OPEROPER
OPER
OPEROPER
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TING ANDTING AND
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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._______________
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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
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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
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
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