing, and the lower pump body.

THE IMPELLER ASSEMBLY IS HEAVY. DO NOT ATTEMPT TO LIFT THE ASSEMBLY WITHOUT THE AID OF ANOTHER PERSON OR PERSONS. FAILURE TO DO SO COULD RESULT IN THE IMPELLER ASSEMBLY FALLING, WHICH COULD RESULT IN PERSONNEL INJURY OR PROPERTY DAMAGES.

Muscle Pumps

m. Remove the remaining screws from

the rear bearing housing, and the lower pump body.

n. Lift the impeller assembly from the

lower pump housing. Set the assembly aside.

o. Clean the gasket surfaces of the upper

and lower pump bodies, as well as those on the AutoLube® and the rear bearing housing face.

p. Clean the clearance ring and clearance

ring seats in both the upper and lower pump body halves to remove all the “build up” material so that the new clearance ring will seat properly.

NOTE: Pitting of the clearance rings may occur from the “build up” of material and the effects of corrosion. Once the seats are cleaned, any pitting on the clearance rings is considered normal.

2. Disassembly (Single-Stage Pump)

a. Place the impeller shaft assembly on a

workbench. Note the orientation of impeller vanes and clearance rings.

b. Carefully remove the AutoLube®

assembly from pump shaft end.

c. Remove the outer retaining ring and

outer clearance ring.

NOTE: Before removing impeller, note the orientation of vanes for proper reassembly. The vanes will turn in a clockwise manner when viewed from the front.

WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHILE HEATING THE IMPELLER TO REMOVE OR INSTALL IT INTO THE IMPELLER SHAFT. HEATED METAL CAN CAUSE INJURY TO YOUR HANDS.

DO NOT OVER HEAT THE IMPELLER. THE IMPELLER IS CONSTRUCTED OF BRONZE. IF THE IMPELLER IS OVERHEATED (AND TURNS RED OR BLUE DURING REMOVAL FROM THE SHAFT), IT HAS BEEN WEAKENED AND MUST BE RE PLACED.

d. Using an acetylene torch, carefully

heat the “eye” and hub of the impeller in an even fashion for approximately two minutes.

e. When heated properly, the impeller

should be removed from the shaft using a gear puller. If the impeller moves but does not slide free, do not immediately reheat. Allow the complete assembly to cool to room temperature, then reheat and continue removing the impeller.

f. Allow the components to cool to room

temperature.

g. Remove the inner clearance ring. h. Remove the impeller key.

3. Assembly (Single -Stage Pump)

a. Clean the impeller shaft and the

keyway.

b. Check the water way in the seal

hous ing for restrictions.

c. Install the inner retaining ring.

d. Install the new gasket on the seal

hous ing face.

e. Verify the key is free to slide in the

i mpeller keyway, then install the key into the ke yway.

5-16

Muscle Pumps

IF THE IMPELLER OR CLEARANCE RINGS ARE DROPPED, DAMAGED OR DEFORMED, THEY WILL NEED TO BE REPLACED.

f. Install the inner clearance ring over

the impeller shaft with proper orientation.

IMPORTANT: Mark the impellers as to whether they are the primary or secondary impeller in relation to the AutoLube®. Improper or backward installation of the impellers affects pump performance.

b. Place the impeller shaft assembly on a

workbench. Note position of impellers and mark for reasse mbly.

c. Remove impeller retaining rings.

WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHILE HEATING THE IMPELLER TO INSTALL IT INTO THE IMPELLER SHAFT. HEATED METAL CAN CAUSE INJURY TO YOUR HANDS.

g. Using the torch, heat the “eye” and

WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHILE HEATING THE IMPELLER TO REMOVE OR INSTALL IT INTO THE IMPELLER SHAFT. HEATED METAL CAN CAUSE INJURY TO YOUR HANDS.

hub of the new impeller in an even fashion for approximately two minutes. Then, slide the impeller onto the shaft with vanes in proper orientation. (Note: vanes will turn in clockwise di rection when viewed from the front of the impeller assembly). If the impeller does not fully slide onto the shaft allow the assembly to cool to room temperature

before re-heating. h. Install the outer retaining ring.

i. Install the outer clearance ring in the

proper orientation.

j. Carefully slide the AutoLube®

assembly over pump shaft. k. Install the impeller shaft assembly on

the pump.

4. Disassembly (Two-Stage Pump) a. Remove AutoLube® assembly from

front of impeller shaft.

5-17

DO NOT OVER HEAT THE IMPELLER. THE IMPELLER IS CONSTRUCTED OF BRONZE. IF THE IMPELLER IS OVERHEATED (AND TURNS RED OR BLUE DURING REMOVAL FROM THE SHAFT), IT HAS BEEN WEAKENED AND MUST BE REPLACED.

d. With an acetylene torch, carefully

heat the “eye” and hub of the first i mpeller in an even fashion for approxi mately two minutes.

e. When heated properly, remove

impeller from shaft using a gear puller. If the impeller moves but fails to slide free, do not immediately reheat. Allow the complete assembly to cool to room temperature, then reheat and continue removing the impeller.

f. Remove the center support bearing.

Then rotate the impeller shaft assembly end for end and heat and remove the second impeller.

g. Remove the impeller key.

Muscle Pumps

5. Assembly (Two-Stage Pump)

a. Clean the impeller shaft, the keyway,

and the seal housing and face.

b. Check the waterway in the seal

hous ing for restrictions. c. Install the new gasket on the seal

hous ing face.

d. Install the key into the keyw ay.

IF THE IMPELLERS OR THE CLEARANCE RINGS ARE DROPPED, DAMAGED OR DEFORMED, THEY WILL NEED TO BE REPLACED.

e. Install the inner clearance ring with

proper orientation.

WEAR PROTECTIVE, HEAT-RESISTANT GLOVES WHILE HEATING THE IMPELLER TO INSTAL L IT INTO THE IMPELLER SHAFT. HEATED METAL CAN CAUSE INJURY TO YOUR HANDS.

f. Using the torch, heat the “eye” and

hub of each impeller for approxi -

mately two minutes. Then, slide the

individual impellers onto the shaft

making sure they are in the correct

orientation. Make sure the center sup-

port bearing is installed between

impellers. If an impeller does not fully

slide onto the shaft allow the

assembly to cool to room temperature

before reheating. g. Install the outer retaining ring. h. Install the outer clearance ring with

proper orientation. i. Slide AutoLube® assembly over

pump shaft.

6. Installation (Impeller and Clearance

Rings)

a. Install the pump body gaskets to the

lower pump body, trimming as necessary to fit.

FAILURE TO LINE UP THE CLEARANCE RING LOCK NOTCHES WITH THE PUMP BODY TABS (AS DESCRIBED IN THE NEXT STEP) MAY RESULT IN PUMP DAMAGE AND PUMP FAILURE.

b. Install the impeller assembly into the

lower pump housing, carefully aligning the clearance ring lock notches with the clearance ring lock tabs in the lower pump body. Then, rotate the clearance rings to one side to open up lock notches to line up with the lock tabs in the upper pump body.

c. through the rear bearing housing and

the seal hous ing. Do not tighten.

d. Install the 1/2-13UNC X2 inch long

cap screws into the AutoLube® hous ing and lower pump body.

e. Make sure the dowel pins are in the

upper pump body to assist in aligning the lower pump body with the upper pump body.

f. Using a lifting device, slowly raise the

lower pump body and the impeller assembly into place, ma king sure that the lower pump body aligns with the dowel pins and the clearance ring notches align with the clearance ring lock tabs in upper pump body.

g. Rotate the impeller shaft and check

for freedom of movement when the lower pump body and the impeller assembly is in place.

5-18

Muscle Pumps

h. Apply Loctite 242 and install the four

5/8-11UNC X5 inch long cap screws

(one in each corner of the lower pump

body). Tighten snug but do not fully

torque.

i. Install the 1/2–13UNC X 1-3/4 inch

long screws in the rear bearing

hous ing and mechanical seal housing,

also install the 1/2-13UNC X2 inch

long cap screws into the AutoLube®.

Tighten to 53 ft-lb (72 Nm).

j. Remove the lifting device. k. Apply Loctite 242 to the 1/2-13UNC

X 1-3/4 inch long screws, lower pump

body cap screws and install them.

Tighten snug but do not fully torque.

l. Torque the 5/8-11UNC X5 inch long

cap screws to 150 ft-lb (203 Nm),

then, starting from the center and

moving outward tighten the lower

pump body cap screws to 65 ft-lb (88

Nm).

THE GEARBOX ASSEMBLY WEIGHS OVER 500 LBS (228 KG). SUPPORT THE LOWER GEARBOX ASSEMBLY WITH A LIFTING DEVICE. FAILURE TO DO SO COULD RESULT IN THE ASSEMBLY FALLING, WHICH COULD RESULT IN PERSONAL INJURY OR PROPERTY DA MAGE.

m. Install the gearbox, refer to paragraph

B.1, this section.

n. Operate the pump and check for leaks.

5-19

Muscle Pumps

G. Relief Valve Systems

1. PM/PMD Control Valve

(Refer to figure 6-14)

a. Park the vehicle on a level surface.

Shut down the engine. Set the parking

brake and chock the front and rear

tires. b. Drain the fire pump. Tag and

disco nnect wires to indicator light.

c. Rotate the adjustment handwheel

counterclockwise to remove the

spring te nsion. d. Remove the cap screw and nut

attaching the adjustment handwheel to

the adjustment shaft. Then, remove

the handwheel.

IDENTIFY AND MARK THE LINE CONNECTIONS ON THE CONTROL BODY BEFORE REMOVING. IMPROPER CONNECTION OF LINES MAY RESULT IN THE FAILURE OF THE PILOT VALVE, WHICH COULD CAUSE DAMAGE TO THE FIRE PUMP.

e. Remove the pump discharge pressure

line and the relief valve line from the

control body of the pilot valve.

f. While holding the pilot valve, remove

the four 1/4-20UNC X5/8 inch long

machine screws attaching the valve

and cover plate to the Pump

Operator’s Panel, and separate the

valve, plate, and the relief valve

setting indi cator (if equipped with

PMD) from the panel. g. Disassemble the Control Valve.

1) Remove the four 5/16-18UNC X

1 inch long allen-head cap screws securing the control body to the rear of the spring housing. Then, remove the control body.

5-20

DO NOT USE PLIERS TO UNSCREW THE CONTROL VALVE FROM THE DIAPHRAGM CLAMP. DAMAGE TO THE CONTROL VALVE WILL RENDER THE PILOT VALVE INOPERATIVE.

2) Unscrew the control valve from the diaphragm clamp. Remove the diaphragm washer and the di aphragm.

3) Remove the retaining ring, the seal and the bea ring.

USE A SPRING COMPRESSOR TO REMOVE THE CONTROL SPRING. THE SPRING IS UNDER COMPRESSION, AND COULD BECOME UNCOMPRESSED, WHICH COULD RESULT IN PERSONNEL INJURY.

4) Turn the adjustment handwheel clockwise to unscrew the adjustment shaft from the adjustment nut. From the handwheel end, remove the adjustment shaft from the spring housing.

5) Remove springs, the adjustment nut, and diaphragm clamp as an assembly from the spring housing, and then separate.

h. Clean all the control components.

Inspect and lubr icate with grease the threads on the adjustment shaft.

i. Assemble the control valve.

Muscle Pumps

USE A SPRING COMPRESSOR TO INSTALL THE PILOT VALVE SPRING. COMPRESSION, AND COULD BECOME UNCOMPRESSED, WHICH COULD RESULT IN PERSONAL INJURY.

ALWAYS REMOVE THE PILOT VALVE DISCHARGE PRESSURE STRAINER, WHICH IS LOCATED IN THE TOP OF THE DISCHARGE SIDE OF THE PUMP. CLEAN OR REPLACE, AS NECESSARY. FAILURE TO DO SO COULD RENDER THE PILOT VALVE INOPERATIVE.

1) Combine both springs, the adjustment nut, and the discharge clamp as an assembly and install into the spring housing. Align the guide pin adjustment nut with the slot in the spring hous ing.

2) Slide the adjustment shaft into the spring housing from the handwheel end. Turn the adjustment handwheel counterclockwise in order to screw the adjustment shaft into the adjustment nut until it bottoms in the diaphragm clamp. Do not put the springs under tension.

3) Lubricate the new bearing, and slide the new bearing and bearing washer over the adjustment shaft into the spring body housing. Install the retaining ring. Then, i nstall the new seal washer and rotate the adjustment shaft in both directions to check for freedom of movement.

4) Install the new diaphragm washer and diaphragm. Screw the control valve into the diaphragm clamp.

5) Install the control body. Apply Loctite 242 to the four 5/1618UNC X 1 inch long allen-head cap screws attaching the control body to the rear of the spring hous ing.

j. Holding the pilot valve, and PMD

indicator assembly if installed, align the cover plate and install the four 1/4-20UNC X 1 inch long allen-head cap screws attaching the spring hous ing to the pump panel.

k. Install the pump discharge pressure

line and relief valve line to control body of the pilot valve, attach electri cal wires to the indicator light.

l. Slide the adjustment handwheel onto

the adjustment shaft, and then install the retaining cap screw and nut.

m. Fill the pump and test the valve for

proper operation and leaks.

2. QD Relief Valve

(Refer to figure 6-15)

a. Drain the pump.

b. Note the location of the wires and

di sconnect the indicator light switch.

c. Disconnect the relief valve supply line

from the pilot valve and drain the line.

d. Remove the two 7/16-14UNC X 1-1/4

inch long cap screws attaching the relief valve indic ator light switch and the mounting bracket assembly to the relief valve cover. Remove the light switch and the bracket.

e. Compress the relief valve return

spring (by hand), and remove the E– clip and washer. Then, remove the return spring.

5-21

Muscle Pumps

f. Remove the two remaining 7/16-

14UNC X 1-1/4 inch long cap screws retaining the relief valve cover to the pump body. Using a twisting motion, carefully remove the relief valve cover

DO NOT PUSH THE RELIEF VALVE TOO FAR INTO THE PUMP BODY AS IT MAY FALL INTO THE PUMP BODY AND BECOME LODGED OR DAMAGED. THE RELIEF VALVE IS MADE OF BRASS AND IS EASILY DAMAGED BY PRYING OR HAMMERING. DAMAGED VALVES MUST BE RE PLACED.

g. Remove the retaining ring securing

the relief valve piston to the relief valve. Gently push the relief valve into the pump body approximately 1 inch (25 mm), and then pull it back out in a snap motion. This should pop the relief valve piston out of the relief valve body. Repeat if necessary.

NOTE: It is not necessary to remove the relief valve unless it is damaged. To remove the relief valve, the relief valve body will have to be removed and the complete relief valve assembly will need to be replaced (as it will be necessary to pry the relief valve body from the pump body, which will likely damage it).

h. Clean and inspect all of the relief

valve assembly components.

i. Clean all sealing surfaces and install

new O-rings and quad ring seals.

j. Install the relief valve piston in the

stem of the relief valve. Do not push the relief valve into the pump body. As it is necessary to start the piston onto the relief valve stem, push the piston until you can grasp the relief stem. Then, pull the relief valve stem outward while pushing on the relief valve piston. Once the relief valve pi ston is seated against the shoulder of

the relief valve stem, install the

k. Operate the relief valve by hand to

l. Slide the relief valve cover gasket and

m. Compress and install the return

n. Align the indicator light switch

o. Connect the relief valve supply line

p. Assemble indicator light switch and

q. Install the switch strap and light

r. Connect the panel mounted indicator

s. With the pump not running and the

retaining ring.

check fre edom of movement.

cover over the top of the relief valve stem to align the relief valve supply line from the pilot valve in the origi nal position. Then, apply Loctite 242 to two 7/16-14UNC X 1-1/4 inch long cap screws and install opposite of each other. Tighten, but do not torque.

spring, and secure it with a washer and E-clip.

bracket with the two empty holes in the relief valve cover. Install the two remaining 7/16-14UNC X 1-1/4 inch long cap screws. Tighten all cap screws to 53 ft-lb (72 Nm).

from the pilot valve. Also, connect the drain line.

the switch strap. Securely tighten the two screws.

switch in the switch bracket. Leave the two screws attaching the switch strap to the switch bracket slightly loose to allow the switch to move in and out for adjustment.

light or a suitable test light to the switch terminals. With the light switch plunger not in contact with the end of the poppet, the light should be lit.

relief valve fully closed, push the light switch in until the switch plunger makes contact with the end of the

5-22

Muscle Pumps

poppet and the light goes out. The

switch is now in the proper posi tion. Tighten the screws holding the switch strap to the bracket.

t. Fill the pump and test the valve for

proper operation and leaks.

3. QG Relief Valve (Refer to figure 6-16)

a. Before removal match mark the relief

valve housing and pump body for proper asse mbly.

b. Disconnect the line to the sensing

valve and drain valve. Make note of the wire conne ctions.

c. Disconnect the indicator light switch.

d. Remove the four 7/16-14UNC X 1-

1/4 inch long cap screws attaching the relief valve assembly to the pump body.

e. Using a twisting motion, remove the

relief valve assembly.

f. To disassemble the valve, remove the

i ndicator light switch, remove the cover-retaining ring and slide the cover out of the relief valve body.

g. Apply a small amount of pressure to

the relief valve piston and remove the piston-retaining ring. Carefully release the pressure held to the piston by the spring.

h. Remove the relief valve stem from the

opposite end, sliding the relief valve stem out of the piston.

i. Reach through the center hole of the

piston and pull the piston out of the indicator switch end of the relief valve body. Then, remove the piston spring.

j. To assemble and install the valve, first

clean and inspect all components.

k. Clean all sealing surfaces and install

new O-ring seals.

l. Install the relief valve into the relief

valve body.

m. Install the piston spring by sliding the

piston into the relief valve body while at the same time sliding the piston onto the relief valve stem.

n. Apply light pressure to the piston to

compress the piston spring and install the piston-retaining ring.

o. Slide the cover into the relief valve

body. Then, install the cover-retaining ring.

p. Slide the relief valve assembly into

the pump body with the side marked “top” up, being careful not to damage the O-rings.

q. Apply Loctite 242 to the four 7/16-

14UNC X 1-1/4 inch long cap screws and install the assembly in the pump body. Tighten to 53 ft-lb (72 Nm).

r. Install collet fitting tight into the valve

cover. Back off 1 to 1-1/2 turns.

s. Install the light switch in the collet

fitting. Leave the collet holding the light switch slightly loose to allow the switch to move in and out for adjustment.

t. Connect the panel mounted indicator

light or a suitable test light to the switch terminals. With the light switch pulled nearly all the way out, the light should be lit.

u. With the pump not running and the

relief valve fully closed, push the light switch in until the light goes out. Hold the collet fitting with a wrench to prevent it from turning, and tighten the collet.

5-23

Muscle Pumps

v. Disconnect the electrical connector.

Tighten the entire collet fitting 1 to 11/2 turns. The switch is now in the proper position. Reconnect the electrical connector.

w. Fill the pump and test the valve for

proper operation and leaks.

4. PG30 Relief Valve (Refer to figure 6-12)

a. Drain the pump. b. Disconnect the indicator light switch. c. Disconnect the line to the sensing

valve.

d. Remove the 7/16-14UNC X2 inch long

sensing valve mounting cap screw.

e. Remove the four 7/16-14UNC X 1-

3/4 inch long cap screws retaining the relief valve assembly to the atmosphere dump.

f. Remove the four 7/16-14UNC X 1-

1/2 inch long relief valve mounting cap screws to remove the relief valve

from the pump body. g. Remove the relief valve assembly. h. Remove the four 7/16-14UNC X 1-3/4

inch long cap screws retaining the relief

valve cover to the relief valve body. i. Remove the indicator light switch

assembly. j. Apply a small amount of pressure to

the relief valve spring, and remove the

spring retaining ring and washer.

Carefully re lease the pressure held on

the spring and then remove the spring. k. Remove the relief valve cover.

l. Remove the piston-retaining ring.

m. Remove the relief valve from the

opposite end, sliding the relief valve stem out of the piston.

n. Reaching through the center hole of

the piston, ge ntly pull the piston from the indicator switch end of the relief valve body.

o. Before assembling and installing the

valve, clean and inspect all components of the relief valve assembly.

p. Clean all sealing gasket surfaces and

install new O-rings and gaskets.

q. Install the relief valve into the relief

valve body.

r. Slide the piston into the relief valve

body while at the same time sliding the piston onto the relief valve stem. Then, install the piston-retaining ring.

s. Install the new gasket, and then install

the cover onto the relief valve body.

t. Install two 7/16-14UNC X 1-3/4 inch

long cap screws finger-tight (to keep the relief valve cover aligned with the valve body).

u. Install the valve spring over the relief

valve stem. Then, apply pressure to the valve spring to compress the spring.

v. Install the spring washer and the

retaining ring.

w. Remove the two 7/16-14UNC X 1-3/4

inch long cap screws installed to keep the relief valve cover aligned with the valve body. Place the indicator switch bracket into position on the relief valve cover. Apply Loctite 242 to the four cap screws, install, and tighten to 53 ft-lb (72 Nm).

x. Apply Loctite 242 to the four 7/16 x

1-1/2 inch long cap screws and install the new gasket and the relief valve to the pump surface.

5-24

Muscle Pumps

y. Apply Loctite 242 to the four 7/16-

14UNC X 1-1/2 inch long cap screws

and install the new gasket and relief

valve assembly to the atmosphere

dump. Tighten to 53 ft-lb (72 Nm). z. Apply Loctite 242 to the 7/16-14UNC

X2 inch long cap screw, install the

sensing valve and tighten. Make sure

the arrow on the sensing valve points

upward.

aa. Assemble indicator light switch and

the switch strap and securely tighten

the two screw s. bb. Install the switch strap and light

switch assembly in the switch bracket.

Attach flasher assembly to bracket.

Leave the two screws attaching the

switch strap to the switch bracket

slightly loose to allow the switch to

move in and out for adjustment.

cc. Connect the panel mounted indicator

light or a suitable test light to the

switch terminals. With the light

switch plunger not in contact with the

end of the poppet, the light should be

lit.

dd. With the pump not running and the

relief valve fully closed, push the light

switch in until the switch plunger

makes contact with the end of the

poppet and the light goes out. The

switch is now in the proper posi tion.

Tighten the screws holding the switch

strap to the bracket.

ee. Connect the line to the sensing valve.

ff. Fill the pump and test the valve for

proper operation and leaks.

5. Sensing Valve (Refer to figure 6-13)

a. Disconnect the following lines at the

sensing valve:

q Pilot valve discharge line q QG relief valve line q PG relief valve line q Sensing valve pump suction line q Drain lines

b. Remove the 7/16-14UNC X2 inch

long sensing valve mounting cap screw.

c. Remove the four 5/16-18UNC X 1

inch long cap screws attaching the control body to the rear of the spring housing. Remove the control body, being careful not to lose the sensing valve spring.

d Remove the control valve from the

sensing valve body.

e. Unscrew the sensing valve from the

diaphragm, being careful not to damage the control valve. Remove the di aphragm.

f. Before installing the sensing valve,

clean all components.

ALWAYS REMOVE THE SENSING VALVE SUCTION INLET SCREEN. CLEAN OR RE PLACE AS NECESSARY. THE SCREEN IS LOCATED IN THE SUCTION SIDE OF THE PUMP. FAILURE TO DO SO MAY RENDER COMPONENTS INOPERATIVE.

g. Install a new diaphragm on the

di aphragm clamp. Apply Loctite to the threads on the control valve and i nstall the control valve into the sensing valve body.

h. Install the sensing valve spring into

the valve body cover.

5-25

Muscle Pumps

i. Apply Loctite 242 to the four 5/16-

18UNC X 1 inch long cap screws and

attach the control body to the rear of

the spring housing. Make sure that the

sensing valve spring properly aligns

with the diaphragm clamp.

j. Make sure the “up” arrow is aligned

properly.

k. Apply Loctite 242 to the 7/16-14UNC

X2 inch long sensing valve mounting

cap screw. Tighten to 40 ft-lb (51 Nm).

l. Connect the lines.

m. Fill the pump and test the valve for proper

operation and leaks.

H. TRV Service

(Refer to figure 6-11)

1. Disconnect electrical wiring, discharge

line and drain tubing.

2. If TRV-L kit is installed. a. Unscrew pressure switch from fitting.

b. Remove el bow.

c. Remove 1/8 MNPT x 1/8 FNPT

fitting.

3. Unthread thermal relief valve from

attachment flange .

4. Check inlet strainer for blockage. This

should be accomplished once a year or more frequently in pumping water with impurities.

5. Apply coating of Loctite PST (or equal

thread sealer) rethread thermal relief valve into attachment flange.

6. If TRV-L kit is installed, apply coating of

Loctite PST to threads of fitting before assembly of parts.

a. Install 1/8 MNPT x 1/8 FNPT fitting

into TRV body.

b. Install elbow into fitting and tighten

so elbow outlet is positioned in the up position.

c. Install pressure switch in elbow outlet.

7. Reconnect drain tubing, discharge line, and electrical wiring.

8. Fill the pump and test the valve for proper operation and leaks.

I. Anode Replacement

(Refer to figure 6-17)

1. Consumable zinc anodes should be i nspected at least every 12 months.

2. A minimum of two anodes per pump is recommended.

3. One anode should be installed on the suction side and the other on the discharge side of the pump.

4. To inspect the anodes, drain the pump.

5. Remove four 7/16-14UNC X 1-1/4 inch long cap screws and remove the anode and flange assembly.

6. Inspect the consumable zinc anode and replace when over 75% of zinc has been consumed (the original anode is 1.25 inches di ameter by 2.125 inches long).

7. Clean all gasket surfaces.

8. Replace all gaskets, replace anode assembly if required, apply Loctite 242 to the four 7/16-14UNC X 1-1/4 inch long cap screws, install, and tighten to 40 ft-lb (54 Nm).

9. Fill the pump and test for leaks.

5-26

Muscle Pumps

J. Qtwo Transfer Valve

1. Drain the pump IMPORTANT: The transfer valve is a timed

device. It is therefore important during disassembly to note the location of the transfer bracket locating pin, the transfer drum stop pin, the transfer drum sleeve -locating pin, and the transfer drum stem key. It is not necessary to remove the transfer bracket locating pin, the transfer drum sleeve locating pin, or the transfer drum stop pin during disassembly.

2. Turn the adjustment handwheel clockwise until it stops. The transfer indicator should be at the top of the slotted guide in the cover plate.

3. Remove the two allen-head setscrews from the transfer indicator guide. Slide the transfer indic ator guide (on an adjustment stem) towards the transfer valve.

4. Remove the stem drive gear lock pin. Slide the adjustment stem from the stem drive, the support, and the transfer indicator guide, being careful not to drop or damage the transfer indicator guide and transfer indicator.

5. Remove the four 7/16-14UNC X 1-1/4 inch long cap screws retaining the transfer bracket assembly to the pump body. Carefully remove the transfer bracket and the transfer valve drum.

6. Disassemble the valve.

a. Remove the locating pin that secures

the countershaft in place.

b. Remove the countershaft from the

countershaft gear.

c. Remove the countershaft gear and the

countershaft gear spring from the transfer bracket assembly.

d. Remove the allen-head setscrew from

the transfer drum gear. Slide the transfer drum gear from the drum

stem. Remove the woodruff key from

e. Separate the transfer bracket from the

f. Slide the transfer drum from the transfer

7. Assemble the Valve a. Clean and inspect all sealing surfaces

b. Install new O-ring seals on the

c. Slide the transfer drum into the

d. Install the woodruff key into the

e. Assemble the countershaft gear spring

8. Install the Transfer Valve

a. Align the transfer drum stop pin, the

the transfer drum stem.

transfer drum by sliding it from the transfer drum stem.

sleeve.

and the mating surfaces of the transfer valve drum and sleeve. Clean and inspect the transfer bracket bushings and bushing surface on the transfer valve stem and the transfer valve adjustment stem.

transfer valve drum stem and the transfer valve bracket.

transfer bracket, being careful not to damage the bearing surfaces. Then, rotate the transfer drum until the drum stop pin is in the correct position.

transfer drum stem. Install the transfer drum gear onto the transfer drum stem. Apply Loctite 242 to the allen-head set screw and install the transfer drum gear.

in the countershaft gear, and position the asse mbly into place in the transfer bracket. Then, install the countershaft and the countershaft-locating pin to lock the countershaft in place.

transfer bracket-locating pin, and the transfer drum sleeve locating pin into proper position.

5-27

Muscle Pumps

b. Install the transfer valve drum and

bracket assembly into the pump body.

c. Apply Loctite 242 to the four 7/16-

14UNC X 1-1/4 inch long transfer bracket cap screws, and install and tighten to 53 ft-lb (72 Nm).

d. Slide the adjustment stem through the

cover plate, the transfer indicator guide, and the support and transfer bracket.

e. Insert the stem drive gear into place in

the transfer bracket, and then slide the adjustment stem through the stem drive gear.

f. Insert the stem drive gear lock pin

into place, locking the stem drive gear onto the adjustment stem.

g. Apply Loctite 242 to the transfer

indi cator guide set screws and install. Do not tighten.

h. Turn the adjustment handwheel

counter clockwise until it stops. Make sure the transfer indicator is at the top of the slotted guide toward the transfer indicator, making certain that the transfer indicator engages the transfer indicator guide in the top groove. Then, tighten the inside setscrew in the transfer guide indicator.

i. Rotate the adjustment handwheel

from stop to stop. The transfer indicator should move freely from the top to the bottom of the slo tted guide in the cover plate.

j. Tighten the outside setscrew in the

operation indicator guide, and recheck the movement of the transfer indicator.

k. Fill the pump and test the valve for

proper operation and leaks.

K. Qtwo Check Valves (two-stage only)

(Refer to figure 6-4)

1. Drain the pump. NOTE: there are two check valves (one on each

side) in the suction side on the front of the Qtwo pump body. The following procedure is used for both check valves.

2. Remove the four 1/2-13UNC X 1-1/4 inch long cap screws from the check valve cover on the front side of the pump body. Note position of check valve for reassembly.

3. Remove the check valve.

4. Clean the gasket surfaces, and inspect the check valve pivots and pivot sockets.

5. Install the check valve.

6. Install the new gasket in the pump body.

7. Apply Loctite to the four cap screws and secure the check valve cover to the pump body with the cap screws, being careful to align the check valve pivot with the pivot socket in the check valve cover. Tighten to 53 ft-lb (75 Nm).

8. Fill the pump and test the valve for proper

operation and leaks.

5-28

Muscle Pumps

L. Tank to Pump Check Valve

1. Drain the water tank and the pump.

2. Disconnect the control linkage at the Tank-to-Pump Valve.

3. Disconnect both ends of the flexible hose connecting the water tank to the Tank-toPump valve. Then, slide the flexible hose toward the water tank outlet or the Tankto-Pump valve plumbing.

NOTE: If the tank-to-pump valve is air -operated, drain the vehicle’s air system and disconnect the supply and the return line on the valve actuator, but do not remove the actuator from the valve. Also, the tank-to-pump valve may be connected to the pump body by cap screws or studs with nuts. If studs are used, it may be necessary to remove some or all of the studs to remove the valve. If so, remove only the studs necessary to remove the valve, as any studs left will assist in realigning the valve during installation.

4. Remove the eight 7/16-14UNC X 1-1/2 inch long cap screws retaining the tank-topump valve to the pump body.

5. Remove the tank-to-pump valve and associ ated plumbing.

NOTE: The back flow valve is a flat butterfly plate with two pivots attached at the top. These pivots fit into two open pivot soc kets in the pump body. When the gasket is removed, the back flow valve may fall out.

6. Remove the old gasket from the pump body.

7. Remove the back flow valve.

8. To install the back flow valve, first clean all of the gasket surfaces on the pump body and the tank-to-pump flange.

9. Install the back flow valve. Using two fingers, hold the pivots in the pivot sockets and check the valve for freedom of movement.

10. Install a new gasket.

11. Apply Loctite 242 to the eight 7/1614UNC X 1-1/2 inch long cap screws and attach the tank-to-pump valve to the pump body. Tighten to 53 ft-lb (72 Nm).

12. Slide the flexible connection hose so it is evenly spaced and secured on the water tank outlet and the tank-to-pump valve plumbing.

13. Attach the tank-to-pump valve controls and linkage.

14. Fill the pump and test the valve for proper operation and leaks.

M. Suction Extension and Suction Tube

1. Place apparatus out of service.

2. Open and drain pump body.

3. Remove twelve 7/16-14UNC X 1-1/4 inch long cap screws from suction tube flange.

4. Clean suction tube and all components.

5. Remove fourteen 1/2-13UNC X 1-1/4 inch long cap screws from the suction tube extension.

6. Clean the suction tube extension and all components.

7. Clean seating surfaces of pump body, housing, suction tube extension and suction tube.

8. Place a new gasket on the seating surface of the pump body. Apply a light coat of grease to the gasket to hold it in place.

9. Reinstall suction tube extension, insert fourteen 1/2-13UNC X 1-1/4 inch cap long screws, torque to 65 ft-lb (88N -m).

5-29

Muscle Pumps

10. Place a new gasket on the seating surface of the suction tube extension. Apply a light coat of grease to the gasket to hold it in place.

11. Reinstall the suction tube, insert twelve 7/16-14UNC X 1-1/4 inch long cap screws. Using a criss-cross pattern, torque to 40 ft-lb (54 N-m).

12. Fill the pump and test for leaks.

N. Gearbox Disassembly and Assembly

G-Series

1. Removal and Disassembly

a. Park the vehicle on a level surface. Shut

down the engine. Set the parking brake

and chock the front and rear tires. b. Drain the water from the pump. c. Drain the gearbox lubricant. d. Disconnect the drive shafts from the

gearbox.

e. Disconnect the pump gearbox cooling

lines.

f. Disconnect the electrical switches and

the airlines.

g. Remove the fire pump gearbox. See

paragraph B.1, this section.

h. Secure the pump gearbox into a

holding fixture.

i. Remove and disassemble the

interm ediate shaft assembly (refer to figure 5-7).

1) Remove the 7/16-14UNC X 1 inch long cap screw holding the intermediate shaft washer, remove the washer.

2) Carefully press the intermediate gear shaft out of the gearbox hous ing from the rear to the front.

3) Reach into the top of the gearbox housing and remove the interm ediate gear spacer and the interm ediate gear.

5-30

Muscle Pumps

4) Remove the intermediate gear bearing from the inte rmediate gear.

5) Remove the two different size interm ediate shaft seal rings from the intermediate gear shaft.

6) Cle an and inspect each component of the intermediate shaft assembly. Inspect bearings for wear, pitting, and damage. Inspect the gear tooth surface for wear da mage and pitting, replace all components that are worn, damaged, or pitted.

j. Remove and disassemble the tail shaft

assembly (refer to figure 5-8).

NOTE: If the tail shaft and sliding gear shaft require service it is not necessary to remove the gearbox from the apparatus.

NOTE: If only the tail shaft assembly needs to be removed, set the gearshift mechanism to engage the sliding gear with the sliding gear shaft (pump position).

1) Loosen the 3/8-16UNC inch hex nut locking the gearshift rod end to the gear shaft. Remove the gearshift rod end with the hex nut.

2) Remove the 1/2-20 UNF X 1/2 inch long nylon locking set screw, gearshift lock spring and gearshift ball from the gea rshift shaft cap.

3) Remove two 5/16-18 hex nuts and two 5/616-18UNC X 1 inch long cap screws and remove the cylinder cover.

4) Remove the outer retaining ring locking the cylinder piston to the gearshift shaft

5) Remove the cylinder piston, then remove the inner retaining ring.

6) Remove two 7/16-14UNC X 1 inch long nylon locking cap screws and remove the shifting cylinder.

5-31

Muscle Pumps

NOTE: The gearshift fork cannot be removed from the sliding gear shaft until the sliding gear is removed.

7) Remove four 7/16-14UNC X 1 inch long nylon locking cap screws securing the rear bearing cap to the gearbox housing.

8) Remove the tail shaft assembly from the gearbox housing.

9) Remove the inner tail shaft bearing retaining ring from the tail shaft.

10) Remove the inner tail shaft bearing from the shaft and rear bearing cap.

11) Remove the inner tail shaft outer retaining ring from the tail shaft.

12) Remove the outer tail shaft bearing retaining ring.

13) Remove the tail shaft from the rear bearing cap.

14) Remove the outer tail shaft bearing from the rear bearing cap.

15) Remove the drive shaft oil seal from the rear bearing cap.

16) Clean and inspect each component of the tail shaft assembly. Inspect bearings for wear, pitting, and damage. Inspect gear tooth surface for wear, damage, and pitting. Replace all components that are worn, damaged, or pitted.

k. Remove and disassemble the sliding

gear assembly (refer to figure 5-7).

NOTE: If the tail shaft and sliding gear shaft require service it is not necessary to remove the gearbox from the apparatus.

NOTE: If only the sliding gear assembly needs to be removed, set the gearshif t mechanism to engage the sli ding gear with the tail shaft (road position).

1) Remove four 7/16-14UNC X 1 inch long nylon locking cap screws securing the front bearing cap to the gearbox housing.

2) Remove the sliding gear assembly from the gearbox housing.

3) Remove the sliding gear bearing retaining ring from the sliding gear shaft.

4) Remove the sliding gear bearing from the sliding gear shaft and front bearing cap.

5) Remove the sliding gear shaft from the front bearing cap.

6) Remove the drive shaft oil seal from the front bearing cap.

7) Reaching through the top of the gearbox housing, carefully remove the sliding gear.

NOTE: Make a note of the location of the gearshift fork in relation to the gearshift shaft before removing.

8) Loosen the 7/16-14UNC X 1-3/4 inch long cap screw attaching the gearshift fork to the gearshift shaft, and then pull the shaft from out of the gearbox hous ing.

9) Reaching through the top of the gearbox housing, carefully remove the gearshift fork with the cap screw attached.

10) Clean and inspect each component of the sliding gear assembly, i nspect bearing for wear, pitting, and damage, inspect gear tooth surface for wear, damage, and pi tting, replace all components that are worn, da maged, or pitted.

5-32

Muscle Pumps

l. Inspect the Cooling Tube for Damage

and Leaks.

m. Remove and disassemble the

remainder of the gearshift shaft cap.

1) Remove two 7/16-14UNC cap screws, then remove the gearshift shaft cap. See figure 6-5.

2) Remove the gearshift switches from the gearshift shaft cap..

3) Clean and inspect each component of the gearshift shaft cap assembly. Replace all components that are worn, damaged or pitted.

2. Assembly and Installation

a. Assemble and install the gearshift cap.

1) Install new switch seal ring on the gearshift switches. Thread gea rshift switch into the gear shift shaft cap.

2) Install a new gearshift cap gasket on the gearbox housing.

3) Apply Loctite 242 to the two 7/16-14UNC cap screws and install the gearshift shaft cap to the gearbox housing. Secure cap with two 7/16-14UNC cap screws.

b. Assemble and install the sliding gear

assembly.

1) Reaching through the top of the gearbox housing, hold the gearshift fork in place, slide the gearshift shaft through the opening in the front of the gearbox housing, through the gearshift fork. Insure fork is in the proper pos ition.

2) Apply Loctite 242 to the 7/1614UNC X 1-3/4 inch long cap screw that attaches the gearshift fork onto the gearshift shaft. Tighten to 25 ft-lb (34 Nm).

3) Reaching through the top of the gearbox housing, place the sliding gear into the shift fork. Make sure the shift fork groove on the sliding gear is oriented towards the front of the gearbox.

4) Install a new drive shaft oil seal in the front bearing cap.

5) Using a brass drift or a bearing install ation tool, install the sliding gear bearing allowing the retaining ring to contact the surface of the front bearing cap.

6) Install the slinger on the sliding gear shaft.

7) Insert the sliding gear shaft into the front bearing cap by sliding it from the front to the rear. Be sure to be careful when sliding shaft through the drive shaft oil seal and bearing.

8) Install bearing retaining ring.

9) Install a new front bearing cap gasket onto the front bearing cap (hold gasket in place using a general purpose grease).

10) Apply Loctite 242 to the four 7/16-14UNC X 1 inch long cap screws. Then install the sliding gear shaft and front bearing cap and tighten to 40 ft-lb (54 Nm).

11) The sliding gear shaft will mesh with the sliding gear. Insure the gearshift fork is in its proper position.

5-33

Muscle Pumps

c. Assemble and install the tail shaft

assembly.

1) Using a brass drift or a bearing installation tool, install the outer tail shaft bearing in the rear bearing cap.

2) Install a new drive shaft oil seal in the rear bearing cap.

3) Insert the tail shaft into the rear bearing housing, be careful when sliding the shaft through the drive shaft oil seal and tail shaft outer bearing.

4) Install the tail shaft retaining ring to secure the outer tail shaft bearing in its proper position on the tail shaft.

5) Install the inner tail shaft retaining ring.

6) Using a brass drift or a bearing installation tool, install the inner tail shaft bearing from the outside inuntil the retaining ring contacts the surface of the tail shaft hous ing.

7) Install the tail shaft inner bearing inner retaining ring.

8) Install the sliding gear shaft needle bearing in the front end of the tail shaft.

9) Apply a light coating of grease and apply new gasket to tail shaft hous ing.

10) Install the tail shaft and rear bearing cap. Be careful when sliding the tail shaft with the sliding gear needle bearing wil l slide over the male end of the sliding gear shaft.

11) Apply Loctite 242 to the four 7/16-14UNC X 1 inch long cap screws. Then install the rear bearing cap and tighten the cap screw to 40 ft-lb (54 Nm).

12) Install a new shifting cylinder gasket.

13) Install a new gearshift shaft seal ring in the shifting cylinder.

14) Install the shifting cylinder by sliding it over the gearshift shaft until it contacts the gearbox housing. Apply Loctite 242 to the two 7/16-14UNC X 1 inch long nylon locking cap screws and tighten.

NOTE: Install piston retaining rings with flat side (square corners) facing away from pi ston.

15) Install the inner piston-retaining ring on the gearshift.

16) Install a new piston inner seal ring on the gearshift shaft.

17) Install a new piston outer seal ring on the cylinder piston.

18) Install the cylinder piston on the gearshif with the flat side of the pi ston facing the interior of the cylinder.

19) Install the outer piston-retaining ring on the gearshift shaft.

20) Install a new gearshift shaft seal on the cylinder cover.

21) Install cylinder cover by sliding over the gearshift shaft. Apply Loctite 242 to the two 5/16 -18UNC X 1 inch long hex head screws and two 5/16-18UNC studs and tighten.

5-34

Muscle Pumps

22) Install the gearshift rod end on the end of the gearshift shaft. Tighten the 3/8-16UNC locking hex nut.

d. Assemble and install the intermediate

shaft assembly.

1) Press a new intermediate gear bearing into the intermediate gear.

2) Install new intermediate shaft seal rings on the ends of the interm ediate shaft.

3) Reaching through the top of the gearbox place the intermediate gear in position towards the front of gearbox hous ing.

4) On the XG gearbox, hold the i ntermediate gear spacer in position towards the rear of the gearbox hous ing. Install the intermediate shaft (front cutout facing down) through the front opening in the gearbox housing.

5) Press the intermediate shaft through the intermediate gear and the intermediate gear spacer until the cut out on the front of the shaft is flush with the surface of the gearbox housing.

6) Apply Loctite to the 7/16-14UNC X 1 inch long cap screw, install the intermediate shaft washer and tighten cap screw.

7) Rotate the sliding gear shaft and manually shift the gearshift shaft to check for proper operation.

8) Using a lifting device remove the gearbox from the holding fixture.

9) Install the fire pump gearbox; see paragraph B.2, this section.

J-Series

(Refer to figure 6-6)

1. Removal and Disassembly

a. Park the vehicle on a level surface.

Shut down the engine. Set the parking brake and chock the front and

rear tires. b. Drain the water from the pump.

c. Drain the gearbox lubricant. Remove

magnetic plug, level plug and sight

gauge plug. d. Disconnect the drive shaft from the

gearbox.

e. Remove the fire pump gearbox. See

paragraph B.1, this section.

f. Secure the pump gearbox into a

holding fixture.

g. Remove and disassemble the idler

shaft assembly (refer to figure 6-6).

1) Remove the locknut and washer

from the idler shaft.

2) Carefully press the idler shaft out

of the gearbox housing.

3) Reach into the top of the gearbox

hous ing and remove the idler gear.

4) Remove the idler gear bearing

from the gear.

5) Remove the two different size

idler shaft seal rings from the idler gear shaft.

6) Clean and inspect each component

of the idler shaft assembly. Inspect bearings for wear, pitting and damage. Inspect the geartooth surface for wear, damage and

5-35

Muscle Pumps

pitting, replace all components

that are worn, damaged or pitted.

h. Remove and disassemble the input

shaft assembly.

1) Remove the 1/2-13UNC X 1-1/4 inches long cap screw and washer.

2) Using an appropriate pulle r, remove the companion flange from the input shaft.

3) Remove the .375x1.563 long square key from the input shaft.

4) Remove the oil seal from the companion flange end of the drive shaft, then remove the bearing retaining ring.

5) Remove oil seal from other sides of gearbox and remove the bearing retainer ring.

6) Using proper press, carefully press input shaft from gearbox housing.

7) Remove bearings and .500 x

2.063 long square key from input shaft.

8) Note orientation of gear, then reach into top of gearbox housing and remove input gear from gearbox hous ing.

9) Using bearing puller, remove bearing from gearbox housing if necessary.

2. Assembly and Installation

a. Assemble and install the input shaft.

1) Obtain a new 309 bearing and install in non-drive side of gearbox hous ing.

2) Install new split ring in non-dive side of housing.

3) Place input gear into gearbox

hous ing in proper orientation.

4) Install .500 x 2.063 long key in the input shaft. Holding input gear in place, start to insert input shaft. Make sure key in shaft aligns with slot in gear. Make sure shaft aligns with bearing.

5) Install a new spherical roller bearing over input shaft. Align the shaft and bearing with housing and carefully press bearing into place.

6) Install new split ring into gearbox hous ing.

7) Press new oil seals into both sides of gearbox housing.

8) Install .375 x 1.563 key on input shaft, then install companion flange.

9) Apply Loctite 242 to 1/2-13UNC X 1-1/2 inches long cap screws, then install washer and cap screw.

b. Assemble and install the intermediate

shaft assembly.

1) Press new idler gear bearings into the idler gear.

2) Install new shaft seal rings on the ends of the intermediate shaft.

3) Reaching through the top of the gearbox, place the intermediate gear in position towards the front of the gearbox housing.

4) Press the idler shaft through the idler gear until the shaft is seated in the gearbox housing.

5) Apply Loctite to the idler shaft threads, install the idler shaft washer and loc knut. Tighten lock nut.

5-36

Hale MG User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual