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Hale RSD User Manual

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RSD Single Stage Pump
Operation and Service
Maintenance Manual
Hale Products Inc. ◆ A Unit of IDEX Corporation
700 Spring Mill Avenue
Telephone: 610-825-6300
Web......www.haleproducts.com
◆ Conshohocken, PA 19428 U.S.A.
Manual p/n: 029-0020-92-0

NOTICE !

Hale Products, Inc. cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice.
All Hale products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER
IN YOUR CORRESPONDENCE.
ECN No REV CHANGE FROM BY DATE APVD
0299 A INITIAL RELEASE LwH 01/20/2006 MAL
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
Conshohocken, PA 19428 USA
Manual p/n: 029-0020-92-0, Rev. -A Printed in U.S.A.
WRITTEN BY LwH ISSUE DATE COPYRIGHT ©
CHECKED BY PW 03/03/2006
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
© Hale Products, Inc. 2006
All Rights Reserved
Table of Contents ❑

Contents Page

RSD Series Single-Stage PTO Pump
Hale RSD Single-Stage Pump ................................................................................ 9
Figure A: RSD Series Single-Stage PTO Pump Capacity ....................................................9
Figure B: Overview, RSD Single-Stage Pump.................................................................... 10
1 Safety Precautions................................................................................................. 11
1.1 Guidelines......................................................................................................................... 11
2 Introduction........................................................................................................... 15
2.1 Principles of Operation ...................................................................................................15
Centrifugal Force ..............................................................................................................................15
Figure 2-1: Centrifugal Force - Rotating Disk .....................................................................15
Figure 2-2: Pump Water Flow, Cutwater ............................................................................16
2.2 Pump Components .......................................................................................................... 16
Volute, Pump Body...........................................................................................................................16
Figure 2-3: Typical Pump and Gearbox Overview..............................................................17
Impeller.............................................................................................................................................17
Figure 2-4: Impeller Operation............................................................................................17
Clearance Rings ...............................................................................................................................18
Mechanical Seal ...............................................................................................................................18
Figure 2-5: Typical Mechanical Seal Overview...................................................................18
Ball and Tapered Bearings ...............................................................................................................19
2.3 Pump Drives ..................................................................................................................... 19
Figure 2-6: Pump / Engine Rotation ...................................................................................19
Gearbox............................................................................................................................................20
HALE Power Takeoff (PTO) Driven Pumps......................................................................................20
Hale Engine Mounted Pumps (-M Series) ........................................................................................20
2a Accessories ............................................................................................................. 21
2a.1 Anodes .............................................................................................................................. 21
Figure 2a-1: Hale 1-1/4” NPT Anode.................................................................................. 21
2a.2 Auxiliary Cooling..............................................................................................................22
2a.3 Pressure and Relief Valve Control.................................................................................. 22
Figure 2a-2: P Series Relief Valve System Arrangement...................................................22
Thermal Relief Valves (TRV) .......................................................................................................... 23
Figure 2a-3: Thermal Relief Valve, TRV.............................................................................23
TRV-L Kit....................................................................................................................................24
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
3
❑ Table of Contents
Contents - continued Page
2a.4 Priming Systems.............................................................................................................. 24
Figure 2a-4: Rotary Vane and ESP Priming Pumps...........................................................25
Priming Valves..................................................................................................................................25
Figure 2a-5: SPVR Priming Valves ....................................................................................26
Figure 2a-6: PVG Priming Valves.......................................................................................26
2a.5 Torrent SVS Valves..........................................................................................................26
Figure 2a-7: Typical SVS Valve Primary Components...................................................... 26
3 Basic Operation .....................................................................................................27
3.1 Overview ........................................................................................................................... 27
3.2 Stationary Pumping Operations..................................................................................... 28
Pumping From a Hydrant, General Operation..................................................................................28
Figure 3-1: Driver’s Compartment Indicator Lights.............................................................28
Figure 3-2: Pump Operator’s Panel.................................................................................... 29
TPM Operation from a Hydrant ........................................................................................................ 31
Draft Limiting Factors .......................................................................................................................31
Pumping From Draft ......................................................................................................................... 31
Pumping from On Board Water Tank (Split-Shaft PTO)................................................................... 34
3.3 Pumping In Relay.............................................................................................................36
Relay Procedures ............................................................................................................................. 37
3.4 Tandem (Series) Pumping............................................................................................... 38
Tandem Procedures .........................................................................................................................39
3.5 Pump-To-Road Shift Procedures ................................................................................... 39
3.6 Pump and Roll.................................................................................................................. 40
3.7 Relief Valve Procedures.................................................................................................. 40
Standard Relief Valve Procedures ...................................................................................................40
TPM Relief Valve Procedures .......................................................................................................... 41
Figure 3-3: TPM / PMD Relief Valve Control...................................................................... 41
TPM System with Engine Governor.................................................................................................. 42
Increasing Pressure................................................................................................................... 42
Decreasing Pressure ................................................................................................................. 43
3.8 Emergency Pump Shift Procedures............................................................................... 43
3.9 Post Operation Procedures ............................................................................................ 44
4 Preventive Maintenance........................................................................................45
4.1 Overview ........................................................................................................................... 45
4.2 Post Operation ................................................................................................................. 45
4.3 Extreme Conditions......................................................................................................... 45
During Freezing Weather .................................................................................................................45
Salt Water, Contaminated Water, or Foam Solution..................................................................46
4
RSD Series Single-Stage PTO Pumps
p/n: 029-0020-92-0
Table of Contents ❑
Contents - continued Page
4.4 Weekly ...............................................................................................................................46
Relief Valve Test...............................................................................................................................46
Governor Test...................................................................................................................................47
Priming System Test.........................................................................................................................47
Pump Shift Warning Indicator Lights ................................................................................................47
Valve Maintenance ...........................................................................................................................48
Intake Strainers.................................................................................................................................48
Verify All Gauges are in Working Order............................................................................................48
Operate Pump Controls....................................................................................................................48
Inspect Water and Foam Tanks........................................................................................................49
Check Auxiliary Engine.....................................................................................................................49
4.5 Monthly..............................................................................................................................49
Valve Lubrication ..............................................................................................................................49
Gearbox Lubrication .........................................................................................................................49
Figure 4-1: Gearbox Oil Change Plugs...............................................................................50
Pump Mounting, Drive Line and Flange Bolts .................................................................................. 50
Priming System Test (Dry Vacuum Test) .........................................................................................50
Figure 4-2: Priming Valve Handle.......................................................................................51
4.6 Annual ............................................................................................................................... 52
Replace Gearbox Oil ........................................................................................................................52
Relief Valve System..........................................................................................................................53
Check Drain Lines to Multi-Drain......................................................................................................54
Clean Priming Pump.........................................................................................................................54
Performance Testing Overview ........................................................................................................54
Tank-to-Pump Flow Rate Test ...................................................................................................54
Table 4-3: Pump Ratings (GPM / LPM)..............................................................................55
Performance Testing Equipment and Materials................................................................................55
Performance Testing .......................................................................................................................57
Worn Clearance Rings and Impeller Hubs .......................................................................................58
Anode Check ...................................................................................................................................58
Figure 4-4: Hale Anode ......................................................................................................58
5 Troubleshooting .................................................................................................... 59
Figure 5-1: Sample, Serial Nameplate................................................................................59
Figure 5-2: Troubleshooting Chart......................................................................................59
PTO Will Not Engage........................................................................................................59
Pump Loses Prime or Will Not Prime. ..............................................................................59
Insufficient Pump Capacity. ..............................................................................................61
Insufficient Pressure. ........................................................................................................62
Remote Control Difficult to Operate..................................................................................62
Engine Speeds Too HIGH for Required Capacity or Pressure.........................................62
Cavitation..........................................................................................................................63
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
5
❑ Table of Contents
Contents - continued Page
5 Troubleshooting - continued
Relief Valve Does Not Relieve Pressure When Relief Valves are Closed. ...................... 63
Relief Valve Does Not Recover and Return to Original Pressure
Setting After Opening Valves. ..........................................................................................64
Relief Valve Opens When Control Valves are Locked Out. .............................................64
Unable to Obtain Proper Setting on Relief Valves............................................................64
Discharge Valves Are Difficult to Operate. .......................................................................64
Water/Moisture in Pump Gearbox. ................................................................................... 65
Rotation Symptoms. .........................................................................................................65
6 Repair .....................................................................................................................67
6.1 Overview ........................................................................................................................... 67
6.2 General Repair Guidelines.............................................................................................. 67
Before You Begin... ..........................................................................................................................67
Table 6-1: Typical Torque Values Chart............................................................................. 69
Gearbox Assembly ...........................................................................................................................70
6.3 Cleaning and Inspection Guidelines .............................................................................. 70
Bearings ...........................................................................................................................................71
Tools Required .................................................................................................................................71
6.4 RSD Pump and Gearbox Overview ................................................................................ 73
Figure 6-2: RSD Series Single-Stage Pump ...................................................................... 73
6.5 Removing the Assembly ................................................................................................. 74
Removing the Assembly................................................................................................................... 74
Installing the Assembly.....................................................................................................................75
6.6 Removing the Gearbox Only........................................................................................... 76
Removal ...........................................................................................................................................76
Figure 6-3: Typical RSD Gearbox Removal .......................................................................76
Installation ........................................................................................................................................ 78
6.7 Servicing the RSD Pump................................................................................................. 79
Suction Head.................................................................................................................................... 79
Figure 6-4: RSD Pump Parts Overview..............................................................................80
Installation Notes - Suction Head...............................................................................................81
Volute ............................................................................................................................................... 82
Figure 6-5: Typical Water Cooling Lines ............................................................................ 82
Installation Notes – Volute ......................................................................................................... 83
Impeller.............................................................................................................................................83
Figure 6-6: Inducer - 1,500 GPM Pump ............................................................................. 84
Clearance Rings, Impeller Measurement .........................................................................................85
Figure 6-7: Clearance Ring and Impeller ID / OD Measurement........................................85
750 - 1,250 GPM Pump ............................................................................................................. 85
1,500 GPM Pump ...................................................................................................................... 86
Installation Notes – Impeller (and Inducer) ................................................................................ 86
6
RSD Series Single-Stage PTO Pumps
p/n: 029-0020-92-0
Table of Contents ❑
Contents - continued Page
6.7 Servicing the RSD Pump - continued
Pump Gear, Shaft and Oil Seal ........................................................................................................ 87
Figure 6-8: Pump Gear, Shaft and Seal Replacement .......................................................87
Installation – Pump Head, Shaft and Oil Seal ............................................................................89
6a Mechanical Seal Assembly ................................................................................... 91
Removing the Seal ...........................................................................................................................91
Figure 6a-1: Mechanical Seal Overview / Replacement.....................................................91
Installing Seal ...................................................................................................................................92
6b Gearbox Service .................................................................................................... 95
6b.1 Input Shaft and Gear Assembly ......................................................................................95
Disassembly, including Oil Seal........................................................................................................ 95
Figure 6b-6: Input Shaft and Gear Assembly .....................................................................96
Reassemble, including Oil Seal........................................................................................................97
6c Available Options - Repair................................................................................... 99
6c.1 Tachometer Drive ........................................................................................................... 99
Figure 6c-1: Tachometer Drive Option ...............................................................................99
Installation Notes........................................................................................................................99
6c.2 Engine Drive .................................................................................................................100
Figure 6c-2: RSD Engine Drive Option............................................................................. 100
Servicing the Oil Seal / Input Shaft Assembly ................................................................................100
Servicing the Input Shaft .......................................................................................................... 102
Replacing the Oil Seal..............................................................................................................102
Installation Notes - Engine Mounting .......................................................................................102
7 Installation ........................................................................................................... 103
7.1 Overview ......................................................................................................................... 103
7.2 Frame Mounting .............................................................................................................103
General Mounting ...........................................................................................................................103
7.3 Driveline Issues.............................................................................................................. 104
Drive Line and Flange Bolts............................................................................................................ 104
Issues ............................................................................................................................................. 104
Table 7-1: Maximum Recommended Driveline Lengths ...................................................105
7.4 Plumbing Connections ..................................................................................................106
Appendix A: Glossary......................................................................................... 107
Appendix A-1: Measurements ........................................................................... 111
Conversion Chart ...........................................................................................................111
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
7
❑ Table of Contents
Contents - continued Page
Appendix C: Alternate Lubricant Manufacturers........................................... 113
Table C-1: Alternate Lubricant Manufacturers.................................................................. 113
Appendix C1: Lube and Sealant Specifications ............................................... 115
Table C1-1: Oil Capacity and Recommendation .............................................................. 115
Grease............................................................................................................................................116
Loctite Sealant................................................................................................................................116
Oil ...................................................................................................................................................116
Recommended Cleaners ................................................................................................................ 116
Appendix D: Hose Friction Loss ....................................................................... 117
Table D-1: Hose Friction Loss (PSI / BAR 100 Feet) ....................................................... 117
Appendix E: Nozzle Size vs. Pressure................................................................119
Chart E-1: Nozzle Flow and Pressure Ratings, Part 1 .....................................................119
Chart E-2: Nozzle Flow and Pressure Ratings, Part 2 .....................................................120
Appendix F: Cavitation......................................................................................121
Figure F-1: Sample, Cavitation Regions........................................................................... 121
Process of Cavitation...................................................................................................................... 121
Warning Signs of Cavitation (Discharge and Gauges) ................................................................... 122
Discharge Pressure ................................................................................................................. 122
Vacuum Compound Gauge ..................................................................................................... 122
To Eliminate Cavitation................................................................................................................... 122
During Operations ........................................................................................................................ 123
Figure F-2: Lift Loss from Temperature............................................................................123
Figure F-3: Lift Loss from Elevation.................................................................................. 123
Figure F-3a: Lift Loss from Barometric Reading...............................................................123
Preventive Measures...................................................................................................................... 123
Figure F-4: Hose Size vs. Pump Rating Capacity ............................................................ 124
Express Warranty ...............................................................................................125
Hale Products, Inc. ........................................................................................................................ 126
8 Drawing Package.................................................................................................127
RSD Series ..............................................................................................................................128
Available Options ..................................................................................................................... 128
8
RSD Series Single-Stage PTO Pumps
p/n: 029-0020-92-0

Hale RSD Single-Stage Pump

The Hale line of RSD Single-Stage PTO Pumps can be used as initial attack pumps or as auxiliary pumps in conjunction with the apparatus main pump. RSD pumps offer the versatility, dependability, reliability, ease of operation and reduced maintenance that is so necessary to effective fire fighting.
Hale RSD pumps are compact in size and lightweight for easy mounting. The apparatus builder must supply the transmission PTO (power takeoff) and connecting shaft.
Hale offers various models of the RSD series single-stage pumps. The anticipated use and position on the apparatus determines the model selected as well as the drive unit. Flow capacities are shown in Figure A: RSD Series Single-Stage PTO Pump Capacity.)
Overview ❑
Model Type Capacity
Standard Single-Stage RSD Series
Pump. Engine rotation and opposite engine rotation.
Optional Single-Stage RSD Series
Pump. Engine rotation only.

Figure A: RSD Series Single-Stage PTO Pump Capacity

Up to 1,250 GPM (4,732 LPM). NFPA Rated at 750 to 1,250 GPM (2,839 to 4,732 LPM), per Standard 1901.
Up to 1,500 GPM (5,678 LPM). NFPA Rated at 750 to 1,500 GPM (2,839 to 5,678 LPM), per Standard 1901.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
9
❑ Overview
10

Figure B: Overview, RSD Single-Stage Pump

RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0

1 Safety Precautions

HALE SERIES PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPER­ATORS. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDE­LINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL.
ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDER­STOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE PUMP.
WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCE­DURES, INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN.
Safety ❑
IMPORTANT !
Hale is a registered trademark of Hale Products, Incorporated. All other brand and product names are the trademarks of their respective holders.

1.1 GUIDELINES

THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCE­DURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDE­LINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED IN THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS (TO PREVENT ANY MOVE­MENT OF THE APPARATUS), AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
❑ Use care when removing the pump assembly from its packaging to pre-
vent personal injury and/or damage to the system.
NOTICE !
Section 1: Safety Precautions Hale Products, Inc., Nov. 2005, Rev-A
❑ To fully support the pump assembly, use all mounting bolt holes provided
on the gearbox and/or the pump. See the pump assembly plate drawing, located at the back of this manual, for additional installation information.
11
❑ Safety
ALL FASTENERS ON THE HALE PUMP AND GEARBOX ASSEMBLY HAVE BEEN SELECTED FOR THEIR APPLICATION. HALE PRODUCTS DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTER­NATIVE POSES A SERIOUS SAFETY RISK.
CAUTION !
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC ADHESIVE/SEALANT, SUCH AS LOCTITE
❑ Installation should be performed by a trained and qualified installer, such
®
#242 OR EQUIVALENT.
as your authorized Hale representative. Be sure the installer has suffi­cient knowledge, experience and the proper tools before attempting any installation.
WARNING !
THE HALE PUMP AND GEARBOX ASSEMBLY CAN BE HEAVY AND BULKY. ADDING ACCESSORIES TO THE SYSTEM ALSO INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING FOR THE APPROXIMATE WEIGHT.
BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVER­HEAD CRANE, JACKS, CHAINS, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE HALE PUMP AND GEAR­BOX ASSEMBLY.
❑ The installer is responsible for observing all instructions and safety pre-
cautions in his or her daily routine as dictated by regional safety ordi­nances or departmental procedures.
12
❑ DO NOT permanently remove or alter any protective feature, guard or
insulating devices, or attempt to operate the system when these guards are removed.
Doing so voids the Hale pump warranty. Also see heading “Express Warranty” on page 125.
❑ Any of the above could affect system capacity and/or safe operation of
the system and is a serious safety violation which could cause personal injury or could affect safe operation of the pump.
Hale Products, Inc., Nov. 2005, Rev-A
Section 1: Safety Precautions
Safety ❑
WARNING!
NO MODIFICATIONS MAY BE MADE TO THE HALE PUMP AND GEARBOX ASSEMBLY WITHOUT PRIOR WRITTEN PERMISSION FROM:
Hale Products, Incorporated
Fire Suppression Division
700 Spring Mill Avenue
Conshohocken, PA 19428 U.S.A.
Telephone ..........610-825-6300
Fax .....................610-825-6440
Web....................www.haleproducts.com
❑ Rotating drive line parts can cause injury. Be extremely careful that NO
part of your body (head, feet, arms, legs, fingers, hair, etc.) is in an area of rotating parts where you could be subject to injury.
❑ Make sure everyone is clear of the apparatus before shifting to the
PUMP position. Verify the parking brake is set and the wheels are chocked to prevent any movement of the apparatus.
❑ Make sure proper personal protective equipment is used when operating
or servicing the apparatus.
WARNING!
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALL­ING FORCE (PRESS) FITTED PARTS. WEAR PROTECTIVE, HEAT-RESIS­TANT GLOVES WHEN HANDLING PARTS THAT REQUIRE HEATING FOR INSTALLATION AND/OR REMOVAL. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE OR HAND INJURY.
DO NOT OVERHEAT PARTS CONSTRUCTED OF BRONZE (E.G. IMPELLER). OVERHEATING (PART TURNS RED OR BLUE) CAN WEAKEN THE PART AND IT MUST THEN BE REPLACED.
❑ DO NOT operate the system at pressures higher than the maximum
rated pressure. Always use the lowest possible relief valve settings to enhance operator and equipment safety. Also see Section 2 “Introduc­tion” on page 15 for additional information.
Section 1: Safety Precautions Hale Products, Inc., Nov. 2005, Rev-A
❑ Relieve all system pressure, then drain all water from the system before
servicing any of its component parts.
❑ Use only pipe, hose and fittings which are rated at or above the maxi-
mum pressure rating at which the water pump system operates.
13
❑ Safety
❑ Per NFPA 1962 requirements, large diameter hose, marked “supply
❑ If leakage from the drain hole in the pump head is noticed or suspected,
❑ If a pump is operated without water for extended periods, or without dis-
❑ DO NOT attempt to pump until all the GREEN pump indicators in the cab
❑ DO NOT advance the throttle unless the OK TO PUMP indicator is illumi-
Hose 3-1/2” to 5” (89 - 127 mm) diameter” shall not be used at operating pressures exceeding 185 PSI (13 BAR). Large diameter hose, marked “Supply Hose 6” to 5” (152 mm) diameter” shall not be used at operating pressures exceeding 135 PSI (9 BAR).
the impeller must be removed and the mechanical seal must be inspected and/or replaced.
charging water, it could overheat. This can damage the mechanical seal, impeller or the drive mechanism.
and panel are ON. Also see Section 3 “Basic Operation” on page 27 for additional information.
nated. Also see Section 3 “Basic Operation” on page 27 for additional information.
❑ DO NOT leave the cab, after selecting the PUMP mode, until all the
GREEN pump indicators in the cab and panel are illuminated. Also see Section 3 “Basic Operation” on page 27 for additional information.
❑ DO NOT attempt emergency manual shift procedures while the engine is
running. Also see Section 3 “Basic Operation” on page 27 for additional information.
❑ Never attempt to shift the pump (PUMP-to-ROAD, vise versa) while the
truck transmission is in gear. Always shift the truck transmission to NEU­TRAL (N) and verify the speedometer is ZERO (0) before shifting the pump. Also see Section 3 “Basic Operation” on page 27 for additional information.
❑ DO NOT reduce the pressure on the INTAKE gauge below zero (0).
Serious damage to the water main could result.
❑ Some vehicles maintain air on the shift cylinder continuously regardless
of transmission setting, and some only have air applied when the vehicle transmission is in NEUTRAL.
Use caution when servicing.
❑ Use only PAC-EASE Rubber Lubricant Emulsion (or equal) on the rubber
mechanical seal parts to ease installation. DO NOT use other lubricant types as damage to the mechanical seal and seat could occur.
14
❑ Before connecting any cord sets or wiring harnesses, inspect the seal
washer in the connector.
If the seal washer is missing or damaged, water can enter the connector causing corrosion. This could resulting in possible system failure.
Section 1: Safety Precautions
Hale Products, Inc., Nov. 2005, Rev-A

2Introduction

2.1 PRINCIPLES OF OPERATION

Centrifugal Force
Hale pumps are centrifugal pumps that operate on the principle of centrifu­gal force created by a rapidly spinning disk. (See Figure 2-1: “Centrifugal Force - Rotating Disk.”)
As the disk rotates, it throws water from the center toward the outer circumference of the disk. The velocity at which the water travels from the center directly relates to the diameter of the disk and the speed of rotation.
Introduction ❑
When water is confined in a closed container, such as the volute (pump body), the velocity of the water is converted to pressure that rises to a level depen­dent on the speed of rotation.
There are three interrelated factors that regulate the performance of a centrifugal pump:
❑ SPEED (RPM) If the speed of rotation
increases with flow held constant, fluid pressure increases.
❑ PRESSURE If pressure changes with speed held constant, the flow,
measured in gallons or liters per minute (GPM/LPM), changes inversely; if pressure increases, flow decreases. Pressure is measured in pounds per square inch (PSI) or BAR.
❑ FLOW If the pressure is held constant, the flow increases with an
increase in the speed of rotation. Flow is measured in the number of gal­lons of fluid per minute (GPM/LPM) that a pump can deliver when sup­plied from draft.
A centrifugal pump is preferred by the fire protection service due to its ability to fully utilize any positive suction inlet pressure, reducing the amount of work done by the pump.
Figure 2-1: Centrifugal
Force - Rotating Disk
Section 2: Introduction Hale Products, Inc., Nov. 2005, Rev-A
For example, if the required discharge pressure is 120 PSI (8.3 BAR) and the inlet pressure is 45 PSI (3.1 BAR), the pump must only produce the dif­ference in pressure or 75 PSI (5.2 BAR).
15
❑ Introduction
This contributes to improved performance with reduced maintenance. De­creased maintenance is aided by centrifugal pumps having few moving parts.
As the impeller rotates, the water moving outward in the impeller creates reduced pres­sure, or a vacuum in the suc­tion eye, allowing atmospheric pressure to push water into the pump impeller replacing the water discharged. (See Figure 2-2: “Pump Water Flow, Cut­water.”)
During operation, water enters the suction eye of the impeller. The rotating impeller vanes develop discharge pressure and via the “cutwater *,” directs the water to the discharge opening.
* The “cutwater” is a wedge that divides the water between the volute (pump body) and the pump discharge.
Figure 2-2: Pump Water Flow, Cutwater

2.2 PUMP COMPONENTS

(See Figure 2-3: “Typical Pump and Gearbox Overview,” on page 17.)
The Hale single-stage pump consist of:
❑ Volute (Pump Body)
❑ Impeller and Clearance Ring
❑ Mechanical Seal
❑ Gearbox
Volute, Pump Body
(See Figure 2-3: “Typical Pump and Gearbox Overview,” on page 17.)
As water discharges from the impeller, it enters the volute (pump body). The volute is constructed from fine-grain cast iron and shaped so that its area increases from the cutwater to its full capacity at the volute throat.
16
Hale Products, Inc., Nov. 2005, Rev-A
Section 2: Introduction
Introduction ❑
Note: Stainless Max pumps (volute and impeller) are construction of corrosion
resistant stainless steel (Models SMM / SMD and SMR Series).
This gradual increase in size maintains a con­stant average velocity through the volute.
The volute is a single piece, and must be removed to service the impeller, clearance rings, and mechanical seal. Removal of the volute can often be accom­plished without remov­ing the pump and gearbox assembly from the apparatus.
Figure 2-3: Typical Pump and Gearbox Overview
Impeller
The impeller provides velocity to the water. Water enters the rotating impel­ler at the intake (or eye), and is confined by the shrouds and the vanes to build pressure. The vanes guide water from the inlet to the discharge and reduce the turbulence of the spinning water.
Figure 2-4: Impeller Operation
Section 2: Introduction Hale Products, Inc., Nov. 2005, Rev-A
Figure 2-4: “Impeller Operation” traces a drop of water from the intake of the impeller to the discharge outlet.
17
❑ Introduction
Clearance Rings
Clearance rings prevent pressurized water that is leaving the pump volute from returning to the intake of the impeller. Clearance rings at the impeller intake also prevent leakage, accomplished by limiting the radial clearance between the spinning impeller and the stationary clearance ring. Also see Figure 2-3: “Typical Pump and Gearbox Overview” on page 17.
Typically, a clearance ring has a radial clearance of about 0.0075” (0.191 mm) or between 0.015” to 0.020” (0.381-0.508 mm) per side. However, due to foreign material found in the water, this clearance increases over time as the pump is operated. Clearance rings are designed for replacement when wear limits cause the pump to exceed NFPA standards for satisfactory performance.
Mechanical Seal
The “maintenance-free,” mechanical seal is common to Hale pumps. (See Figure 2-5: “Typical Mechanical Seal Overview.”)
The stationary seat is in con­stant contact with a rotating seal ring to prevent leakage. The sealing dia­phragm is made of a rubber elas­tomer specifically designed for high-tempera-
ture operations.
Note: Mechanical seals do not drip like other pump packing. A Hale pump with a drip from the seal requires service.
Figure 2-5: Typical Mechanical Seal Overview
WARNING !
18
IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT COULD OVERHEAT. THIS CAN DAM­AGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.
Hale Products, Inc., Nov. 2005, Rev-A
Section 2: Introduction
Ball and Tapered Bearings
Bearings support and align the impeller and input shafts for smooth opera­tion. They are the most common anti-friction bearings used and offer a major contribution to the life of a fire pump. When replacing bearings, it is important that you do not interchange bearing manufacturer’s components. The bearing race and cone must always be replaced in matching sets, as supplied by the manufacturer.

2.3 PUMP DRIVES

Hale pumps produce the volumes and pressures shown on their perfor­mance curves. However, maximum pump performance is sometimes lim­ited by the power capacity and speed limits of the engine, transmission, and PTO. (See Figure 2-6: “Pump / Engine Rotation.”)
Introduction ❑
Three common pump drives are used on fire fighting apparatus:
❑ Split-shaft gearbox from
the apparatus drive shaft ­the most common pump drive
❑ Operation from a Power
Take-Off (PTO) from the truck transmission or drive train
❑ A stand-alone drive with
separate engine (auxil­iary engine)
Note: Also see Plate #843A “Vehicle Mounted Pump Applications” located at the back of this manual. (See Section 8 “Drawing Package” on page 127.)
Figure 2-6: Pump / Engine Rotation
Hale pumps are available for either engine rotation (clockwise), or opposite engine rotation (counterclockwise) PTO operation.
Section 2: Introduction Hale Products, Inc., Nov. 2005, Rev-A
WARNING!
NEVER OPERATE A HALE PUMP ABOVE THE CONTINUOUS TORQUE RAT­ING FOR ITS TRANSMISSION OR PTO, OR ABOVE THE RECOMMENDED PTO OUTPUT SPEED AS RECOMMENDED BY THE PUMP / APPARATUS MANUFACTURER.
19
❑ Introduction
Gearbox
Hale pumps are equipped with an all ball bearing-type gearbox, utilizing helical gears to reduce operating noise. Hale gearboxes are available in a variety of ratios to accommodate a wide range of manufacturer require­ments for engines, transmissions, and PTOs, (speed and available horsepower).
Gearboxes are also available in various mounting configurations (e.g., short (S), long (L), extra long (XL), split-shaft, PTO (top, left-hand, right-hand), rear mount, etc.) to accommodate the wide range of apparatus manufac­turer requirements.
Hale pumps also feature, as standard equipment, a gearbox cooling tube to maintain proper operating temperatures.
HALE Power Takeoff (PTO) Driven Pumps
Hale pumps feature a 1-1/2” (38 mm) input (drive) shaft for connection to a PTO driveline. Optional 1410, 1510 and 1610 companion flanges are also available.
Hale Engine Mounted Pumps (-M Series)
Certain Hale pumps are available with an adapter to accept #2, #3 and #4 SAE bell housings. Elastomeric drive discs are also available for 10” (254 mm) and 11.5” (292 mm) clutch discs.
20
Hale Products, Inc., Nov. 2005, Rev-A
Section 2: Introduction

2a Accessories

In addition to the basic Hale pump and gearbox, the following options and/or accessories are available to complete a system installation:
❑ Anodes
❑ Auxiliary Cooling, standard on some equipment
❑ Pressure Control Devices (Relief Valves or Governors)
❑ Thermal Relief Valve (TRV)
❑ Priming Systems
❑ Torrent Stainless Steel SVS Valves

2A.1 ANODES

Accessories ❑
The Hale Anode System helps prevent damage caused by galvanic corro­sion in the pump. Galvanic corrosion occurs when different conducting materials are connected electrically and exposed to fluid. Galvanic corro­sion, results in corrosion of the less resistant of the two metals, while the more resistant metal is protected. (See Figure 2a-1: “Hale 1-1/4” NPT Anode.”)
Hale offers two types of anodes (consumables) for pump pro­tection from galvanic corrosion:
❑ Zinc anode - recommended
for all pumps where corro­sion is an issue, including brackish or salt water expo­sure.
❑ Magnesium anode - avail-
able for use if the pump already uses zinc anodes and galvanic corrosion is still
Figure 2a-1: Hale 1-1/4” NPT Anode
a concern. Magnesium anodes contain a notch in the hex head for identification.
Section 2a: Accessories Hale Products, Inc., Nov. 2005, Rev-A
The Anode kit is designed for installation in the standard Hale 115 series flange opening. On fabricated manifolds and similar applications, the installer must provide 1-1/4” NPT openings and install anodes directly. It is recommended that one anode be installed on each suction manifold and one on the discharge side.
21
❑ Accessories
Typically, three (3) are used. Anodes can be mounted in any position, hori­zontal or vertical. Anodes should be inspected periodically * and replaced when over 75% of the metal has been consumed. Performance of the anode varies with water quality and PH.
* Zinc anodes should be inspected every twelve (12) months. Magnesium anodes, which are consumed at a faster rate, should be inspected ever three (3) or four (4) months.

2A.2 AUXILIARY COOLING

For pumps not equipped with standard gearbox cooling, a cooler option is available to protect the gearbox, the apparatus engine, and the pump. The gearbox cooler circulates pump water to transfer heat from the gearbox oil to the pump discharge, thus maintaining proper operating temperatures.

2A.3 PRESSURE AND RELIEF VALVE CONTROL

Note: For additional information about the pressure and relief valves in your sys­tem, also see the separate manual provided with the valves.
P Series Relief Valve System
22
Figure 2a-2: P Series Relief Valve System Arrangement
Hale Products, Inc., Nov. 2005, Rev-A
Section 2a: Accessories
Accessories ❑
The P Series relief valve system is a bronze, variable-pressure setting, relief valve that prevents undue pressure per the requirements of NFPA Standard
1901. An AMBER indicator light on the operator control panel signals when the valve is open. (See Figure 2a-2: “P Series Relief Valve System Arrangement,” on page 22.)
The P series relief valve system consists of a panel mounted control valve (PM) and a P25, P30 or P30V relief valve. The valve is mounted in the dis­charge piping and plumbed back to the pump suction. Valve connections are either flanged or Victaulic
™.
Thermal Relief Valves (TRV)
Section 2a: Accessories Hale Products, Inc., Nov. 2005, Rev-A
Figure 2a-3: Thermal Relief Valve, TRV
23
❑ Accessories
The optional TRV protects the pump from overheating. It is attached to the discharge piping either by flange mounting or 1-1/4” NPT threaded connec­tion (38 mm for Model TRVM). (See Figure 2a-3: “Thermal Relief Valve, TRV,” on page 23.)
The valve monitors the temperature of the water in the pump. When tem­peratures exceed 120° F (49° C), the valve automatically opens. Depend­ing on the installation, a small amount of water either discharges to the ground or into the water tank allowing cooler water to enter. After the tem­perature returns to a safe level, the valve closes.
TRV-L Kit
The TRV-L kit includes a chrome panel placard with a warning light, a light test button, and a pre-assembled wire harness. The RED light illuminates when the TRV is open and discharging water. Also see Figure 2a-3: “Ther­mal Relief Valve, TRV” on page 23.
An optional buzzer, mounted on the operator panel, provides an audible warning.

2A.4 PRIMING SYSTEMS

Priming pumps are used to evacuate air in the suction hose and pump. The vacuum created allows atmospheric pressure to push water from the static source through the suction hose and into the pump.
Hale pumps use Rotary Vane Positive Displacement pumps for priming. (See Figure 2a-4: “Rotary Vane and ESP Priming Pumps,” on page 25.)
The priming pump has a rotor mounted off-center (eccentric) to the pump body housing. The rotor vanes slide in grooves and are held against the body housing by centrifugal force.
As a vane turns toward the discharge, it recedes into the rotor compressing the air. As the rotor continues past the discharge, the vane advances out­ward from the groove and against the body housing. During this cycle, the space between the rotor and housing case fills with air. The vanes, acting as wipers, force air out of the discharge, creating a vacuum in the main pump allowing atmospheric pressure to push water into the hose and suc­tion side of the pump.
The Hale ESP series priming pump is an environmentally friendly primer that does not require a separate lubricant reservoir. The vanes and pump body are self-lubricating for maintenance free operation. (See Figure 2a-4: “Rotary Vane and ESP Priming Pumps,” on page 25.)
24
Hale Products, Inc., Nov. 2005, Rev-A
Section 2a: Accessories
Accessories ❑
Figure 2a-4: Rotary Vane and ESP Priming Pumps
An ESP priming pump also uses a single control to open the priming valve between the pump and the priming pumps, and start the priming motor.
Priming Valves
Hale priming valves open when the priming pump is operated to allow the air to escape from the pump.
Two priming valves are offered:
❑ Hale Semi-Automatic Priming Valve (SPVR), for Remote Mounting
A hose is connected from the SPVR to the priming port on the pump body. A single push button on the operator’s panel starts the priming pump motor. When a vacuum is created, the SPVR opens. (See Figure 2a-5: “SPVR Priming Valves,” on page 26.)
Releasing the push button stops the priming pump and the SPVR closes.
❑ The Hale PVG Priming Valve
Section 2a: Accessories Hale Products, Inc., Nov. 2005, Rev-A
The PVG is mounted on the pump operator’s panel. The PVG is a com­bination valve and switch. (See Figure 2a-6: “PVG Priming Valves,” on page 26.)
When the handle on the PVG is pulled out, the valve opens and the switch energizes the primer motor. Pushing the handle in de-energizes the motor and closes the valve.
25
❑ Accessories
❑ The Hale PVG Priming Valve - continued
Figure 2a-5: SPVR Priming Valves
Figure 2a-6: PVG Priming Valves

2A.5 TORRENT SVS VALVES

Torrent SVS valves con­trol the flow to and from the full range of Hale pumps. SVS valves enable the operator to shut off flow completely, or throttle the flow rate from a trickle to full flow. Numerous adapters tai­lor the valve to almost any installation require­ment. (See Figure 2a-7: “Typical SVS Valve Pri­mary Components.”)
See separate manual for additional information.
Figure 2a-7: Typical SVS Valve Primary Components
26
Hale Products, Inc., Nov. 2005, Rev-A
Section 2a: Accessories

3 Basic Operation

THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCE­DURES. NOT ALL PROCEDURES IN THIS SECTION MAY APPLY TO YOUR SPE­CIFIC OPERATIONAL REQUIREMENTS. REFER TO ONLY THOSE SECTIONS WHICH APPLY TO YOUR OPERATIONAL REQUIREMENTS.
THESE PROCEDURES DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED IN THE APPARATUS MANUFACTURER'S MANUAL.
ALWAYS REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAV­ING JURISDICTION FOR OPERATING PROCEDURES, SETTING WHEEL CHOCKS, AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS. ALL VALVES, DRAIN COCKS AND CAPS SHOULD BE CLOSED.
Operation ❑
WARNING !
NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRANSMISSION TO NEUTRAL (N) AND VERIFY THE SPEEDOMETER IS AT ZERO (0) BEFORE MAKING A PUMP TRANSMISSION SHIFT.

3.1 OVERVIEW

This section provides typical information and procedures for the operation of Hale pumps. The procedures provided are for “split-shaft” and “PTO” pump applications:
❑ Pumping from a hydrant - on page 28.
❑ Pumping from draft - on page 31.
❑ Pumping from an onboard tank (Split-Shaft PTO) - on page 34.
❑ Pumping in relay - on page 36.
❑ Tandem (series) pumping - on page 38.
❑ Pump and Roll - on page 40.
❑ Post-operation procedures - on page 44.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
Note: Also refer to NFPA 1901 Regulations for additional information for apparatus split-shaft and PTO requirements.
27
❑ Operation

3.2 STATIONARY PUMPING OPERATIONS

Pumping From a Hydrant, General Operation
1. Position the truck for the best hydrant hookup and discharge hose layout.
2. Bring the truck to a complete stop and apply the truck parking brake.
3. Shift the truck transmission to the NEUTRAL position. See WARNING ! note on page 27.
4. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP. Also see heading “Pump-To-Road Shift Procedures” on page 39.
Engage the PTO (power take-off) per the PTO manufacturer’s instructions (move the in-cab pump shift control valve from the ROAD position to the PUMP position). The GREEN shift warning lights illuminate in a second or two, indicating a complete shift. (See Figure 3-1: “Driver’s Compartment Indicator Lights.”)
28
Figure 3-1: Driver’s Compartment Indicator Lights
Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
CAUTION !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB ARE ON.
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL.”)
5. Exit the driving compartment only after all the preceding steps are com­pleted and you are sure the appropriate lights in the cab and panel are ON.
6. Verify that the pump panel GREEN shift indicator OK TO PUMP light illumi­nates and that all hose connections are complete.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
Figure 3-2: Pump Operator’s Panel
For “Split-Shaft” operation
❑ After pump shift is completed place the truck transmission in the proper
pump operating range or gear. For most pumpers this is direct drive (1:1) ratio. In addition, the speedometer should register after the shift has been completed.
❑ If the shift does not complete, shift truck transmission back to NEUTRAL
(N) and repeat the entire procedure.
❑ Some vehicles drive the speedometer from the front wheel of the chas-
sis. In this case, the speedometer will not register after shifting to the PUMP position. See the chassis manual for details.
29
❑ Operation
7. Open the hydrant. Bleed off the air from the suction hose.
8. Open the suction valve to allow water flow into the pump.
9. To eliminate air pockets, open the appropriate valve to expel air or prime the pump, if so equipped. Also see heading “Pumping From Draft” on page 31.
10. Note the discharge and intake pressures as applicable, then open the engine throttle gradually until the master discharge gauge indicates the desired pressure.
11. Set the automatic relief valve according to your fire department policy, if so equipped. If your fire department does not have a policy, see heading “TPM Operation from a Hydrant” on page 31.
CAUTION !
DO NOT REDUCE THE PRESSURE ON THE INTAKE GAUGE BELOW DEPART­MENT LIMITS. SERIOUS DAMAGE TO THE WATER MAIN COULD RESULT.
12. If the master intake gauge shows a vacuum before the desired discharge pressure or flow is achieved, it indicates that you are receiving all the water that the suction piping (hydrant) can supply.
13. If you need to increase pressure when this occurs, pump flow must be reduced or the water supply improved.
To increase the pressure, reduce the pump flow. However, the master intake gauge reading must be maintained at 5 PSI (0.34 BAR), minimum.
14. As the throttle (engine speed) is increased, the pressure gauge reading increases.
15. Close the throttle slowly until the pressure begins to stabilize and track with engine speed. If this does not correct the problem, you may be trying to pump more capacity than is available from the supply. Also check the inlet strainers for possible debris restricting the flow.
16. Open the discharge valves.
30
IMPORTANT !
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 TO CIRCULATE WATER.
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
17. When pumping operations are completed, gradually reduce the pump pres­sure until the engine returns to IDLE speed. See heading “Pumping From Draft” on page 31. Disengage the PTO per the PTO manufacturer’s instruc­tions. Also see heading “Pump-To-Road Shift Procedures” on page 39.
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 is always opened first, and if it cannot handle the pres­sure rise, the external relief valve dumps water on the ground. When the inter­nal relief valve opens, the panel light illuminates, and when the external dump valve opens, the light on the panel FLASHES.
Draft Limiting Factors
The effect of raised water temperatures when pumping from a positive pressure source (i.e., a hydrant) is negligible on fire pump performance. However, when pumping from draft (static source such as a pond, lake or basin), elevated water temperature does have a limiting effect.
Water temperatures above 95°F (35°C) cause a noticeable decrease in lift when drafting. Also see Figure F-2: “Lift Loss from Temperature” on page 123.
Barometric pressures below 29” Hg. are another factor that can limit lift when drafting. High elevations and storm conditions can affect maximum flow avail­able from any pump. Also see Figure F-3a: “Lift Loss from Barometric Reading” on page 123.
Pumping From Draft
1. Position the apparatus as close to the water source as practical. The pump can draw 100% of its rated capacity with less than a 10 foot (3.05 meters) vertical lift and 20 feet (6 meters) of suction hose.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
As the vertical lift increases to above 10 feet (3 meters), pump capacity is reduced. Also see Figure F-3: “Lift Loss from Elevation” on page 123.
2. Bring the truck to a complete stop and apply the truck parking brake.
31
❑ Operation
3. Shift the truck transmission to the NEUTRAL position. See WARNING ! note on page 27.
4. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP. Also see heading “Pump-To-Road Shift Procedures” on page 39.
Engage the PTO (power take-off) per the PTO manufacturer’s instructions (move the in-cab pump shift control valve from the ROAD position to the PUMP position). The GREEN shift warning lights illuminate in a second or two, indicating a complete shift. (See Figure 3-1: “Driver’s Compartment Indicator Lights” on page 28.)
Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
CAUTION !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB ARE ON.
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 29.)
5. Exit the driving compartment only after all the above steps are completed and you are sure that the appropriate lights in the cab and panel are ON.
6. Verify that the pump panel GREEN shift indicator OK TO PUMP light illumi­nates and that all hose connections are complete.
For “Split-Shaft” operation
❑ After pump shift is completed place the truck transmission in the proper
pump operating range or gear. For most pumpers this is direct drive (1:1) ratio. In addition, the speedometer should register after the shift has been completed.
❑ If the shift does not complete, shift truck transmission back to NEUTRAL
(N) and repeat the entire procedure.
❑ Some vehicles drive the speedometer from the front wheel of the chas-
sis. In this case, the speedometer will not register after shifting to the pump position. See the chassis manual for details.
7. Activate the priming pump by pulling the control handle located on the pump panel or by pressing the push button.
32
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
Your departmental manual for pumping should specify the correct RPM for priming. However, in general, priming should be operated at IDLE.
Running the engine at speeds higher than 1,200 RPM during priming is not recommended. It does not improve the priming operation but can cause damage to the pump.
CAUTION !
IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO (0), OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND WITHIN 30 TO 45 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
STOP THE PUMP AND CHECK FOR AIR LEAKS OR POSSIBLE PROBLEMS. SEE SECTION 5 “TROUBLESHOOTING,” ON PAGE 59.
8. Monitor the intake and discharge master gauges. When the pump is primed, the intake indication reading falls below zero (0), and the discharge pressure starts to increase. You may also hear water splashing on the ground from the primer, indicating the pump is primed.
9. Gradually open the discharge valve until water emerges in a steady stream. Then open the other discharge valves to the desired setting.
10. Open the engine throttle gradually until the desired pressure or flow is achieved.
CAUTION !
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.
11. If the pump is cavitating, warn personnel that the flow is being REDUCED.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
In this case, close the throttle slowly until you operate without cavitation.
The following possibilities can also lead to cavitation:
❑ Large nozzle tips - reduce flow by using a smaller nozzle.
33
❑ Operation
❑ Air enters with the water - Even though the pump may be primed, air
leaks can cause rough operation and an increase in engine speed without an increase in pressure or flow.
If an air leak is suspected, discontinue pumping - see heading “Trouble­shooting” on page 59.
❑ Hot water - see Figure F-2: “Lift Loss from Temperature” on page 123.
❑ Low barometer - see Figure F-3a: “Lift Loss from Barometric Reading”
on page 123.
❑ High lift - see Figure F-3: “Lift Loss from Elevation” on page 123.
Note: Also see Section “Appendix F: Cavitation” on page 121.
12. 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 periodically to release hot water.
13. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy, see heading “TPM Operation from a Hydrant” on page 31.
14. To avoid pump overheating, if not equipped with the Hale TRV valve, open the pump auxiliary cooling system valve, or slightly open the tank fill line.
15. After completion of pumping procedures, gradually reduce the engine RPM to IDLE speed. See heading “Pump-To-Road Shift Procedures” on page
39. Disengage the PTO per the PTO manufacturer’s instructions. Also see heading “Post Operation Procedures” on page 44.
Pumping from On Board Water Tank (Split-Shaft PTO)
1. Position the truck for the best hydrant hookup and discharge hose layout.
2. Bring the truck to a complete stop and apply the truck parking brake.
3. Shift the truck transmission to the NEUTRAL position. See WARNING ! note on page 27.
4. Make sure the truck is at a complete stop before you attempt to shift from ROAD to PUMP.
34
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
Move the in-cab pump shift control valve from the ROAD position to the PUMP position. The shift warning lights illuminate in a second or two, indi­cating a complete shift. (See Figure 3-1: “Driver’s Compartment Indicator Lights” on page 28.)
Notes: If the truck manufacturer has used another in-cab valve to achieve pump shift or offers an electric switch, follow the instructions supplied with that valve.
CAUTION !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ON.
DO NOT OPEN THROTTLE UNLESS ALL GREEN PUMP INDICATOR LIGHTS ARE ON. (SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 29.)
5. 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.
6. Verify that the pump panel shift indicator OK TO PUMP green light is ON and that all hose connections are complete.
7. Open the tank suction valve.
8. 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.
CAUTION !
IF DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO, OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND WITHIN 30 TO 45 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
STOP THE PUMP AND CHECK FOR AIR LEAKS OR POSSIBLE PROBLEMS. SEE SECTION 5 “TROUBLESHOOTING,” ON PAGE 59.
9. Open the engine throttle gradually until the desired pressure or flow is achieved.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
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. Also see Section “Appendix F: Cavita­tion” on page 121.
35
❑ Operation
10. If the pump is cavitating, warn personnel.
WARNING !
DO NOT OPEN THROTTLE UNTIL ALL GREEN PUMP LIGHTS ARE ON. (SEE FIG­URE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 29.)
11. Gradually open the discharge valve until the water emerges as a steady stream. Then open the other discharge valves to the desired setting.
12. Set the automatic relief valve or governor according to your fire department policy (or the separate governor manual). If your fire department does not have a policy, see heading “TPM Operation from a Hydrant” on page 31.
13. To avoid pump overheating, if not equipped with the Hale TRV valve, open the pump auxiliary cooling system valve, or slightly open the tank fill line.
14. After completion of pumping procedures, gradually reduce the engine RPM until it is at an IDLE speed. See heading “Pump-To-Road Shift Procedures” on page 39. Disengage the PTO per the PTO manufacturer’s instructions. Also see heading “Post Operation Procedures” on page 44.

3.3 PUMPING IN RELAY

Relay pumping is the movement of water through a number of consecutive pumpers, from suction to discharge. Relay operations are necessary when the water source is too far away from the fire to be pumped efficiently by one pumper. 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 TPM (if available) very low. This limits the incoming pump pressure by dumping water on the ground before the discharge hose lines are connected and are flowing water.
Then, as the incoming water is used the relief valve control can be increased to the desired operating pressure and set as instructed. This technique also helps to purge air from the incoming hose and the pump before it gets to a danger­ously high pressure.
36
Use this procedure after the hose is positioned, the apparatus are in position, and the pumps are engaged. For setup and engagement instructions for appa­ratus receiving pressurized water, see heading “Pumping From a Hydrant, Gen­eral Operation” on page 28.
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
Relay Procedures
1. Open two discharge gates on all pumps, except on the pump at the source, to expel air from the hose lines and pumps.
2. On each pump, attach the hose lines to one of the discharges and leave the other discharge uncapped.
Note: Uncapping the second discharge gate is not necessary if a relay valve is installed. The relay valve, connected to the intake side of the pump, automatically opens and dumps water on the ground if too high a pressure is supplied, thus protect­ing the pump.
If no relay valve is present, the operator must watch the intake gauge for a high-pres­sure reading. If this is reached, open the gate controlling the uncapped discharge to dump excess water on the ground and reduce pressure.
3. Supply the pump at the water source with water; prime if necessary.
The discharge pressure must not exceed 185 PSI (13 BAR) for 5” (127 mm) large diameter hose, or 135 PSI (9 BAR) for 6” (152mm) hose, per NFPA Standards 1962. See heading “Pumping From a Hydrant, General Opera­tion” on page 28. Also see heading “Pumping From Draft” on page 31.
IMPORTANT !
FOR ADDITIONAL SUPPLY HOSE AND PRESSURE SETTING INFORMATION, SEE NFPA STANDARDS 1962.
4. 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.
5. Adjust the throttle on the pump at the water source for the required operat­ing pressure. Watch the gauges to avoid cavitation.
“Appendix F: Cavitation” on page 121.
The pump operator at the fire scene must advise all other pump operators of the amount of water needed at the fire ground.
6. Adjust the discharge pressure or flow at the fire scene to supply the lines being used.
Also see heading
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
7. Observe the gauges carefully, and adjust the pressure or flow as needed.
37
❑ Operation
8. 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 the pump.
Follow this procedure for every pump in the relay until the pump at the water source is shut down.
NOTICE !
LOCAL TRAINING PROCEDURES MAY VARY SLIGHTLY FROM ABOVE. IN THIS CASE, ALWAYS FOLLOW LOCAL TRAINING PROCEDURES.

3.4 TANDEM (SERIES) PUMPING

Tandem pumping operations may be used when higher pressures are required than a single engine is capable of supplying. This sometimes occurs when the pumper is attempting to supply high-rise sprinkler or standpipe systems or long hose layouts.
Note: Two 1,000 GPM (3,785 LPM) pumpers in a series from a hydrant can produce 500 GPM (1,893 LPM) at 500 PSI (35 BAR) if the relief valve systems allow 500 PSI.
CAUTION !
WHEN SUPPLYING HOSE LINES IN A TANDEM PUMPING OPERATION IT IS POS­SIBLE TO SUPPLY GREATER PRESSURE THAN THE HOSE CAN WITHSTAND. PRESSURE SUPPLIED TO THE HOSE SHOULD NOT EXCEED THE PRESSURE AT WHICH THE HOSE IS ANNUALLY TESTED BY THE DEPARTMENT.
CONSULT NFPA 1962, “STANDARD FOR THE CARE, USE AND SERVICE TEST­ING OF FIRE HOSE INCLUDING COUPLINGS AND NOZZLES,” FOR THE TEST PRESSURES RECOMMENDED FOR THE TYPE OF FIRE HOSE USED BY YOUR FIRE DEPARTMENT. DEPARTMENTS THAT ROUTINELY PERFORM HIGH-PRES­SURE TANDEM PUMPING OPERATIONS MAY HAVE HOSE DESIGNATED FOR THAT SPECIFIC FUNCTION.
In tandem pumping, the pumper directly attached to the water supply source pumps water through its discharge outlet(s) into the intake(s) of the second engine. This enables the second engine to discharge water at a much higher pressure than a single engine could have supplied. The higher pressure results from the pumps acting in series.
38
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
Tandem Procedures
1. Using the large intake hose, connect the first pumper to the hydrant steamer. Open the hydrant until the pump is primed.
2. Position the second pumper “discharge-to-intake” with the first pumper.
3. Open a discharge to flow water.
4. Adjust the throttle on the first pumper until the intake gauge reads approxi­mately 5 PSI (0.34 BAR)
5. Connect the second pumper to the unused streamer intake of the first pumper, using a large intake hose (approximately 2-1/2” / 64 mm).
6. Both pumpers pump water to the fire. Also see heading “Pumping From a Hydrant, General Operation” on page 28.
NOTICE!
LOCAL TRAINING PROCEDURES MAY VARY SLIGHTLY FROM ABOVE. IN THIS CASE, ALWAYS FOLLOW LOCAL TRAINING PROCEDURES.

3.5 PUMP-TO-ROAD SHIFT PROCEDURES

(For Split-Shaft Gearboxes)
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 about four (4) seconds. Check to make sure the speedometer reads ZERO (0).
3. Move the pump shift control valve lever to the ROAD position. The in-cab and panel pump indicator lights go out when the pump transmission starts to shift into the ROAD position.
NOTICE !
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
REFER TO THE FIRE DEPARTMENT PROCEDURES FOR REMOVING WHEEL CHOCKS, AS WELL AS LAY OUT AND CONNECTION OF SUCTION AND DIS­CHARGE HOSES.
39
❑ Operation

3.6 PUMP AND ROLL

IMPORTNAT !
DURING PUMP AND ROLL OPERATION, IT IS NECESSARY TO SLOW THE FOR­WARD MOTION OF THE APPARATUS TO THE PTO MANUFACTURER'S RECOM­MENDED ENGAGEMENT SPEED.
The following outlines a “general” pump and roll procedure:
1. Slow the apparatus to a safe PTO engagement speed as recommended by the PTO manufacturer’s recommendations.
Note: Most PTOs must be engaged while the apparatus is stopped. Only a "Hot Shift" PTO can be engaged while the apparatus is rolling.
2. Engage the PTO.
3. Verify the PUMP ENGAGED light is ON. Also see Figure 3-1: “Driver’s Compartment Indicator Lights” on page 28.
4. Open the valve between the tank and pump suction.
5. Observe pump discharge pressure and verify that the pump pressure increases.
6. Prime the pump, if necessary.
7. Open the discharge valves and commence operations.

3.7 RELIEF VALVE PROCEDURES

Be sure to select the correct procedure based on how the truck is equipped. (See Figure 3-3: “TPM / PMD Relief Valve Control” on page 41.) Some trucks may utilize a governor in place of the relief valve.
Standard Relief Valve Procedures
Note: Be sure to select the correct procedure, according to the relief valve in your system.
1. Increase the engine RPM to the desired pump operating pressure while reading the discharge pressure gauge.
40
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
2. Turn the handwheel slowly counterclockwise until the relief valve opens. The pilot light illuminates and the master pressure gauge drops a few PSI (BAR).
3. Turn the handwheel slowly clockwise until the master pressure gauge rises to the desired pressure and the pilot light goes out. The relief valve now operates at the set pressure.
4. When the pump is not in operation, turn the handwheel clockwise to a posi­tion slightly above the normal operating pressure. When the pump is put into operation again, reset the valve to the desired operating pressure. More complete and detailed information is found in the relief valve manual.
TPM Relief Valve Procedures
Note: Be sure to select the correct procedure, according to the relief valve in your system.
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 is achieved (as indicated on the master pressure gauge while the pump is discharging water), slowly move the adjusting handwheel counterclockwise until the relief valve opens.
3. The AMBER indicator light illuminates. (See Figure 3-3: “TPM / PMD Relief Valve Con­trol.”)
4. Turn the handwheel slowly clockwise until the light goes out. The relief valve now oper­ates at the set pressure.
5. When the pump is not in operation, turn the handwheel clockwise to a position slightly above the normal operating pressure. More complete and detailed information is found in the relief valve manual.
CAUTION !
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
THE PRESSURE INDICATOR ON THE PANEL IS ONLY A ROUGH INDICATION OF TPM SETTING. ALWAYS USE THE PRECEDING PROCEDURE TO PROPERLY SET THE TPM RELIEF VALVE SYSTEM.
Figure 3-3: TPM / PMD
Relief Valve Control
41
❑ Operation
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 per the manufacturer’s manual.
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 illuminates.
5. Turn the handwheel slowly clockwise until the AMBER light just goes out. Then turn the handwheel one additional full turn clockwise.
CAUTION !
THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.
6. Place 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
❑ Set the TPM to a pressure (by the indicator) slightly higher than the
desired new pressure.
❑ Place the governor control in the RPM mode, and increase the speed to
the new pressure.
❑ Turn the TPM handwheel counterclockwise until the relief valve opens and
the AMBER pilot light illuminates. (See Figure 3-3: “TPM / PMD Relief Valve Control” on page 41.)
❑ Turn the handwheel slowly clockwise, until the AMBER light just goes out.
Then turn the handwheel one additional full turn clockwise for proper operation.
42
CAUTION !
THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.
❑ Place the governor control in the pressure governor mode; the system is
now set.
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating
Operation ❑
Decreasing Pressure
❑ Put the governor control in the RPM mode, and reduce the speed to the
new pressure.
❑ Move the TPM handwheel counterclockwise until the relief valve opens
and the AMBER pilot light illuminates.
❑ Turn the handwheel slowly clockwise until the AMBER light just goes out.
Then turn the handwheel one additional full turn clockwise.
CAUTION !
THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION.
❑ Place the governor control in the PRESSURE GOVERNOR mode; the
system is now set.

3.8 EMERGENCY PUMP SHIFT PROCEDURES

Before implementing manual override shift procedures, repeat recommended shift procedures. If the shift fails, proceed as follows:
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, place the in-cab shift control in the NEUTRAL (N) position. (Neutral position is exactly in the middle of the ROAD and PUMP position.
5. Shut down the engine.
WARNING !
DO NOT ATTEMPT EMERGENCY SHIFT PROCEDURES WHILE THE ENGINE IS RUNNING.
Section 3: Operating Hale Products, Inc., Nov.2005, Rev-A
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.
43
❑ Operation
❑ Insert the tool into the hole provided, then pull or push the shaft manually.
❑ Pull the shift shaft OUT for PUMP position (after in-cab control valve
selection), or push shift shaft IN 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.
Note: Certain apparatus may offer a manual shift override handle or separate cable for activation.

3.9 POST OPERATION PROCEDURES

1. Return the engine to IDLE, then slowly close all valves.
2. Place the transmission in NEUTRAL, then slowly shift from PUMP to ROAD to disengage the pump.
3. Drain the pump (especially important in freezing weather):
❑ Open the discharge valves, remove suction tube caps, and discharge
valve caps.
❑ Open the pump body drain cocks or Hale multiple drain valve. If a multiple
drain valve is used, all pump drain lines should be connected to this valve.
❑ On two-stage pumps, move the transfer valve back and fourth between
the VOLUME and PRESSURE positions.
4. If sea water, dirty water, alkaline water or foam solution has been used, FLUSH THE PUMP WITH CLEAN WATER.
5. If installed, drain the gearbox cooler. After the pump is completely drained, replace all caps and close all valves.
6. Remove the wheel chocks only when preparing to leave the scene.
7. Fill out the Pump Run Log, indicating total pumping and out-of-station time.
8. Report all pump, vehicle and equipment malfunctions, and irregularities to the proper authority.
9. Know and follow all local procedures. See WARNING ! note on page 27.
44
Hale Products, Inc., Nov.2005, Rev-A
Section 3: Operating

4 Preventive Maintenance

4.1 OVERVIEW

Hale RSD Single-Stage PTO 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 following procedures are for normal use and conditions. Extreme condi­tions may indicate a need for increased maintenance. The procedures in this section identify measures needed to ensure lengthened pump life and continu­ing dependability. Always follow local maintenance and test procedures.
Preventive Maintenance ❑

4.2 POST OPERATION

1. 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.
2. Verify that all discharge valves, booster line valves, drain valves, and cocks are closed.
3. Tighten suction caps.

4.3 EXTREME CONDITIONS

Extreme conditions occur when the pump has been operated during freezing weather or as a result of pumping from a water source that contains material that is harmful to the pump if not purged.
During Freezing Weather
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
In freezing weather, drain the pump as follows:
1. Open all discharge and suction valves, remove suction tube caps and dis­charge valve caps.
2. Open pump body drain cocks and/or Hale multiple drain valve.
45
❑ Preventive Maintenance
3. After the pump is completely drained, replace all caps and close all valves.
Salt Water, Contaminated Water, or Foam Solution
1. Flush the pump and suction hoses by using water from a hydrant or other CLEAN water source.
2. After pumping foam through the pump, flush as above until all foam residue is flushed from the system.
3. Drain the gearbox cooler, if installed.

4.4 WEEKLY

Weekly maintenance consists of testing the relief valve system or governor, the priming system and the pump shift warning indicator lights. If testing criteria is not met, refer to Section 5 “Troubleshooting” on page 59, for corrective mainte­nance procedures.
❑ Test the relief valve or governor system - see page 46
❑ Test the priming system - see page 47.
Establish and HOLD prime control for about three (3) to five (5) seconds to flush fresh water through the priming pump.
Note: DO NOT apply lubricant the primer pump vanes or vane slots. Lubricant and cold water produces a gummy residue that renders the unit inoperative.
❑ Test the pump shift warning indicator lights - see page 47
❑ Perform valve maintenance - see page 48
❑ Check and clean the intake strainers - see page 48
❑ Verify all gauges are in working order - see page 48
❑ Operate pump controls - see page 48
❑ Check auxiliary engine - see page 49
Relief Valve Test
When the relief valve is not in operation, maintain a setting above the normal operating pressure. (See Figure 3-3: “TPM / PMD Relief Valve Control” on page 41.) Also refer to NFPA 1901 standards.
1. Prepare to pump from the onboard water tank with the discharge valve back to the water tank open less than 1/2 way. Also see heading 2a.3 “Pressure and Relief Valve Control” on page 22.
46
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Preventive Maintenance ❑
2. Increase pump pressure up to 150 PSI (10 BAR), as indicated on the mas­ter pressure gauge, per your normal operating procedures.
3. Turn the relief valve handwheel counterclockwise until the relief valve opens and the AMBER light illuminates. The master pressure gauge should drop at least 5 to 10 PSI (0.35 to 0.7 BAR). (See Figure 3-3: “TPM / PMD Relief Valve Control” on page 41.)
4. Turn the control valve handwheel clockwise then counterclockwise a few times to ensure that the handwheel turns freely. Observe the master pres­sure gauge and indicator light for 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 preventive maintenance.
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 (0) reading on the master intake gauge.
3. Continue operation for three (3) to five (5) seconds after the primer starts flushing water through the pump to clear any possible dirt or slug (gum) buildup.
4. Verify that the master intake gauge readings hold for approximately five (5) minutes after you release the primer control. A drop of 10” Hg. during this 5 minute period is anticipated per NFPA 1901 standards.
5. If air leaks are heard or the gauge bounces back to or above zero (0), the pump or valves require service.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Pump Shift Warning Indicator Lights
1. Switch to non-pumping operations and verify the warning indicators are OFF. See Section 3 “Basic Operation” on page 27.
47
❑ Preventive Maintenance
CAUTION !
MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS BEFORE SHIFTING TO THE PUMP POSITION. VERIFY THE PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT ANY MOVEMENT OF THE APPARATUS.
2. Verify that the warning indicators in the cab and the pump control panel function properly.
3. Repair or replace any malfunctioning indicators.
Valve Maintenance
Properly functioning valves are integral to the operation of the pump. Refer to the separate valve manual for proper valve maintenance procedures.
For example, lubricate all moving parts of the suction, discharge, hose drain, and multi-drain valves and valve linkage with a good grade, lithium base grease. For recommended grease, see “Appendix C1: Lube and Sealant Specifications” on page 115.
Note: The PMD valve should be lubricated every six (6) months.
Intake Strainers
❑ Check and clean any debris from the intake.
❑ Flush the pump, if required, using depar tmental / company procedures.
❑ Repair or replace any damaged strainers.
Verify All Gauges are in Working Order
Any gauge that is repeated in the cab or another panel must agree with the gauge on the operator's panel. Gauges not reading within 10% of the cali­brated test gauge must be removed from service and re-calibrated.
48
Operate Pump Controls
Operate the pump drive controls to verify the pump engages. Verify all indicator lights work properly.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Inspect Water and Foam Tanks
Visually inspect water and foam tanks for proper level and gauge readings. If any debris is present, flush the tanks to protect the pump from wear caused by dirty water or foam concentrate.
Check Auxiliary Engine
See separate engine manufacturer’s manual.

4.5 MONTHLY

Monthly maintenance includes the weekly maintenance procedures plus:
Preventive Maintenance ❑
❑ Valve lubrication - see page 49
❑ Gearbox lubrication - see page 49
❑ Dry vacuum testing - see page 50
❑ Checking the pump and drive line bolts - see page 50
Valve Lubrication
1. On handwheel-type valves, including PM, PMD, etc., first remove old grease and paint, then use a dry lubricating spray on gears.
2. Lubricate suction threads with a light coat of a good grade, lithium base grease. For recommended grease, see “Appendix C1: Lube and Sealant Specifications” on page 115.
Gearbox Lubrication
Incorrect oil types or amounts of oil result in unnecessary high oil temperature and possible wear or damage. Change the oil every twelve (12) months, depending on pump usage. All lubricants must meet service rating API GL-5 requirements.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Note: For domestic use, Hale recommends using an SAE EP-90, 80W90 Lubricant or “RoadRanger” Full Synthetic SAE 50 Transmission Lubricant, manufactured by the
®
Eaton ISO68 lubricant, or equivalent.
Corporation, or equivalent. For International use, Hale recommends using an
49
❑ Preventive Maintenance
1. For Gearbox capacity - see head­ing “Appendix C1: Lube and Sealant Specifications” on page
115.
2. Remove the oil fill plug, and check the oil level of the gearbox. (See Figure 4-1: “Gearbox Oil Change Plugs.”)
3. The oil level should be up to the bottom of the plug hole.
4. If the oil appears white or “milky,” a water leak is indicated. Remove the drain plug and drain the oil into a suitable container. Examine the oil for metal flakes or other contamination.
Figure 4-1: Gearbox Oil Change Plugs
Have clean disposable shop rags and oil dry handy and a suitable container to collect the fluid.
Note: If water leak / contamination is suspected, see Section 5 Troubleshooting, heading “Water/Moisture in Pump Gearbox.” on page 65.
5. Either of these conditions indicates maintenance is required on the unit. See Section 6b “Gearbox Service” on page 95.
Pump Mounting, Drive Line and Flange Bolts
Check all drive line, mounting and flange bolts to ensure:
❑ No bolts are missing
❑ All bolts are tight. Use a torque wrench to torque bolts to the drive train man-
ufacturer's recommended specifications.
❑ Bolts used are “Grade 5” strength minimum for mounting and “Grade 8” min-
imum strength for driveline.
Priming System Test (Dry Vacuum Test)
(Refer to NFPA 1901 or NFPA 1911 Standards)
1. Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if so equipped).
50
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Preventive Maintenance ❑
2. Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel.
3. Engage the priming pump until the gauge indicates 22” Hg. vacuum.
4. Compare the readings of the test gauge and the apparatus gauge. Note any difference.
5. STOP the priming pump and observe the gauge. If the vacuum falls more then 10” Hg. in five (5) min-
Figure 4-2: Priming
Val v e H an d le
utes, it is an indication of at least one air leak.
6. Vacuum leaks may often be detected by ear if the apparatus engine is turned OFF. Correct leaks immediately before returning the pump to service.
7. Test the suction hose as follows:
❑ Attach the suction hose to the pump.
❑ Place the suction tube cap on the end of the hose in place of a strainer.
❑ Close all valves and drains. Cap all suction openings and the outlet of the
suction side relief valve (if so equipped).
❑ Connect a test vacuum gauge or manometer to the intake test gauge con-
nection on the pump panel.
❑ Engage the priming pump until the gauge indicates at least 22” Hg.
❑ Watch the gauge. If the vacuum falls more then 10” in five (5) minutes it is
a certain indication of at least one air leak.
❑ Verify the test gauge and the apparatus gauge display the same readings.
Repair and/or replace gauges that do not display the correct pressure.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
IMPORTANT !
IF LEAKS CANNOT BE DETECTED BY FOLLOWING THE PROCEDURE, IT IS ADVISABLE TO TEST THE PUMP HYDROSTATICALLY. TO TEST:
❑ OPEN ALL VALVES
❑ PLACE CAPS ON ALL VALVES
❑ CONNECT A POSITIVE PRESSURE SOURCE (TYPICALLY 250 PSI / 17 BAR)
❑ INSPECT THE PUMP FOR LEAKS
51
❑ Preventive Maintenance

4.6 ANNUAL

Annual maintenance consists of post-operation, weekly, and monthly mainte­nance. Maintenance for extreme conditions may also apply. In addition, the annual maintenance includes the following tasks:
❑ Replacing the pump gearbox oil - see page 52. Also see Figure 4-1: “Gear-
box Oil Change Plugs” on page 50.
❑ Relief valve system, check and repair - see page 53.
❑ Checking individual drain lines from the pump to the multi-drain to ensure
proper drainage and protection from freezing - see page 54.
❑ Performance testing, including Test tank-to-pump flow rate - see page 54.
❑ Disassembly of priming pump to clean vanes - see page 54. (Also see sep-
arate manual provided.)
IIMPORTANT !
DO NO USE A LUBRICANT ON THE PRIMING PUMP VANES AND VANE SLOTS. LUBRICANT AND COLD WATER FORM AN EVENTUAL GUMMY RESIDUE THAT RENDERS THE PRIMING SYSTEM INOPERATIVE. A COMPLETE AND THOR­OUGH DISASSEMBLY AND CLEANING IS THEN REQUIRED.
❑ Running the yearly pump test to check performance levels - see page 54.
(See NFPA 1911 standard for more details.)
Replace Gearbox Oil
1. Remove the drain plug (magnetic) and drain the gearbox oil into a suitable container. For container size based on gearbox capacity, see “Appendix C1: Lube and Sealant Specifications” on page 115. Also see Figure 4-1: “Gearbox Oil Change Plugs” on page 50. Have clean disposable shop rags and oil dry handy.
2. Examine the oil for contamination (e.g., water – turns the oil a milky color or settles to the bottom). Also see Section 5 Troubleshooting, heading “Water/Moisture in Pump Gearbox.” on page 65.
3. Properly dispose of the used oil.
4. Inspect the magnetic drain plug. If metal filings are present, remove the cover plate to visually inspect and clean all internal components.
52
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Preventive Maintenance ❑
Also clean the drain plug (magnetic).
5. Repair or replace components as necessary. See Section 6b “Gearbox Service” on page 95.
6. Replace the cooler or cover, if necessary.
7. Remove the oil fill plug and install the drain (magnetic) plug, using suitable thread sealant.
8. Fill the gearbox with an approved gear oil until oil just begins seeping from the oil level plug opening. For gearbox capacity, see “Appendix C1: Lube and Sealant Specifications” on page 115.
9. Install the oil fill plug using suitable thread sealent.
Relief Valve System
1. Place apparatus out of service in accordance with your departmental procedures.
2. Test the relief valve system in accordance with weekly maintenance check. Also see heading 4.4 “Weekly” on page 46.
3. If the relief valve is not working, clean the strainers as follows:
❑ Open pump compartment panel and locate the relief valve system
strainer(s).
On all relief valve systems, the standard strainer is located in one of the pump pressure ports. On a TPM, an additional strainer is located in one of the pump vacuum ports.
Note: An optional panel-mounted strainer is mounted on some apparatus.
❑ Disconnect tubing, then remove strainer.
❑ Clean any debris from strainer and check for damage.
❑ Using a suitable thread sealant (Loctite PST or equivalent) reinstall
strainer.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
❑ Reconnect tubing.
4. Test apparatus and check for leaks around strainer fittings.
5. Place apparatus back in service.
53
❑ Preventive Maintenance
Check Drain Lines to Multi-Drain
Drains are supplied on the pump and piping at the lowest points where water could collect and freeze, rendering the pump ineffective. Most drain lines are piped together to a multi-drain to allow the entire system to be drained by one valve.
It is necessary to inspect each line of the multi-drain to ensure the entire system is draining when the valve is operated. Inspect each connection and verify the individual lines to the multi-drain are free of debris. Repair and/or replace any lines that are damaged, kinked, or corroded.
Clean Priming Pump
Disassemble the priming pump and clean the housing and vanes. Inspect the vanes for wear and replace as necessary. Reassemble the pump and test for proper operation. (Also see separate manual provided.)
IIMPORTANT !
DO NO USE A LUBRICANT ON THE PUMP VANES AND VANE SLOTS. LUBRI­CANT AND COLD WATER FORM AN EVENTUAL GUMMY RESIDUE THAT REN­DERS THE ESP PRIMING SYSTEM INOPERATIVE. A COMPLETE AND THOROUGH DISASSEMBLY AND CLEANING IS THEN REQUIRED.
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 first placed in service. This provides some measure of performance deterioration, if any. (See Table 4-3: “Pump Ratings (GPM / LPM)” on page 55.)
A pump must be able to pump FULL rated capacity at 150 PSI (10 BAR), 70% capacity at 200 PSI (14 BAR) and 50% capacity at 250 PSI (17 BAR).
Tank-to-Pump Flow Rate Test
Note: This procedure is provided as a reference only. It does not supersede any
local procedures.
54
1. Fill the water tank until it overflows.
2. Close the tank fill line, bypass the cooling line, and all the pump intakes.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Capacity
Pressure
PSI (BAR)
500
(1,893)
Preventive Maintenance ❑
Pump Rating in GPM (LPM)
750
(2,839)
1,000
(3,785)
1,250
(4,732)
1,500
(5,678)
FULL 150 (10)
FULL 165 (11)
70% 200 (14)
50% 250 (17)
500
(1,893)
500
(1,893)
350
(1,325)
250
(946)
750
(2,839)
750
(2,839)
525
(1,987)
375
(1,420)
1,000
(3,785)
1,000
(3,785)
700
(2,650)
500
(1,893)
1,250
(4,732)
1,250
(4,732)
875
(3,312)
625
(2,366)
1,500
(5,678)
1,500
(5,678)
1,050
(3,975)
750
(2,839)
Table 4-3: Pump Ratings (GPM / LPM)
3. Attach sufficient hose lines and nozzles to pump the desired discharge rate.
4. With the pump in gear, open the discharge to which the hose is attached and begin pumping water.
5. Increase the engine throttle until the maximum consistent pressure is obtained on the discharge gauge.
6. Close the discharge valve without changing the throttle setting. Refill the tank through the top fill opening or a direct tank line. The bypass valve may be opened during this time to prevent pump overheating.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
7. Reopen the discharge valve and check the flow through the nozzle using a Pitot tube or flow meter. Adjust the engine throttle to bring the pressure to the amount previously determined.
8. Compare the flow rate measured to the NFPA minimum or the designated rate of the pump. If the flow rate is lower, a problem may exist in the tank­to-pump line. The minimum flow rate should be continuously discharged until 80% of the tank is discharged.
9. The pump should not experience mechanical problems, power loss, or overheat during the test.
Performance Testing Equipment and Materials
To accurately test pumper performance, a Pitot Gauge, a calibrated pump mas­ter pressure gauge, and a master vacuum gauge or manometer are required. ALL gauges must be carefully tested for accuracy. Gauge testing is appropri­ately accomplished with a certified dead weight gauge tester.
55
❑ Preventive Maintenance
Pumpers should be tested from draft at not over a 10’ (3 meters) lift with 20’ (6 meters) of suction hose. Pumpers rated at 1,500 GPM and above often require two separate 20’ lengths of suction hose and a lower lift height.
Use smooth bore test nozzles of accurate size with the pitot gauge. The vol­ume pumped is then determined by reference to discharge tables for smooth nozzles. Preferably, nozzles will be used on a Siamese deluge gun for greatest accuracy. A stream straightener, just upstream of the nozzle is advisable.
REFER TO LOCAL PROCEDURES FOR PUMP TESTING PROCEDURES AND PRACTICES AS WELL AS APPLICABLE NFPA STANDARDS.
For Pitot Gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 6.0 BAR). Also see “Appendix E: Nozzle Size vs. Pressure” on page 119 at the back of this manual.
The amount of discharge hose required for the service tests is dependent on the flow requirements and capacity test point. Provide adequate hose to dis­charge the rated capacity with a flow velocity less that 35 ft./sec.
Also see “Appendix D: Hose Friction Loss” on page 117 at the back of this manual.
Since NFPA standards specify both GPM and pressure, it is usually necessary to restrict the flow somewhat to build up the pump pressure. In normal pump­ing, this restriction would be caused by the friction loss in the lines. It is com­mon practice to gate the discharge valves as required to maintain pressure.
Notes:
● For 750 GPM (2,839 LPM) test, two 2-1/2” (64 mm) lines should be laid from the
pumper to the nozzle
● For 1,000 GPM (3,785 LPM) test, three lines are required
● For the 1,250 (4,731 LPM) and 1,500 GPM (5,677 LPM) tests, four or more lines
are required between the pumper and the nozzle.
Because deluge guns are not always available, other hose layouts may be used, such as one, 2-1/2” (64 mm) line to a 1-3/8” (35 mm) nozzle for 500 GPM (1,892 LPM). Generally, the nozzle used on one, 2-1/2” line should not be larger than 1-1/2” (38 mm) for accuracy in measuring GPM (LPM).
Another alternative when a deluge gun is not available consists of a 1-1/4” (32 mm) nozzle on one and a 1-1/2” (38 mm) nozzle on the other to pass 1,000 GPM (3,785 LPM). The sum of the flow from both nozzles is the GPM (LPM) delivered by the pump. For good pitot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 5.8 BAR).
56
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Preventive Maintenance ❑
Performance Testing
Note that the NFPA standards require a 10% reserve in pressure at the capacity run when the apparatus is delivered. Also see NFPA 1901 Standard for testing procedures.
1. Test the relief valve (per NFPA 1901 standards):
❑ Set the relief valve flow rate capacity at 150 PSI (10 BAR).
❑ SLOWLY close the discharge valves. The rise in pressure shall not
exceed 30 PSI (2 BAR), or approximately 180 PSI (12 BAR) operating pressure.
❑ SLOWLY open the discharge valves to re-establish the original pressure
(150 PSI).
2. Perform Steps 2 and 3 of the post operation maintenance procedures - see heading “Post Operation Procedures” on page 44.
3. Run the standard pump test in accordance with NFPA 1901 standards to check pump performance.
Run the engine for 20 to 30 minutes to stabilize the engine temperature. Then run the pump for:
❑ Two (2) hours at FULL capacity and at 150 PSI (10 BAR)
❑ Thirty (30) minutes at 70% capacity and at 200 PSI (14 BAR)
❑ Thirty (30) minutes at 50% capacity and at 250 PSI (17 BAR)
❑ Additionally, an engine overload test is required which consists of pump-
ing at FULL capacity and at 165 PSI (11 BAR) for ten (10) minutes.
4. If the apparatus does not reach performance levels, proceed to Section 5 “Troubleshooting” on page 59.
5. Compare results of this test to those when the apparatus was first delivered. If the apparatus performance has dropped appreciably, com­pared to its original performance, it needs to be serviced.
Note: 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.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
57
❑ Preventive Maintenance
Worn Clearance Rings and Impeller Hubs
Before assuming that clearance ring wear is at fault or that clearance ring replacement requires pump disassembly, it is advisable to thoroughly check other possible causes of low performance.
Clearance rings limit the internal bypass of water from the discharge side of the pump back to suction. The radial clearance between the impeller hub and the clearance rings is only a few thousandths of an inch when new. In clear water, the clearance rings continue to effectively seal for many years of operation.
In dirty or sandy water, the impeller hub and clearance rings wear faster. The more wear, the greater the bypass and lower pump performance.
It should not be necessary to replace clearance rings until a loss in pump per­formance is noticed during the annual test – see “Performance Testing” on page 57. For clearance ring and impeller service, see heading “Impeller” on page 83.
Often, replacing the clearance rings reduces the bypass and restores the pump to near original performance. A complete restoration requires that the impeller also be replaced. See Section 6.6 “Removing the Gearbox Only” on page 76 for maintenance and repair information if pump disassembly is required.
Anode Check
Hale offers two types of anodes (consumables):
❑ Zinc anode - recommended for
all pumps where corrosion is an issue, including brackish or salt water exposure. Zinc anodes should be inspected every twelve (12) months.
❑ Magnesium anode - available if
the pump already uses zinc anodes and galvanic corrosion is still a concern. Magnesium anodes, which are consumed at a faster rate, should be inspected ever three (3) or four (4) months. Magnesium anodes contain a notch in the hex head for identification.
Figure 4-4: Hale Anode
58
Replace anodes when over 75% of the metal has been consumed. Perfor­mance of the anode life varies with water quality and pH. Anodes conform to MIL Spec. A180001.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0

5 Troubleshooting

Table 5-2 lists conditions, possible causes and suggested corrective action measures. Before calling Hale Products or your Hale authorized parts service center for assis­tance, eliminate problem causes using the following table.
If you cannot correct a problem, please have the following information prior to calling the Hale Customer Service for assistance. Con­tact Customer Service at telephone number 610-825-6300.
❑ Pump model and serial numbers - see Figure 5-1: “Sample, Serial
Nameplate”
Troubleshooting ❑

Figure 5-1: Sample, Serial Nameplate

Condition
PTO Will Not Engage.
Pump Loses Prime or Will Not Prime.
Chart continued on
next page.
❑ Pump configuration information
❑ Observed symptoms and under what conditions the symptoms occur
Note: The serial number location varies depending on the pump model, but it is generally displayed on the pump operator's panel and/or the side of the gearbox.
Possible
Cause
• Consult the PTO manufacturer’s instructions.
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE
GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ILLUMINATED.
Electric priming sys­tem.
Note: Weekly priming is recommended to ensure proper operation.
Inoperative priming system or possible clogged priming pump.
• NO recommended engine speed is required to operate the elec­tric primer. However, 1,000 engine RPM maintains the electrical system while providing enough speed for initial pumping operations.
• See Section 2a, heading “Priming Valves” on page 25.
Note: Using lubricant on the vanes and vane slots during disassem­bly and cleaning eventually causes a gummy residue to develop, ren­dering the system inoperative.
DO NOT LUBRICATE VANES AND VANE SLOTS.
Suggested Corrective Action
Troubleshooting Hale Se ries Pumps, Nov.-05, Rev-A

Figure 5-2: Troubleshooting Chart

59
❑ Troubleshooting
Condition
Pump Loses Prime or Will Not Prime ­continued.
Possible
Cause
Inoperative priming system or possible clogged priming pump
- continued.
• Check the priming system by performing a “Dry Vacuum Test” per NFPA standards. If the pump holds vacuum, but primer pulls less than 22” Hg., it could indicate excessive wear in the primmer.
• See Section 4 Preventive Maintenance, heading “Weekly” on
Suggested Corrective Action
page 46. Also see Section 4 Preventive Maintenance, heading “Annual” on page 52.
• See Section 2a, heading “Priming Valves” on page 25.
• Repair and/or replace accordingly.
Note: Using lubricant on the vanes and vane slots during disassembly and cleaning eventually causes a gummy residue to develop, rendering the sys­tem inoperative.
Suction lifts too high. • DO NOT attempt lifts exceeding 22’ (6.7 meters) except at low
elevation.
Blocked or restricted suction strainer.
• Remove obstruction from suction hose strainer.
• Thoroughly clean strainer screen.
Suction connections. • Clean and tighten all suction connections.
• Check suction hose and hose gaskets for possible defects - repair and/or replace.
Air trapped in suction line.
• Avoid placing any part of the suction hose higher than the suction intake.
• Suction hose should be laid out with continuos decline to fluid supply.
• If trap in hose in unavoidable, repeated priming may be needed to eliminate air pockets in suction hose.
Chart continued on
next page.
60
Insufficient priming. • Proper priming procedures should be followed.
• Do not release the primer control before assuring a complete prime.
• Open the discharge valve slowly during completion of prime to ensure complete prime.
NOTICE !
DO NOT RUN THE PRIMER OVER FORTH-FIVE (45) SECONDS. IF PRIME IS
NOT ACHIEVED WITHIN 45 SECONDS, STOP AND LOOK FOR CAUSES
(AIR LEAKS OR BLOCKED SUCTION HOSES).
Pump pressure too low when nozzle is
• Prime pump again and maintain higher pump pressure while opening the discharge valve slowly.
opened.
Figure 5-2: Troubleshooting Chart
Hale Series Pumps, Nov.-05, Rev-A
Troubleshooting
Troubleshooting ❑
Condition
Pump Loses Prime or Will Not Prime ­continued.
Insufficient Pump Capacity.
Possible
Cause
Suggested Corrective Action
Air leaks. • Attempt to located and correct air leaks using the following
procedures:
• Perform “Dry Vacuum Test” on pump per NFPA standards with 22” Hg. minimum vacuum required with loss not to exceed 10” Hg. in five (5) minutes.
• If a minimum of 22” Hg. cannot be achieved, the priming device or system may be inoperative, 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.
• After priming shut OFF the engine. Audible detection of a leak is often possible.
• 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, accessories or piping connections.
• The suction side relief valve can leak. Plug the valve outlet connection and retest
Insufficient engine power.
• Engine power check and tune up may be required for peak engine and pump performance.
• Also see Section “Rotation Symptoms.” on page 65.
• 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 truck manual for proper speed counter ratio.
Relief valve improp­erly set - if so equipped.
Suction hose diame­ter is too small for the volume being dis­charged.
Restriction in suction line at strainer.
Chart continued on
next page.
Troubleshooting Hale Se ries Pumps, Nov.-05, Rev-A
• If relief valve pressure is set too low it allows the valve to open and bypass water.
• Reset the relief valve pressure accordingly.
• Also see Section 4 Preventive Maintenance, heading “Relief Valve Test” on page 46.
• Use larger suction hose.
• Shorten total length by remove one length at a time.
• Reduce volume of discharge.
• Remove any debris restricting entrance of water at the strainer.
• Also see Section 4 Preventive Maintenance, heading “Intake Strainers” on page 48.
Figure 5-2: Troubleshooting Chart
61
❑ Troubleshooting
Condition
Insufficient Pump Capacity ­continued.
Insufficient Pres­sure.
Possible
Cause
Air leaks. • See heading “Air leaks.” under condition “ Pump Loses Prime or
Will Not Prime” on page 61.
Partial collapse of the lining in a suction hose.
Engine governor set incorrectly.
Truck transmission in wrong gear or clutch is slipping.
Insufficient engine power.
• Damage to the outer lining may allow air between the outer and inner linings causing a partial collapse.
• Replace hose and retest.
• If the engine governor is set too LOW (pressure), when on auto­matic, engine speed decelerates before the desired pressure is achieved.
• Reset governor per manufacturer’s procedures.
• Recheck the pumping procedures for the recommended transmis­sion or gear range - review Section 3 “Basic Operation,” beginning on page 27.
• Use a mechanical speed counter on the pump panel to check speed against possible clutch or transmission slippage or inaccu­rate tachometer.
• Check truck manual for proper speed counter ration.
• See previous heading “Insufficient Pump Capacity.” on page 61.
Suggested Corrective Action
Remote Control Difficult to Oper­ate.
Engine Speeds Too HIGH for Required Capac­ity or Pressure.
Chart continued on
next page.
Lack of lubrication. • Lubricate the remote control linkages and collar with oil. For lubri-
cant recommendations, see “Appendix C1: Lube and Sealant Specifications” on page 115.
Truck transmission in wrong gear or range.
Lift too high, suction hose too small.
Faulty suction hose. • Inner lining of suction hose may collapse when drafting and is
Blockage at suction hose entry.
• Recheck the pumping procedures for the recommended transmis­sion or gear range - review Section 3 “Basic Operation,” beginning on page 27.
• Check truck manual for proper speed counter ration.
• Higher than normal lift (10 ft. / 3.1m) causes higher engine speeds, high vacuum and rough operation.
• Use larger suction hose.
• Move the pump closer to the water source.
usually undetectable.
• Try a different suction hose on the same pump.
• Test for comparison against original hose.
• Clean suction hose strainer of obstruction. Also see Section 4 Preventive Maintenance, heading “Intake Strainers” on page 48.
• Follow recommended practices for laying suction hose.
• Keep off the bottom of the fluid supply by at least 2’ (0.6 meters) below the surface of the fluid.
62
Figure 5-2: Troubleshooting Chart
Hale Series Pumps, Nov.-05, Rev-A
Troubleshooting
Troubleshooting ❑
Condition
Engine Speeds Too HIGH for Requir­ed Capacity or Pressure ­continued.
Cavitation
(Pump beginning to cavitate.)
Note: Also see “Appendix F: Cavita­tion” on page 121.
Possible
Cause
Pump is approaching “Cavitation.”
• Gate the discharge valves to allow pressure to increase. This reduces the flow.
Suggested Corrective Action
• Reduce the throttle opening to the original pressure setting.
• See “Appendix F: Cavitation” on page 121.
Worn pump impel­ler(s) or clearance
• Repair and/or replace as needed. See Section 6 “Repair” on page 67.
rings.
Impeller blockage. • A blocked impeller can prevent loss of both capacity and
pressure.
• Back flushing the pump from discharge to suction may free the blockage.
• Removing half the pump body may be necessary - this is consid­ered a major repair.
Discharging more water than the pump is taking in.
• Increase the flow into the pump with more and/or larger intake lines.
• Gate the discharge valves to reduce flow and maintain pressure.
Air leak. • Verify that the air bleeder on the suction tube is NOT open.
• Locate and eliminate all air leaks during maintenance.
Drafting too high. • Verify lift hose, hose friction, water temperature and other lift limit-
ing factors are reduced or eliminated.
• Locate the pump closer to the water source.
Relief Valve Does Not Relieve Pres­sure When Relief Valves are Closed.
Chart continued on
next page.
Water temperature too high.
Suction hoes diame­ter is too small for the volume being dis­charged.
Restriction in suction line at strainer.
Incorrect setting of control (PDM) Valve.
Figure 5-2: Troubleshooting Chart
• Reduce volume discharge by lowering the RPM or gating the dis­charge valves.
• Locate a source of cooler water.
• Use a large suction hose.
• Shorten the total length by removing one length of hose.
• Reduce volume of discharge.
• Remove any debris restricting entrance of water at the strainer.
• Also see Section 4 Preventive Maintenance, heading “Intake Strainers” on page 48.
• Check and repeat proper procedures for setting relief valve system.
• See Section 3 Operation, heading 3.7 “Relief Valve Procedures” on page 40.
Troubleshooting Hale Se ries Pumps, Nov.-05, Rev-A
63
❑ Troubleshooting
Condition
Relief Valve Does Not Relieve Pres­sure When Relief Valves are Closed
- continued.
Relief Valve Does Not Recover and Return to Origi­nal Pressure Setting After Opening Valves.
Relief Valve Opens When Control Valves are Locked Out.
Unable to Obtain Proper Setting on Relief Valves.
Possible
Cause
Relief valve inoperative.
Dirt in system causing sticky or slow reaction.
Relief valve inoperative.
Drain hole in housing, piston or sensing valve is blocked.
Using the wrong pro­cedures.
Suggested Corrective Action
• Possibly in need of lubrication. Remove valve from pump, dis­mantle, clean and lubricate.
• Refer to relief valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
• Check and repeat proper procedures for setting the relief valve system.
• See Section 3 Operation, heading 3.7 “Relief Valve Procedures” on page 40.
• Blocked bleed orifice - clean the bleed orifice with a small wire or straightened paper clip.
• Refer to relief valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
• Clean the valve drain hole with a small wire or straightened paper clip.
• Refer to relief / sensing valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
• Check instructions for setting the relief valve and reset.
• See Section 3 Operation, heading 3.7 “Relief Valve Procedures” on page 40.
Discharge Valves Are Difficult to Operate.
Chart continued on
next page.
Blocked strainer. • Check and clean the strainer in the supply line from the pump dis-
charge to the control valve. Check truck manual for location.
• Also see Section 4 Preventive Maintenance, heading “Intake Strainers” on page 48.
• Check and clean tubing lines related to the relief and control valves.
Dirty control valve. • Remove the control valve and clean.
“Hunting” condition. • Insufficient water supply from the pump to the control valve.
• Check the strainer and relief valve system for flow restrictions.
• Remove and clean the control valve.
Lack of lubrication. • Recommended weekly lubrication of discharge and suction valve.
• Use a good grade, petroleum based, silicone grease.
• For Hale Products, SVS Valves, etc., use Never-Seez Food Grade with PTFE.
• Also see “Appendix C1: Lube and Sealant Specifications” on page 115.
• Refer to separate valve manual for additional information.
Figure 5-2: Troubleshooting Chart
® White
64
Hale Series Pumps, Nov.-05, Rev-A
Troubleshooting
Troubleshooting ❑
Condition
Discharge Valves Are Difficult to Operate
- continued.
Water/Moisture in Pump Gear­box.
Possible
Cause
Valve in need of more clearance for operation.
Leak coming from above the pump.
Operating or a driving condition that sub­merges the gearbox in water.
Normal condensation. • Depending on area / region where unit is operated, normal con-
Leaking oil seal or mechanical seal.
• Multi-gasket design allows additional gaskets for more clearance and free operation.
• Note: Adding too many gaskets to the valve eventually causes leakage.
• Check all piping connections and tank overflow for possible spill­age falling directly onto the pump gearbox.
• Repair accordingly.
• Visually inspect the unit for external signs of water leakage.
• Was the unit submerged in water? Does your unit include an air vent / breather where water can enter if submerged? If so, change oil. Also see Section 4 Preventive Maintenance, heading “Replace Gearbox Oil” on page 52.
densation can develop over time.
• Periodic inspection and possibly more frequent oil changes are needed.
• Inspect the oil seals and replace as needed. If the oil seal checks OK, the mechanical seal may be leaking.
• There must be NO leaks at the mechanical seal. See Section 6a “Mechanical Seal Assembly” on page 91.
• Hydrostatic test the system to determine leakage.
Suggested Corrective Action
Rotation Symp­toms.
(Reduced pres­sure 60-100 PSI [4.1-6.9 BAR] and reduced flow.)
Wrong impeller installed.
Wrong application attempted.
IT IS POSSIBLE TO REASSEMBLE THE PUMP INCORRECTLY OR WITH THE
WRONG PARTS. ALWAYS COMPARE THE REPLACEMENT PARTS WITH THE
• Verify the new impeller vanes are oriented the same as the old impeller before installing. (See Figure 2-6: “Pump / Engine Rota­tion,” on page 19.)
• Refer to relief / sensing valve manual and follow maintenance instructions for disassembly, cleaning and lubrication.
• The pump was installed on an application for which it was not intended, i.e., front mount vs. rear mount.
NOTICE !
ORIGINAL HARDWARE. CONTACT CUSTOMER SERVICE AT HALE
PRODUCTS TO ANSWER QUESTIONS OR CONCERNS.
Figure 5-2: Troubleshooting Chart
Troubleshooting Hale Se ries Pumps, Nov.-05, Rev-A
65
❑ Troubleshooting
Notes
______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________
66
Hale Series Pumps, Nov.-05, Rev-A
Troubleshooting

6 Repair

6.1 OVERVIEW

Corrective Maintenance ❑
This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Hale pump and gearbox compo­nents. To completely dismantle the pump and gearbox, follow the disas­sembly instructions in the order which they appear in this section. At any point in the disassembly process, the unit can be reassembled by following the instructions in the reverse.
Service should be performed by a trained and qualified service technician, or your authorized Hale Products service representative. Be sure you have sufficient knowledge, experience and the proper tools.
Wherever there is a requirement for new parts, it is recommended to use only Hale authorized replacement parts for optimum safety of the equip­ment and its operators and to limit “downtime.”

6.2 GENERAL REPAIR GUIDELINES

Before You Begin...
For a parts breakdown and identification, see Section 8, heading “Drawing Package” on page 127.
READ ALL INSTRUCTIONS THOROUGHLY
BEFORE BEGINNING ANY SERVICE REPAIR.
1. Place apparatus out of service in accordance with your departmental procedures.
2. Park the vehicle on a level surface. Set the parking brake and chock the front and rear wheels.
Section 6: Corrective Maintenance Hale Products, Inc., Nov.2005, Rev.-A
3. Match mark, tag and/or note, or photograph the orientation of all mechanical and electrical components and connections to the pump and/or gearbox before disconnecting or removing them. This aids in proper reassembly.
4. Determine best method for servicing, i.e., servicing while in the appara­tus or removal from the top or bottom of the apparatus.
67
❑ Corrective Maintenance
BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DIS­CHARGE PIPING AND DRAIN THE PUMP BODIES.
THE HALE PUMP AND GEARBOX ASSEMBLY CAN BE HEAVY AND BULKY. ADDING ACCESSORIES ALSO INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING FOR THE APPROXIMATE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVERHEAD CRANE, JACK, CHAINS, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE PUMP AND GEARBOX ASSEMBLIES.
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALL­ING FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY.
ALL FASTENERS ON THE HALE PUMP AND GEARBOX ASSEMBLY HAVE BEEN SELECTED FOR THEIR APPLICATION. HALE PRODUCTS DOES NOT RECOMMEND REPLACING FASTENERS WITH ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH A WEAKER ALTER­NATIVE POSES A SERIOUS SAFETY RISK.
WARNINGS !
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC ADHESIVE/SEALANT, SUCH AS LOCTITE® #246 FOR GEARBOX AND #242 FOR PUMP.
5. Remove necessary body panels and framework to gain access to the pump compartment and pump and gearbox assembly.
6. When necessary, remove valve operators, discharge and suction piping and valves that would interfere with pump removal.
Have clean disposable shop rags and oil dry handy. Also disconnect cooling tubes from the water manifold and pump, air lines, electrical switches and tachometer cable as required.
7. Where grease is called for, use a Lithium-based grease with 1% to 3% Molybdenum Disulfate. For a listing, see Section “Appendix C1: Lube and Sealant Specifications” on page 115.
Also see Section 4: Preventive Maintenance, heading “Replace Gear­box Oil” on page 52.
8. When replacing fasteners, use the proper nuts, bolts, and other hard­ware. Also ensure screws/bolts are properly torqued where required. (See Table 6-1: “Typical Torque Values Chart,” on page 69.)
68
Many are specifically rated; that is, SAE Grade 5 or higher. Unless oth­erwise specified, fasteners are Grade 5 SAE.
Hale Products, Inc., Nov.2005, Rev.-A
Section 6: Corrective Maintenance
Corrective Maintenance ❑
Bolt Size
Lock Nut size
5/16”18 Zinc-plated steel 17 (23)
5/16”18 Zinc-plated steel, with 360° nylon lock 19 (26)
5/16”18 Silicon bronze 10.3 (14)
3/8”16 Zinc-plated steel 30 (41)
3/8”16 Zinc-plated steel, with 360° nylon local 33 (45)
3/8”16 Silicon bronze 18 (24)
7/16”14 Zinc-plated steel 50 (68)
7/16”14 Zinc-plated steel, with 360° nylon local 53 (72)
7/16”14 Silicon bronze 29 (39)
5/8”-11 Zinc-plated steel 150 (203)
5/8”-11 Silicon bronze 85 (115)
Material
Minimum Torque
Ft.-Lb. (N-m)
Table 6-1: Typical Torque Values Chart
Gearbox - Apply a coating of Loctite #246 High Temperature Remov­able Threadlock (or equivalent) to all bolts on the gearbox before installing.
Hale Series Pump - Apply a coating of Loctite #242 Medium Strength Threadlock (or equivalent) to all bolts on the Pump before installing.
9. Before installing the mechanical seal, use alcohol swabs provided by Hale Products Inc. to clean all grease or oil from the pump shaft and mechanical seal running faces.
When installing the mechanical seal, apply a generous coating of Pac­Ease Rubber Lubricant Emulsion (or equivalent) on the rubber seal parts to ease installation.
WARNING !
DO NOT TOUCH THE CARBON SEAL WHILE INSTALLING THE MECHANICAL SEAL. USE OF ANY OTHER LUBRICANT CAN DAMAGE THE MECHANICAL SEAL AND SEAT.
10. Use a pusher tool or a bearing installation tool when installing bearings and seals to avoid cocking the bearings or marking the bearing faces. Also review heading “Bearings” on page 71.
11. Before placing the apparatus into operation, the pump assembly must be tested and checked for leaks. All leaks must be repaired immediately.
Section 6: Corrective Maintenance Hale Products, Inc., Nov.2005, Rev.-A
69
❑ Corrective Maintenance
Gearbox Assembly
If your service involves the gearbox assembly, it is necessary to perform the following:
1. Drain oil from the gearbox - remove the magnetic pipe plug. Also see Section 4: Preventive Maintenance, heading “Replace Gearbox Oil” on page 52.
2. Have clean disposable shop rags and oil dry handy and a suitable con­tainer to collect the fluid. For gearbox capacity, see “Appendix C1: Lube and Sealant Specifications” on page 115.
3. Disconnect drive shafts, air lines, electrical wiring / switches, tachometer cable and cooling lines, as necessary, from the gearbox.

6.3 CLEANING AND INSPECTION GUIDELINES

When procedures call for cleaning and inspection, use the following guidelines:
1. Inspect all components for excessive or abnormal wear.
IMPORTANT !
WHEN REASSEMBLING, ALL COMPONENTS MUST BE CLEAN AND FREE OF DEFECTS.
2. Whenever gaskets are removed, they must be replaced. Clean all gas­ket material from mating surfaces before installing a new gasket. Be careful not to score the finished surfaces.
3. Seals should be inspected whenever the parts are disassembled. Lightly oil or grease the shaft, O-ring seals and lip seals before reinstall­ing, especially when pressed-in.
4. For Hale recommended cleaners, see “Appendix C1: Lube and Sealant Specifications” on page 115.
5. Inspect the gear tooth surface for wear damage and pitting. Replace all components that are worn, damaged, or pitted.
70
Section 6: Corrective Maintenance
Hale Products, Inc., Nov.2005, Rev.-A
Corrective Maintenance ❑
6. It is recommended to replace O-ring seals and gaskets to avoid unnec­essary downtime later.
7. Replace any hardware that shows signs of excessive wear.
Bearings
Bearings should be inspected whenever the parts are disassembled and must always be replaced in matching sets by manufacturer.
IMPORTANT !
WHEN REPLACING BEARINGS, IT IS IMPORTANT THAT YOU DO NOT INTER­CHANGE BEARING MANUFACTURER’S COMPONENTS. THE BEARING RACE AND CONE MUST ALWAYS BE REPLACED IN MATCHING SETS, AS SUP­PLIED BY THE MANUFACTURER.
❑ Bearings and other components should be cleaned using only recom-
mended solvents.
❑ Inspect bearings for wear, pitting, and damage.
Tools Required
❑ Lifting gear-lever hoist or chain hoist, and short choker
❑ Ball peen hammer
❑ Center punch
❑ Drift punch
❑ Allen wrenches
❑ Strap wrench
❑ Snap ring pliers
❑ Pry bars (2)
❑ Ratchets and wrenches for disassembly
❑ Torque wrench capable of 40, 65, and 135 ft.-lbs. (54, 88, and 183 N-m)
Section 6: Corrective Maintenance Hale Products, Inc., Nov.2005, Rev.-A
❑ Pan (to collect drip oil)
❑ Disposable rags
71
❑ Corrective Maintenance
❑ Oil dry
❑ Wedges
❑ Bearing puller
❑ Pusher tube (a small section of PVC tubing to fit over the shaft)
❑ N-06 or N-07 bearing nut socket or spanner wrench, available from:
Whittet-Higgins at www.whittet-higgins.com or,
35 Higginson Avenue P O Box 8
Central Falls, RI 02863
Phone ................ (401) 728-0700
72
Section 6: Corrective Maintenance
Hale Products, Inc., Nov.2005, Rev.-A
Corrective Maintenance ❑

6.4 RSD PUMP AND GEARBOX OVERVIEW

RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Figure 6-2: RSD Series Single-Stage Pump
73
❑ Corrective Maintenance

6.5 REMOVING THE ASSEMBLY

Removing the Assembly
Review WARNING ! note on pape 68 before beginning any service operation.
1. First, review preceding Section “Before You Begin...” on page 67.
Note: Before beginning the removal process, you may want to make sketch (or photograph) the plumbing and component configuration to aid in re-assembly.
2. Remove necessary body panels and framework to gain access to the pump compartment and pump and gearbox assembly. Make sure there is sufficient clearance above the apparatus to lift the pump and gearbox assembly out of the apparatus.
3. Remove valve operators, discharge and suction piping and valves that would interfere with pump removal.
Have clean disposable shop rags and oil dry handy. Also disconnect cooling tubes from the water manifold and pump, air lines, electrical switches and tachometer cable as needed.
4. Drain oil from the gearbox - remove the magnetic pipe plug. See Sec­tion 4: Preventive Maintenance, heading “Replace Gearbox Oil” on page
52.
Have a suitable container available to collect fluid. For gearbox capac­ity, see “Appendix C1: Lube and Sealant Specifications” on page 115.
5. Disconnect drive shaft, air lines, electrical wiring / switches, tachometer cable and cooling lines, as necessary from the gearbox.
6. With the pump assembly properly supported and balanced, disconnect the mounting brackets (5/8”-11 screws) that secure the assembly to the apparatus chassis frame.
See WARNINGS ! note on pape 68. See Section 8, heading “Drawing Package” on page 127 and review the appropriate Installation Drawing.
7. Always use proper lifting and support apparatus (jacks, hoists, straps, chain, etc.) when servicing the unit. Exercise care when using chains to protect finished surfaces from scratches.
74
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
8. Carefully remove the assembly from the apparatus.
9. Move the pump assembly to a clean work area and clamp into a suitable and stable holding device being careful not to damage any sealing surfaces.
Installing the Assembly
After completing repairs and/or maintenance, install the pump assembly to the apparatus before filling with oil.
1. First, review preceding Section “Before You Begin...” on page 67.
2. Attach proper supporting devices and stabilize the assembly for trans­port to the apparatus. Also see WARNING ! note found on page 68.
3. Place the pump assembly into position within the apparatus.
4. Apply Loctite and insert and tighten mounting hardware that secures the pump assembly to the chassis frame. Torque the fasteners to proper val­ues in accordance with manufacturer’s recommendations. Also see Table 6-1: “Typical Torque Values Chart” on page 69.
5. With the pump assembly secured to the apparatus, remove the lifting device.
6. Connect the drive shaft to the gearbox. Apply a coating of Loctite to the fasteners and torque to the PTO manufacturer’s specifications.
7. Connect all components to the gearbox. Then fill the gearbox to the proper oil level. See Section 4: Preventive Maintenance, heading “Replace Gearbox Oil” on page 52.
8. Reassemble and connect all components removed to gain access to the pump assembly, paying particular attention to your sketch (photographs) and identification match markings/tags (e.g., valves, suction piping, dis­charge piping, valve operators, etc.)
9. Reinstall apparatus frame work and body panels previously removed to gain access to the pump compartment.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
10. Test the pump for proper operation per your departmental requirements. Note and repair any leaks.
11. Recheck and top off oil levels, then return the apparatus to operation.
75
❑ Corrective Maintenance

6.6 REMOVING THE GEARBOX ONLY

Removal
(See Figure 6-3: “Typical RSD Gearbox Removal.”) Also see Figure 6-2: “RSD Series Single-Stage Pump” on page 73.
Figure 6-3: Typical RSD Gearbox Removal
WARNING !
WHEN REMOVING (UNBOLTING) THE GEARBOX FROM THE PUMP, MAKE SURE THE PUMP ASSEMBLY WITH INTERCONNECTING MANIFOLDING, VALVING, ETC. IS ADEQUATELY SUPPORT TO PREVENT THE ASSEMBLY FROM FALLING OUT OF THE APPARATUS.
1. Review preceding sections “Before You Begin...,” on page 67. Also see WARNING ! note found on page 68.
76
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
Note: Before beginning the removal process, sketch or match-mark (tag or
photograph) the plumbing and component configuration to aid in re-assembly.
2. Remove necessary body panels and framework to gain access to the pump compartment and pump and gearbox assembly. Make sure there is sufficient clearance above the apparatus to remove the gearbox.
3. Drain oil from the gearbox - remove the magnetic pipe plug. See Sec­tion 4: Preventive Maintenance, heading “Replace Gearbox Oil” on page
52.
Have a suitable container available to collect fluid. For gearbox capac­ity, see “Appendix C1: Lube and Sealant Specifications” on page 115.
Also have clean disposable shop rags and oil dry handy. Also discon­nect cooling tubes from the water manifold and pump, air lines, electrical switches and tachometer cable as needed.
4. Disconnect drive shaft, air lines, electrical wiring / switches, tachometer cable and cooling lines, as necessary from the gearbox.
5. Connect or position the gearbox to your supporting device and assure that the gearbox is supported. Also see WARNING ! note found on page 68.
6. Remove the four (4) 1/2”-13 screws to separate the upper cover from the gearbox housing, exposing the back end of the pump shaft assem­bly. (See Figure 6-3: “Typical RSD Gearbox Removal.”)
Remove the upper cover housing gasket. Clean all gasket material from mating surfaces before installing a new gasket. Be careful not to score the finished surfaces.
7. Bend the tang(s) back on the pump shaft lock washer, then using a spanner wrench, remove the bearing nut and washer.
8. With the gearbox adequately supported, remove the six (6) 1/2”-13 screws securing the gearbox housing to the pump housing. Also see WARNING ! note found on page 68.
9. Carefully pull the gearbox straight back to slide the assembly from the pump shaft. Note that the pump gear, spacer (and possibly the outer bearing) remain on the pump shaft.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
10. Place a temporary cover over the exposed pump shaft and housing opening to prevent dirt and debris from contaminating the assembly.
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❑ Corrective Maintenance
Remove the gearbox to a clean work area and clamp into a suitable and stable holding device being careful not to damage any sealing surfaces.
11. Remove the gearbox/pump housing gasket. Clean all gasket material from mating surfaces. Be careful not to score the finished surfaces.
12. Carefully inspect pump shaft bearings, gear, and internal parts for signs of excessive wear, pitting or damage. Also see heading “Cleaning and Inspection Guidelines” on page 70.
Repair and/or replace accordingly - see heading “6b Gearbox Service,” beginning on page 95.
Installation
(See Figure 6-3: “Typical RSD Gearbox Removal,” on page 76.)
1. Review preceding sections “Before You Begin...,” on page 67. Also see WARNING ! note found on page 68.
2. Install new gaskets to the seating surfaces of the pump head and the gearbox housing. Apply a light coat of grease to the gasket to hold it in place.
3. Make sure the pump gear and spacer are properly installed, with the raised edge of the gear facing away from the impeller.
IMPORTANT !
MAKE SURE THE PUMP SHAFT SPACER (1/2” / 13 MM) IS INSTALLED ON THE SHAFT BEFORE INSTALLING THE GEARBOX ASSEMBLY. (SEE FIGURE 6-3: “TYPICAL RSD GEARBOX REMOVAL,” ON PAGE 76.)
4. With the gearbox adequately supported, lift it into place and carefully slide the assembly onto the pump shaft assembly and outer bearing, assuring the input gear and pump gear properly mesh.
Apply a coating of Loctite, then insert three (3) 1/2”-13 screws through the pump housing to help hold the gearbox in place. Tighten screws hand tight.
78
5. Apply a coating of Loctite, then insert the remaining 7/16”-14 screws through the pump housing, gearbox and gasket. Tighten all screws in a criss-cross fashion to ensure an EVEN seal and torque to 37 ft.-lbs. (50 N-m).
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
6. Apply a coating of Loctite, then install the lock washer and bearing nut. Tighten the bearing nut to a snug fit then bend the lock washer tangs (2) over into the slots in the nut to secure the nut.
7. Install the gearbox cover with gasket. See preceding Step 2. Tighten the six (6) 1/2”-13 screws in a criss-cross fashion to ensure an EVEN seal and torque the screws to 57 ft.-lbs. (77 N-m).
8. Connect drive shafts, cooling lines, air hoses, and electrical connec­tions to gearbox.
9. Fill gearbox with oil. See Section 4: Preventive Maintenance, heading “Replace Gearbox Oil” on page 52.
10. Reinstall apparatus frame work and body panels previously removed to gain access to the pump compartment.
11. Test the pump for proper operation per your departmental require­ments. Note and repair any leaks.
12. Recheck and top off oil levels, then return the apparatus to operation.

6.7 SERVICING THE RSD PUMP

(See Figure 6-4: “RSD Pump Parts Overview,” on page 80.)
RSD series volutes are mounted for either engine rotation (clockwise), as viewed from the suction inlet, or opposite engine rotation (counterclock­wise).
Note the direction of flow of the impeller for proper mounting of the volute. Also see Figure 2-6: “Pump / Engine Rotation” on page 19.
Suction Head
The suction head is secured by twelve (12) 7/16”-14 screws to the volute. It includes an O-ring seal that must be inspected for cracks, splits, flat spots, etc. whenever the joint face is disturbed. (See Figure 6-4: “RSD Pump Parts Overview,” on page 80.)
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
1. Disconnect the suction, discharge, cooling lines, and any electrical wiring, if applicable.
2. Match mark the volute and suction head to ensure proper re-alignment during reassembly, then remove the twelve (12) 7/16”-14 screws.
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❑ Corrective Maintenance
80
Figure 6-4: RSD Pump Parts Overview
Install two (2) 7/16”-14 jacking screws into the suction head flange. Tighten the jacking screws EVENLY to unseat the suction head, gasket and seal ring from the volute. Support the weight of the suction head. It is heavy and bulky.
IMPORTANT !
WHILE REMOVING THE SUCTION HEAD FROM THE VOLUTE, BE CAREFUL NOT TO DAMAGE THE BRASS CLEARANCE RINGS OR THE IMPELLER.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
3. Remove all remaining gasket material from the suction head and volute being careful not to scratch the finished surfaces.
4. Inspect the front clearance ring, located in the suction head, for wear and replace accordingly. See heading “Clearance Rings, Impeller Mea­surement” on page 85.
Note: Removing the clearance ring renders it inoperative. It must be replaced. A usual good practice, if one ring requires replacement the other should be replaced as well. With the clearance installed in the suction head, verify the impeller clearance - see heading “Clearance Rings, Impeller Measurement” on page 85.
To remove the clearance ring, use a hammer and chisel to collapse the ring in the housing. Do not mar the sealing surface of the suction head.
WARNING !
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALL­ING FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY.
Installation Notes - Suction Head
(See Figure 6-4: “RSD Pump Parts Overview,” on page 80.)
To install the suction head, follow the preceding steps in the reverse order, paying attention to the following:
❑ Review preceding sections “Before You Begin...,” on page 67 and “Clean-
ing and Inspection Guidelines,” on page 70.
❑ Make sure the O-ring is seated in its groove and apply light a coat of
grease to ease installation.
❑ Be careful not to damage the clearance ring or impeller during
installation.
❑ If the clearance ring is removed, use a press to install it into the suction
head being careful not to crush or damage the ring. Verify the inside diameter of the ring - see heading “Clearance Rings, Impeller Measure­ment” on page 85
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
❑ Apply Loctite #242 to all screws and tighten in a criss-cross pattern to
ensure an EVEN seal.
❑ Refer to Table 6-1:“Typical Torque Values Chart” on page 69 for recom-
mended fastener size, material and torque value.
❑ Inspect system for proper operation, then return apparatus to service.
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❑ Corrective Maintenance
Vol ute
(See Figure 6-4: “RSD Pump Parts Overview,” on page 80.)
The volute is sealed to the pump housing with an O-ring and gasket that must also be inspected for splits, cracks, flat spots, etc.
1. Volutes are mounted for either engine rotation (clockwise), as viewed from the suction inlet, or opposite engine rotation (counterclockwise). Note the direction of flow before disassembly. (See Figure 2-6: “Pump / Engine Rotation,” on page 17.)
2. Remove the suction head (if installed) - see heading “Suction Head” on page 79.
3. Disconnect the water line compression fittings and the gearbox water cooling lines from the volute. (See Figure 6-5: “Typical Water Cooling Lines,” on page 82.)
4. Match mark the volute and pump housing to ensure proper re-align­ment during reassembly, then remove the twelve (12) 7/16”-14 screws.
Install two (2) 7/16”-14 jacking screws into the suction head flange. Tighten the jacking
Figure 6-5: Typical Water Cooling Lines
screws EVENLY to unseat the suction head and seal ring from the volute. Support the weight of the volute as it is heavy and bulky.
IMPORTANT !
DO NOT DAMAGE THE BRASS CLEARANCE RINGS OR IMPELLER AS YOU SEPARATE THE VOLUTE (PUMP BODY) FROM THE PUMP HOUSING. THE IMPELLER, CLEARANCE RINGS AND MECHANICAL SEAL ASSEMBLY NEED NOT BE REMOVED.
82
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
5. Inspect the rear clearance ring, located in the pump housing, for wear and replace accordingly. See heading “Clearance Rings, Impeller Mea­surement” on page 85.
6. To remove the clearance ring, use a hammer and chisel to collapse the ring in the housing. Do not mar the sealing surfaces of the housing.
WARNING !
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALL­ING FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY.
Note: Removing the clearance ring renders it inoperative. It must be replaced.
A usual good practice, if one ring requires replacement the other should be re­placed as well. Also verify the impeller clearance. (See Figure 6-7: “Clearance Ring and Impeller ID / OD Measurement,” on page 85.)
Installation Notes – Volute
To install the volute, follow the preceding steps in the reverse order, paying attention to the following:
❑ Review preceding sections “Before You Begin...,” on page 67 and “Clean-
ing and Inspection Guidelines,” on page 70 to ensure a thorough installa­tion.
❑ Make sure the O-ring is seated in its groove and apply light coat of
grease.
❑ Replace all gaskets. Apply a small amount of grease to the gasket(s)
and align on the pump body.
❑ If the clearance rings are removed, use a press to install them back into
the pump and suction heads.
❑ When installing the volute and suction head, DO NOT damage the clear-
ance rings or impeller.
❑ Reconnect all cooling lines, piping and tubing.
❑ Inspect system for proper operation, then return apparatus to service.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Impeller
(See Figure 6-4: “RSD Pump Parts Overview,” on page 80.)
1. Remove the suction head exposing the impeller, clearance rings and mechanical seal. See heading “Suction Head” on page 79.
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❑ Corrective Maintenance
2. Remove the cotter pin from the impeller nut.
3. While holding the impeller with a strap wrench, remove the impeller nut.
Note: On 1,500 GPM (5,678 LPM) pumps, an inducer and shaft key are installed directly in front of the impeller. Remove the inducer and shaft key, then the impeller. (See Figure 6-6: “Inducer - 1,500 GPM Pump.”)
4. To avoid damaging the impeller, use wedges (3) or a bearing puller to remove the impeller from the pump shaft. Place the wedges or puller at the impeller vane area where the metal is the heaviest.
Figure 6-6: Inducer - 1,500 GPM Pump
Note: Tap the pump shaft end, using a dead blow hammer, to free the impeller (or inducer, if included) from the pump shaft. Use care to avoid damage to the shaft threads.
CAUTION !
DO NOT STRIKE THE IMPELLER (OR INDUCER, IF INSTALLED). IRREPARA­BLE DAMAGE COULD RESULT. MAKE CERTAIN THE WEDGES OR PULLER IS PLACED AT THE IMPELLER VANES TO AVOID IRREPARABLE DAMAGE.
5. Slide the impeller from the pump shaft, then remove the impeller shaft key and set safely aside.
6. Inspect the rear clearance ring for wear and replace accordingly. See heading “Clearance Rings, Impeller Measurement” on page 85.
Note: Removing the rear clearance ring from the pump housing renders the ring inoperative. It must be replaced.
7. Removing the impeller may disturb the mechanical seal - install a new seal. See Section 6a “Mechanical Seal Assembly” on page 91.
84
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
Clearance Rings, Impeller Measurement
(See Figure 6-7: “Clearance Ring and Impeller ID / OD Measurement.”)
Figure 6-7: Clearance Ring and Impeller ID / OD Measurement
Inspect the front and back of both clearance ring IDs and ODs in several places for signs of wear. Using a caliper, measure the diameters of each ring in several places.
Note: Clearance rings should be measured while pressed into the body.
When new, the radial clearance between the impeller hub and the clearance rings are between 0.005” to 0.007” (0.127-0.78 mm) per side. Maximum acceptable radial clearance on used pumps is between 0.015” to 0.020” (0.381-0.508 mm) per side.
750 - 1,250 GPM Pump
If the gap between the impeller and the clearance ring is greater than 0.020” (0.508 mm) you must measure the impeller hub diameter.
(See Figure 6-7: “Clearance Ring and Impeller ID / OD Measurement.”) If the impeller diameter is greater than 6.022” (153 mm), the clearance ring must be replaced. If the impeller diameter is less than 6.022 (153 mm) but more than 5.987” (152 mm), the impeller hub diameter can be cut (turned down) and “undersized” clearance rings can be ordered to compensate for the new impeller diameter. Contact Customer Service, Hale Products at 610-825-6300.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
85
❑ Corrective Maintenance
WHEN TURNING IMPELLERS TO FIT UNDERSIZED RINGS, CAUTION MUST BE EXERCISED TO ENSURE THAT THE SEAL RING SURFACE RUNS TRUE WITH THE BORE TO WITHIN 0.002” (0.051 MM).
If the impeller diameter is less than 5.987” (152 mm) and you are not meet­ing pump performance, you may need to replace both the clearance rings and the impeller.
1,500 GPM Pump
If the gap between the impeller and the clearance rings is greater than
0.020” (0.508 mm) you must measure the impeller hub diameter. (See Fig­ure 6-7: “Clearance Ring and Impeller ID / OD Measurement,” on page 85.) If the impeller diameter is greater than 6.472” (164 mm), the clearance ring must be replaced.
CAUTION !
If the impeller diameter is less than 6.472 (164 mm) BUT more than 6.419” (163 mm), the impeller hub diameter can be cut (turned down) and “under­sized” clearance rings can be ordered to compensate for the new impeller diameter. Contact Customer Service, Hale Products at 610-825-6300.
Also see CAUTION ! note found on page 86.
If the impeller diameter is less than 6.419” (163 mm) and you are not meet­ing pump performance, you may need to replace both the clearance rings and the impeller.
Installation Notes – Impeller (and Inducer)
To install, follow the preceding instructions in the reverse order, paying attention to the following:
❑ Review preceding sections “Before You Begin...” on pape 67 and “Clean-
ing and Inspection Guidelines” on pape 70.
❑ Install the impeller (and inducer) shaft key(s) into the slot(s) on the pump
shaft, then install the impeller (and inducer, if included).
❑ Torque the impeller nut to 110 ft.-lbs. (149 N-m).
❑ Continue tightening the impeller nut until the cotter pin can be installed to
lock the nut in place.
86
❑ Inspect the system for proper operation before returning the apparatus to
service.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
Pump Gear, Shaft and Oil Seal
(See Figure 6-8: “Pump Gear, Shaft and Seal Replacement.”)
1. To service the pump shaft assembly and oil seal you must remove the gearbox assembly, then dismantle the pump head assembly from the volute.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Figure 6-8: Pump Gear, Shaft and Seal Replacement
❑ If your RSD pump is engine mounted, by means of a flywheel housing
mount, see Section 6c: Available Options, heading “Engine Drive” on page 100.
❑ For standard gearbox - see heading “Removal” on page 76
2. Review heading “Before You Begin...” on page 67. Also review heading “Cleaning and Inspection Guidelines” on page 70.
3. Match mark the volute and pump head to ensure proper re-alignment during reassembly.
87
❑ Corrective Maintenance
4. With the pump housing properly supported, remove the twelve (12) 7/16”-14 screws securing the pump head to the volute. (See Figure 6-8: “Pump Gear, Shaft and Seal Replacement,” on page 87.)
WARNING !
SECURE THE PUMP HEAD ASSEMBLY TO AN APPROPRIATE HOIST TO PREVENT THE HOUSING FROM FALLING, CAUSING POSSIBLE PERSONAL INJURY OR EQUIPMENT DAMAGE.
5. Slide the pump head assembly back EVENLY to remove the assembly from the volute. Exercise care to avoid damaging the impeller, front clearance ring and O-ring seal as the assembly is removed from the volute. (See Figure 6-8: “Pump Gear, Shaft and Seal Replacement,” on page 87.)
6. Move the pump assembly to a clean work area and clamp into a suitable and stable holding device being careful not to damage any sealing surfaces.
7. Remove the outer bearing (if still attached to the shaft), pump gear, shaft key and spacer and set safely aside.
8. Scrape any gasket material from the mating surfaces of the pump hous­ing and gearbox. (See Figure 6-8: “Pump Gear, Shaft and Seal Replacement,” on page 87.)
9. Remove the impeller, see “Impeller,” on page 83. Also remove the mechanical seal, see heading “Removing the Seal” on page 91.
10. Remove the retaining ring within the pump head.
11. Using a soft mallet, drive the pump shaft (and inner bearing) out the back of the pump head. If necessary remove the mechanical seal sta­tionary seat from the pump head - see Section 6a “Mechanical Seal Assembly” on page 91.
12. Remove the oil seal from the pump head and discard. Oil seals cannot be reused.
13. Carefully inspect the bearings, pump gear and shaft and other parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly.
88
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Corrective Maintenance ❑
Installation – Pump Head, Shaft and Oil Seal
1. Review heading “Before You Begin...” on page 67. Also review heading “Cleaning and Inspection Guidelines” on page 70.
2. Insert (or press) a new oil seal into the bore of the pump head. Apply a coating of general-purpose grease to the seal to ease installation.
3. Press the rear bearing onto the pump shaft. (See Figure 6-8: “Pump Gear, Shaft and Seal Replacement,” on page 87.)
4. Lightly lubricate the pump shaft and carefully insert it, with the inner bearing, into the pump head from front-to-back, taking care to not dam­age the oil seal.
5. Install the retaining ring, shaft spacer, pump gear shaft key the pump gear, with the gear lip facing out, away from the impeller.
6. Install the impeller, see heading “Installation Notes – Impeller (and Inducer),” on page 86.
7. Install the mechanical seal - see heading “Installing Seal” on page 92.
8. Install new gaskets to the seating surfaces of the pump head and the gearbox housing. Apply a light coat of grease to the gasket to hold it on place.
9. With the gearbox adequately supported, lift it into place and carefully slide the assembly onto the pump shaft assembly and outer bearing, assuring the input gear and pump gear properly mesh. Also see WARNING ! note found on page 68.
10. Apply Loctite and insert the 1/2”-13 screws through the pump housing, gearbox and gasket. Tighten all screws in a criss-cross fashion to ensure an EVEN seal and torque screws to 57 ft.-lbs. (77 N-m).
11. Install the lock washer and bearing nut. Tighten the bearing nut to a snug fit then bend the lock washer tangs (2) over into the slots in the nut to secure the nut.
12. Install the gearbox cover with gasket. See preceding Step 8. Tighten the four (4) 1/2”-13 screws in a criss-cross fashion to ensure an EVEN seal and torque screws to 57 ft.-lbs. (77 N-m).
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
13. Apply a light coating of grease to the seal ring groove and install a new O-ring seal on the pump head.
89
❑ Corrective Maintenance
14. Apply Loctite and insert two 7/16”-14 studs in the volute to help guide the pump head onto the volute.
15. Using proper lifting device lift gearbox and pump head assembly and slide into the volute, using the studs as a guide for proper alignment. Ensure you do not damage the O-ring as pump head enters the volute.
16. Apply Loctite and insert remaining 7/16”-14 screws into the pump head and volute. Tighten the screws in a criss-cross fashion to ensure an EVEN seal and torque screws - see Table 6-1: “Typical Torque Values Chart” on page 69.
17. Reconnect drive shafts, electrical, and airlines to gearbox.
18. Inspect the system for proper operation before returning the apparatus to service. Check for leaks and repair any immediately.
90
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0

6a Mechanical Seal Assembly

(See Figure 6a-1: “Mechanical Seal Overview / Replacement.”)
IMPORTANT !
IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE VOLUTE IS NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED.

Removing the Seal

1. To expose the mechanical seal, remove the:
Mechanical Seal ❑
❑ Suction head, if included
❑ Impeller - see heading “Impeller” on page 83.
Figure 6a-1: Mechanical Seal Overview / Replacement
Mechanical Seal Replacement March 2006, Rev-A
CAUTION !
MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICE. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE MATING FACES.
91
❑ Mechanical Seal
CAUTION ! - continued
ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION. SOLID FACES MUST BE CLEANED WITH AN APPRO­PRIATE DEGREASER AND A SOFT CLOTH.
2. From within the volute and/or pump head, and using a hook-type tool, reach in and remove the:
❑ Mechanical seal spring
❑ Seal diaphragm and retainer
❑ Seal, stationary seat
(See Figure 6a-1: “Mechanical Seal Overview / Replacement” on page 91.)
Removing the mechanical seal renders it inoperative and it must be replaced.
3. After all components are removed, carefully inspect clearance rings and other parts for excessive wear or damage. Replace accordingly.
It is recommended to always use Hale genuine replacement parts for opti­mum safety of the equipment and its operators and to avoid unnecessary downtime.

Installing Seal

(See Figure 6a-1: “Mechanical Seal Overview / Replacement” on page 91.)
1. See CAUTION ! warning beginning on pape 91.
2. Clean the bore of the pump head using alcohol swabs. Solid running faces must be cleaned with alcohol wipes, supplied with the Hale repair kit.
WARNING !
OIL AND GREASE WILL DAMAGE THE MECHANICAL SEAL FACE. DO NOT TOUCH THE FACE OF THE MECHANICAL SEAL.
92
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUIVALENT) ON THE RUBBER MECHANICAL SEAL PARTS TO EASE INSTALLATION. USING ANY OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT.
Mechanical Seal Replacement
March 2006, Rev-A
Mechanical Seal ❑
WARNING ! - continued
ENSURE THAT THE PUMP BODY AND IMPELLER BORES AND ALL MATING SURFACES OF THE MECHANICAL SEAL ASSEMBLY ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION PROCESS.
3. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion to the O-ring on the seal head assembly and the pump shaft and seal areas.
4. Without touching the carbon seal, slide the stationary seat into the pump head. (See Figure 6a-1: “Mechanical Seal Overview / Replacement” on page 91.)
5. Carefully push the stationary seat into the pump head bore using a soft, clean pusher tube. Verify the stationary seat is firmly seated in the pump head.
6. Clean the pump shaft with alcohol swabs.
7. Apply a generous coating of PAC-EASE Rubber Lubricant Emulsion to the seal diaphragm. (See Figure 6a-1: “Mechanical Seal Overview / Replace­ment” on page 91.)
8. Without touching the face of the seal ring, push the ring, diaphragm, and retainer onto the shaft with the pusher tube.
9. Keep the shaft well lubricated and verify the seal ring seats against the sta­tionary seat. If binding occurs, apply additional PAC-EASE lubricant.
10. Slide the spring (supplied with the seal) onto the shaft. The spring must seat on the seal retainer.
11. Install the impeller shaft key and carefully slide the impeller over the pump shaft, aligning the keyway with the impeller key. Also see CAUTION ! beginning on pape 91.
❑ Torque the impeller nut to 210 ft.-lbs. (285 N-m).
❑ Continue tightening the impeller nut until the cotter pin can be installed to
lock the nut in place.
Mechanical Seal Replacement March 2006, Rev-A
❑ Install cotter pin and bend over the ends.
93
❑ Mechanical Seal
Notes
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94
Mechanical Seal Replacement
March 2006, Rev-A

6b Gearbox Service

Review heading “Before You Begin...” on page 67. Also review heading “Cleaning and Inspection Guidelines” on page 70. Also see WARNING ! note found on page 68.
To remove and service the gearbox, specifically the input gear and shaft assembly, the gearbox must be removed from the apparatus.
❑ If your RSD pump is engine mounted, by means of a flywheel housing
mount, see Section 6c Available Options, heading “Engine Drive” on page
100.
❑ For standard gearbox removal - see heading “Removal” on page 76.
❑ Match mark the volute and pump head to ensure proper re-alignment during
reassembly.
Gearbox Repair ❑

6B.1 INPUT SHAFT AND GEAR ASSEMBLY

With the gearbox secured in a holding fixture, remove and disassemble the input shaft assembly. (See Figure 6b-6: “Input Shaft and Gear Assembly” on page 96.)
Disassembly, including Oil Seal
1. Review preceding sections “Before You Begin...,” on page 67 and “Cleaning and Inspection Guidelines,” on page 70 to ensure a thorough installation.
2. Remove the twelve (12) 5/16”-11 screws and hardware securing the bottom cover plate and gasket to the gearbox housing. Clean all gasket material from mating surfaces being careful not to score the finished surfaces. (See Figure 6b-6: “Input Shaft and Gear Assembly” on page 96.)
3. Remove the 5/8”-11 screw and washer securing the companion flange (drive shaft flange) to the input shaft.
4. Remove the oil seal from the gearbox housing and discard. Oil seals can­not be reused.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
5. Remove the retaining ring locking the bearing within the housing.
95
❑ Gearbox Repair
Figure 6b-6: Input Shaft and Gear Assembly
7. Using a soft mallet (and brass drift), drive the expansion plug into the gear­box housing and continue to push the input shaft out. Because the input gear is in place, the inner bearing remains within the housing as the shaft is forced out. However, the outer bearing, being a tight fit on the shaft, should come out with the shaft.
As the shaft is removed, hold the input gear to prevent it from dropping free. (See Figure 6b-6: “Input Shaft and Gear Assembly.”) Remove the input gear and set safely aside.
8. Remove the inner bearing from the gearbox housing. A press or soft mallet and bearing pusher tool may be needed.
9. After all components are removed, carefully clean and inspect the bearings, input gear and shaft and other parts for excessive wear, chips, scoring or other damage. Replace all components that are worn, damaged, or pitted.
96
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
Gearbox Repair ❑
Reassemble, including Oil Seal
1. Using a brass drift or bearing installation tool, install the inner bearing in the gearbox housing flush against the housing surface. (See Figure 6b-6: “Input Shaft and Gear Assembly” on page 96.)
2. Place the input shaft in a suitable holding fixture and install the outer bear­ing flush against the shaft raised shoulder.
3. Insert the shaft key and apply a thin coating of general purpose grease to the input shaft, key and bearing mating surfaces. Position the input gear within the housing, then insert the shaft and key through the gear and into the inner bearing.
Note: To insert the outer bearing into the gearbox housing, a bearing installation tool may be needed.
4. Press the assembly in far enough to just allow installation of the retaining ring. Install the bearing retaining ring and spin the shaft to ensure a free, unrestricted movement.
5. Insert (or press) a new oil seal into the bore of the gearbox housing up against the retaining ring. Apply a coating of general purpose grease to the oil seal to ease installation.
6. Install the companion flange, shaft key, washer and 5/8”-11 screw. Apply Loctite #242 to the screw. Tighten and torque the 5/8”-11 screw to 112 ft.­lbs. (152 N-m).
7. Spin the companion flange to ensure a proper assembly with no binding.
8. Install the gearbox assembly to the pump housing. see heading “Installa­tion” on page 78.
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
97
❑ Gearbox Repair
Notes
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98
RSD Series Single-Stage PTO Pu mps
p/n: 029-0020-92-0

6c Available Options - Repair

6C.1 TACHOMETER DRIVE

Option Maintenance ❑
RSD Series Single-Stage PTO Pumps p/n: 029-0020-92-0
Figure 6c-1: Tachometer Drive Option
1. Disconnect the tachometer flexible cable from the tachometer drive assembly, or from the operator panel adapter. (See Figure 6c-1: “Tachometer Drive Option.”)
2. Remove the tachometer drive assembly from the adapter fitting, being careful of the flexible shaft as the assembly is removed.
3. Unthread the adapter fitting from the gearbox housing cover.
Installation Notes
(See Figure 6c-1: “Tachometer Drive Option.”)
To install, follow the preceding steps in the reverse order.
99
❑ Option Maintenance

6C.2 ENGINE DRIVE

100
Figure 6c-2: RSD Engine Drive Option
Servicing the Oil Seal / Input Shaft Assembly
(See Figure 6c-2: “RSD Engine Drive Option.”)
To service the oil-seal, elastomeric drive disk and/or pump input shaft assembly you must disassemble the flywheel housing adapter from the engine mounting. This service repair involves removing of the pump and gearbox assembly and interconnecting manifolding, valving, etc.
1. Review sections “Before You Begin...,” on page 67 and “Cleaning and Inspection Guidelines,” on page 70. Also review WARNING ! note found on page 68.
RSD Series Sing le-Stage PTO Pu mps
p/n: 029-0020-92-0
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