Hale SMR User Manual

SMM / SMR / SMD

Stainless Max Series Pumps

Operation and Maintenance

Manual

HALE PRODUCTS, INC. ● A Unit of IDEX Corporation

700 Spring Mill Avenue ● Conshohocken, PA 19428 U.S.A.

Telephone: 610-825-6300 ● FAX: 610-825-6440

ISO 9001 CERTIFIED

Manual p/n: 029-0020-77-0

NOTICE !

Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale Products 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.

ECO NO REV CHANGED FROM BY DATE APVD

04-229 A RELEASED LwH 09/28/2004 MAL

DRAWN BY: LwH ISSUE DATE: CHECKED BY: PRW 09/28/2004

HALE PRODUCTS, INC.

A Unit of IDEX Corporation

Conshohocken, PA 19428 USA

Manual p/n: 029-0020-77-0, Rev-A Printed in U.S.A.

NOT TO BE REPRODUCED OR USED TO

MAKE OTHER DRAWINGS OR MACHINERY

Table of Contents

Contents Page

SECTION

1: SAFETY PRECAUTIONS ...........................................................1-1

GUIDELINES ................................................................................................................................ 1

SECTION 2: INTRODUCTION......................................................................... 2-1

OVERVIEW .................................................................................................................................. 1

PRINCIPLES OF OPERATION .................................................................................................... 1

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

Figure 2-1: Centrifugal Force, from a rotating disk ....................................................................... 1

Pump Stages........................................................................................................................................... 2

Cavitation ........................................................................................................................................... 3

Figure 2-2: Pump Impeller ........................................................................................................... 3

Figure 2-3: SM Pump Water Flow ................................................................................................ 3

Figure 2-4: Cavitation Regions..................................................................................................... 4

PUMP COMPONENTS - SM SERIES .......................................................................................... 5

Pump Body .............................................................................................................................................. 5

Impeller and Shaft Assembly ................................................................................................................... 5

Figure 2-5: Overview of Hale SM Pump ...................................................................................... 5

Bearings .................................................................................................................................................. 6

Mechanical Seal ...................................................................................................................................... 6

Priming .................................................................................................................................................... 6

Gearbox - SMM and SMD Series ............................................................................................................ 6

Figure 2-6: Mechanical Seal ........................................................................................................ 6

Pedestal - SMR Series ............................................................................................................................ 7

PUMP DRIVES ............................................................................................................................. 7

Figure 2-7: SMM/SMD Pump and Gearbox Configuration .......................................................... 7

Figure 2-8: SMR Pump and Pedestal Configuration ................................................................... 7

SMM-X Series Pump ............................................................................................................................... 8

G-Series Gearbox .............................................................................................................................. 8

Figure 2-9: Overview X-Series Gearbox ...................................................................................... 8

Figure 2-10: Typical Split-Shaft Drive Applications ..................................................................... 9

Mid-Ship Pumps ................................................................................................................................. 9

Shifting .................................................................................................................................................. 10

HALE Power Takeoff Pumps (PTO) ...................................................................................................... 10

ACCESSORIES ......................................................................................................................... 10

Auxiliary Cooling (Overheat Protection) ................................................................................................ 10

Priming Systems ................................................................................................................................... 11

Figure 2-11: ESP Priming Pump ............................................................................................... 11

Figure 2-12: Rotary Vane Priming Pump ................................................................................... 11

Figure 2-13: SPVR Priming Valve .............................................................................................. 12

Figure 2-14: PVG Priming Valve ................................................................................................ 12

Priming Valves ...................................................................................................................................... 12

Stainless Max Series Pumps 3

Table of Contents

Contents - continued Page

ACCESSORIES - continued

Pressure Control ................................................................................................................................... 13

The P Relief Valve System ............................................................................................................... 13

Figure 2-15: Relief Valve System Arrangement ......................................................................... 13

Thermal Relief Valve (TRV) .............................................................................................................. 14

TRV-L Kit .......................................................................................................................................... 14

Figure 2-16: TRV-L Kit ............................................................................................................... 14

APPENDIX A: GLOSSARY ................................................................................. 16

APPENDIX B: MEASUREMENTS ...................................................................... 20

CONVERSIONS ......................................................................................................................... 20

SECTION 3: OPERATING PROCEDURES ....................................................3-1

STATIONARY PUMPING OPERATIONS ..................................................................................... 1

Pumping from a Hydrant (General Operation) ....................................................................................... 1

Figure 3-1: Driver's Compartment Indicator Lights ...................................................................... 2

Figure 3-2: Pump Operator's Panel ............................................................................................. 3

Emergency Pump Shift Procedures ........................................................................................................ 5

TPM Operation from a Hydrant ............................................................................................................... 6

Draft Limiting Factors .............................................................................................................................. 6

Pumping from Draft ................................................................................................................................. 6

Table 3-3: Baseline NFPA Rating .................................................................................................6

(Additional Loses) ........................................................................................................................ 6

Pumping from Onboard Water Tank ........................................................................................................ 9

PUMP AND ROLL OPERATION................................................................................................ 11

RELIEF VALVE PROCEDURES ................................................................................................ 12

TPM /P35 Relief Valve Procedures ..................................................................................................... 12

Figure 3-4: PMD Relief Valve Control ....................................................................................... 12

CAVITATION .............................................................................................................................. 13

Process of Cavitation ............................................................................................................................ 13

Warning Signs of Cavitation (Discharge and Gauges) .......................................................................... 14

Discharge Pressure .......................................................................................................................... 14

Vacuum Compound Gauge .............................................................................................................. 14

How to Prevent Cavitation ..................................................................................................................... 14

During Operations ................................................................................................................................. 14

Table 3-5: Lift Loss from Barometric Pressure ........................................................................... 15

Preventive Measures ............................................................................................................................ 15

Table 3-6: Lift Loss from Elevation .............................................................................................15

Table 3-7: Hose Size for Pump Rating Capacity ........................................................................ 16

POST OPERATION PROCEDURE ............................................................................................ 16

4 Stainless Max Series Pumps

Table of Contents

Contents - continued Page

SECTION

4: PREVENTIVE MAINTENANCE ...............................................4-1

OVERVIEW .................................................................................................................................. 1

POST-OPERATION...................................................................................................................... 1

Flush Pump ............................................................................................................................................. 1

EXTREME CONDITIONS ............................................................................................................. 1

During Freezing Weather ........................................................................................................................ 2

After Pumping from Salt Water, Contaminated Water, or with Foam Solution .................................... 2

AFTER EACH USE ...................................................................................................................... 2

WEEKLY....................................................................................................................................... 2

Relief Valve Test ...................................................................................................................................... 3

Priming System Test ............................................................................................................................... 3

Governor Test.......................................................................................................................................... 3

Figure 4-1: PM Valve Control ....................................................................................................... 3

Pump Shift Warning Indicator Lights ....................................................................................................... 4

Valve Maintenance .................................................................................................................................. 4

Check and Clean the Intake Strainers..................................................................................................... 4

Check Auxiliary Engine ........................................................................................................................... 5

Verify All Gauges are in Working Order................................................................................................... 5

Operate Pump Controls .......................................................................................................................... 5

Inspect Water and Foam Tanks............................................................................................................... 5

Check Roof and Bumper Turrets ............................................................................................................. 5

Check Auxiliary Fire Suppression Equipment ......................................................................................... 5

MONTHLY .................................................................................................................................... 5

Table 4-2: Recommended Lubricants .......................................................................................... 6

Gearbox Lubrication ................................................................................................................................ 6

Priming System Test (Dry Vacuum Test)

(Refer to NFPA 1901 or NFPA 1911) ....................................................................................................... 6

Figure 4-3: Sample Fill Plug ......................................................................................................... 6

Figure 4-4: Prime Control ............................................................................................................. 6

Drive Line and Flange Bolts .................................................................................................................... 7

Indicator Light Test .................................................................................................................................. 8

ANNUALLY .................................................................................................................................. 8

Replace Gearbox Oil ............................................................................................................................... 8

Figure 4-5: Grade 8 Bolt Head .................................................................................................... 8

Figure 4-6: Sample, Drain, Fill and Level Detect Plugs - RH Horizontal Installation .................... 8

Replace Pedestal Oil - SMR Series ........................................................................................................ 9

Figure 4-7: Pedestal Oil Change .................................................................................................. 9

Check Drain Lines to Multi-Drain........................................................................................................... 10

Tank to Pump Flow Rate Test................................................................................................................ 10

Table 4-8: Pump Ratings (GPM/LPM) ........................................................................................ 11

Stainless Max Series Pumps 5

Table of Contents

Contents - continued Page

ANNUALLY - continued

Performance Testing Overview ............................................................................................................. 11

Performance Testing Equipment and Materials ................................................................................ 11

Table 4-9a: Nozzle Flow and Pressure Ratings ......................................................................... 12

Table 4-9b: Nozzle Flow and Pressure Ratings - continued ...................................................... 13

Table 4-10: Hose Friction Loss (PSI/Bar 100 Feet) ................................................................... 14

Performance Testing ........................................................................................................................ 15

Worn Clearance Rings and Impeller Hubs ....................................................................................... 16

Figure 4-11: Clearance Ring and Impeller Measurement........................................................... 16

Anode Check......................................................................................................................................... 17

EXTREME CONDITIONS, MAINTENANCE GUIDELINES ....................................................... 17

Freezing Weather .................................................................................................................................. 17

Contaminated Water ............................................................................................................................. 18

SECTION 5: TROUBLESHOOTING ...............................................................5-1

Figure 5-1: Sample, Serial Plate .................................................................................................. 1

Table 5-2: Troubleshooting ........................................................................................................... 1

PTO Will Not Engage .............................................................................................................................. 1

Pump Will Not Engage ............................................................................................................................ 1

Pump Loses Prime or Will Not Prime ...................................................................................................... 2

Insufficient Pump Capacity...................................................................................................................... 3

Insufficient Pressure................................................................................................................................ 4

Remote Control Difficult to Operate ........................................................................................................ 5

Engine Speeds Too High for Required Capacity or Pressure .................................................................. 5

Cavitation ................................................................................................................................................ 5

Relief Valve Does Not Relieve Pressure... .............................................................................................. 6

Unable to Obtain Proper Setting on Relief Valve ..................................................................................... 6

Discharge Valves Difficult to Operate ...................................................................................................... 7

Water in Gearbox .................................................................................................................................... 7

Rotation Symptoms ................................................................................................................................. 5

Figure 5-3: Engine Rotation ......................................................................................................... 8

SECTION 6: MAINTENANCE AND REPAIR .................................................... 1

OVERVIEW .................................................................................................................................. 1

GENERAL REPAIR GUIDELINES ............................................................................................... 1

Before you begin... .................................................................................................................................. 1

Table 6-3: Critical Measurements ................................................................................................2

Table 6-2: Torque Values .............................................................................................................. 2

Table 6-1: Recommended Lubricants .......................................................................................... 2

Cleaning and Inspection Guidelines ........................................................................................................ 5

Recommended Cleaners......................................................................................................................... 6

Tools Required ........................................................................................................................................ 6

6 Stainless Max Series Pumps

Table of Contents

Contents - continued Page

PUMP AND GEARBOX ASSEMBLY ........................................................................................... 7

Removing Pump Assembly from Apparatus ............................................................................................ 7

Installing Pump Assembly to Apparatus .................................................................................................. 8

Figure 6-4: Stainless Max Pump Assembly ................................................................................. 9

SERVICING THE SM PUMP ........................................................................................................ 9

Suction Tube and Front Clearance Ring ................................................................................................. 9

Inspection ......................................................................................................................................... 10

Installation Notes .............................................................................................................................. 10

Impeller ................................................................................................................................................. 10

Figure 6-5: Clearance Ring Measurement ................................................................................. 10

Inspection ......................................................................................................................................... 11

Figure 6-6: Impeller Measurements ........................................................................................... 11

Installation Notes .............................................................................................................................. 12

Rear Wear Ring .................................................................................................................................... 12

Inspection ......................................................................................................................................... 12

Table 6-7: Impeller Specifications ..............................................................................................12

Installation Notes .............................................................................................................................. 13

Mechanical Seal Assembly ................................................................................................................... 13

Figure 6-8: Wear Ring Measurements ....................................................................................... 13

Figure 6-9: Mechanical Seal Assembly ...................................................................................... 14

Installation ........................................................................................................................................ 15

Volute (Body)......................................................................................................................................... 16

Installation Notes .............................................................................................................................. 17

PUMP HEAD .............................................................................................................................. 17

Removing the Pump Head .................................................................................................................... 17

Installation Notes .............................................................................................................................. 18

PEDESTAL MOUNT................................................................................................................... 18

Front Oil Seal ........................................................................................................................................ 18

Removal ........................................................................................................................................... 18

Figure 6-10: Front Oil Seal Breakdown, Pedestal ...................................................................... 19

Installation Notes .............................................................................................................................. 20

Figure 6-11: Rear Oil Seal Breakdown, Pedestal ....................................................................... 21

Rear Oil Seal ......................................................................................................................................... 21

Removal ........................................................................................................................................... 21

Installation Notes .............................................................................................................................. 22

Bearing Housing .................................................................................................................................... 23

Removal ........................................................................................................................................... 23

Figure 6-12: Pedestal Breakdown .............................................................................................. 24

Installation Notes .............................................................................................................................. 25

HG SERIES GEARBOX ............................................................................................................. 25

Figure 6-13: Oil Seal Breakdown, HG Series ............................................................................ 26

Front Oil Seal ........................................................................................................................................ 26

Removal ........................................................................................................................................... 26

Installation Notes .............................................................................................................................. 27

Stainless Max Series Pumps 7

Table of Contents

Contents - continued Page

HG SERIES GEARBOX - continued

Dismantle the HG Gearbox ................................................................................................................... 28

Figures 6-14: HG Series Gearbox Breakdown .......................................................................... 29

Assemble HG Gearbox ......................................................................................................................... 29

“X” SERIES GEARBOX ............................................................................................................ 30

Oil Seal .................................................................................................................................................. 31

Figure 6-15: Oil Seal Breakdown, “X” Series ............................................................................. 31

Installation Notes .............................................................................................................................. 32

Dismantle the “X” Series Gearbox ........................................................................................................ 33

Upper Housing Assembly ................................................................................................................. 33

Removal ........................................................................................................................................... 33

Installation Notes .............................................................................................................................. 34

Intermediate Shaft Assembly ................................................................................................................ 34

Removal ........................................................................................................................................... 34

Figure 6-16: Intermediate Shaft Assembly, “X” Series ............................................................... 35

Installation Notes .............................................................................................................................. 35

Tail Shaft Assembly ............................................................................................................................... 36

Removal ........................................................................................................................................... 36

Installation Notes .............................................................................................................................. 36

Figure 6-17: Lower Housing Assembly ...................................................................................... 37

Sliding Gear Shaft Assembly ................................................................................................................. 37

Removal ........................................................................................................................................... 38

Installation Notes .............................................................................................................................. 38

Shift Cap and Switch ............................................................................................................................. 39

Removal ........................................................................................................................................... 39

Installation Notes .............................................................................................................................. 39

Shift Cylinder Assembly ........................................................................................................................ 40

Removal ........................................................................................................................................... 40

Figure 6-18: Shift Cylinder Assembly ......................................................................................... 40

Installation Notes .............................................................................................................................. 41

Sliding Gear and Fork Assembly ........................................................................................................... 41

Installation Notes .............................................................................................................................. 42

MAINTENANCE KITS ................................................................................................................42

Three years - ......................................................................................................................................... 42

Five years - ........................................................................................................................................... 42

Complete Overhaul - ............................................................................................................................. 42

SM SERIES OVERVIEW........................................................................................ 43

Figure 6-19: Stainless Max (SM) Pump Overview ..................................................................... 43

Figure 6-20: “HG” Series Gearbox Overview ............................................................................. 44

Figure 6-21: “X Series” Gearbox Overview ................................................................................ 45

Figure 6-22: Pedestal Overview ................................................................................................. 46

8 Stainless Max Series Pumps

Table of Contents

Contents - continued Page

SECTION

OVERVIEW .................................................................................................................................. 1

FRAME MOUNTING .................................................................................................................... 1

Mounting Holes ....................................................................................................................................... 1

DRIVELINE ISSUES .................................................................................................................... 1

PLUMBING CONNECTIONS ....................................................................................................... 4

7: INSTALLATION ............................................................................. 1

Driveline tube size (diameter) – inches (millimeters) ................................................................... 3

Figure 7-1: Maximum Recommended Driveline Lengths ............................................................. 3

EXPRESS WARRANTY .........................................................................................8-1

DRAWINGS

SMR-A Base Pump Installation, Sheet 1 ........................................................................................... 994A

SMR-U Base Pump Installation, Sheet 2 .......................................................................................... 994A

SMD-A Series Pump, with HG Series Gearbox .............................................................................. 1043A

SMD-X Series Pump, with X Series Gearbox ................................................................................. 1041A

SMD & SMM Inlet Configuration Options ........................................................................................ 1045A

Stainless Max Series Pumps 9

Table of Contents

NOTES

_________________________________________________________________________

10 Stainless Max Series Pumps

SECTION 1: SAFETY PRECAUTIONS

IMPORTANT!

THE HALE STAINLESS MAXTM SM 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.

THIS SECTION ON SAFETY MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE CAFSPRO PUMP SYSTEM.

Stainless Max is a trademark of Hale Products, Incorporated. All other brand and product names are the trademarks of their respective holders.

Safety Precautions

GUIDELINES

Read all instructions thoroughly before beginning

any installation process.

NOTICE !

THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES AND POLICIES ESTABLISHED BY YOUR COMPANY, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED BY THE APPARATUS MANUFACTURER'S MANUAL.

REFER TO COMPANY PROCEDURES ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES. ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.

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

❑ Use care when removing the Stainless Max system from its

packaging to prevent personal injury and/or damage to the system.

❑ To fully support the stainless max pump assembly, use all

mounting bolt holes provided in the gearbox and/or pedestal mount.

Stainless Max Series Pumps 1-1

Safety Precautions

WARNING !

THE SM SERIES PUMP AND GEARBOX ARE HEAVY AND BULKY, WEIGHING UP TO 750 TO 850 LBS. / 340 TO 386KGS (APPROXIMATE). BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING SM SERIES PUMP AND GEARBOX ASSEMBLIES.

❑ Installation should be performed by a trained and qualified

installer, or your authorized Hale Products service representative. Be sure the installer has sufficient knowledge, experience and the proper tools before attempting any installation.

❑ The installer is responsible for observing all instructions and

safety precautions in his or her daily routine as dictated by regional safety ordinances or departmental procedures.

❑ DO NOT permanently remove or alter any guard or insulating

devices, or attempt to operate the system when these guards are removed.

Make sure all access / service panels and covers are installed, closed and latched tight, where applicable.

❑ DO NOT remove or alter any hydraulic or pneumatic connections,

electrical devices, etc. DO NOT tamper with or disconnect safety features or modify protective guards (such as covers, or doors). DO NOT add or remove structural parts. Doing so voids the

Stainless Max warranty.

Any of the above could effect system capacity and/or safe operation of the system and is a serious safety violation which could cause personal injury, could weaken the construction of the system or could affect safe operation of the Stainless Max Pump.

WARNING!

NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THE STAINLESS MAX PUMP SYSTEM WITHOUT PRIOR WRITTEN PERMISSION FROM:

Hale Products, Incorporated

Fire Suppression Equipment Group

700 Spring Mill Avenue

Conshohocken, PA 19428

Telephone: .... 610-825-6300

Fax: ............... 610-825-6440

1-2 Stainless Max Series Pumps

Safety Precautions

❑ Rotating drive line parts can cause injury. Be extremely careful

that NO part of your body (head, feet, arms, legs, finger, hair) is in an area of rotating parts where you could be subject to injury.

❑ Make sure everyone is clear of the apparatus. Verify the parking

brake is set and the wheels are chocked to prevent any movement of the apparatus.

❑ DO NOT operate the system at pressures higher than the

maximum rated pressure.

❑ 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

maximum pressure rating at which the water pump system operates.

❑ Before working on the pump, disconnect suction and discharge

piping and drain the pump body.

❑ If excessive leakage from the drain hole in the pump head is

noticed or suspected, the impeller must be removed and the mechanical seal must be inspected.

❑ If a pump is operated without water for extended periods, or

without discharging water, it may overheat. This may damage the mechanical seal or the drive mechanism.

❑ DO NOT leave the cab or attempt to pump until all the “green”

pump indicators in the cab and panel are ON. (Also see Figure 3-2: “Pump Operator’s Panel” on page 3-3.)

❑ DO NOT attempt emergency shift procedures while the engine is

running.

❑ DO NOT advance the throttle unless the "OK TO PUMP" indicator

is ON.

Stainless Max Series Pumps 1-3

Safety Precautions

NOTES

________________________________________________________________________

1-4 Stainless Max Series Pumps

SECTION 2: INTRODUCTION

OVERVIEW

Hale Products currently offers the first and only all Stainless Steel SM Series Pumps in three (3) models:

❑ SMR – rear mounted fire pump ❑ SMM – fully manifolded midship pump ❑ SMD – unmanifolded midship pump

Unless otherwise indicated, these procedures apply to all models of Hale SM Series Pumps. Any variations in operations and maintenance of the different models are addressed within the context of this manual.

The Hale line of pumps are the favorites of fire fighters throughout the world. The SM series are revolutionary fire pumps, constructed of high strength stainless steel. They offer the versatility, dependability, reliability, ease of operation and reduced maintenance, so necessary to effective fire fighting.

Introduction

SM pumps are available with capacities of 1,250 Gallons Per Minute (GPM)/5,000 Liters Per Minute (LPM) and 1,500 GPM (6,000 LPM).

PRINCIPLES OF OPERATION

This section reviews the principles of operation of Hale SM series pumps and provides a description of the pump components.

Centrifugal Force

Hale pumps are centrifugal pumps that operate on the principle of centrifugal force created by a rapidly spinning disk. Figure 2-1 shows that an amount of water has been placed at the center of a disk.

The disk is rotated clockwise or counterclockwise, depending on pump model, at some speed.

The water is thrown from the center toward the outer circumference of the disk.

Figure 2-1: Centrifugal

Force, from a rotating disk

Stainless Max Series Pumps 2-1

Introduction

The velocity at which the fluid travels from the center directly relates to the diameter of the disk and the speed of rotation.

When water is confined in a closed container (such as the pump body or volute), the velocity is converted to pressure and this pressure rises to a level that depends on the speed of rotation. There are three interrelated factors that regulate the performance of a centrifugal pump:

❑ SPEED (RPM) If the speed of rotation increases with flow held

constant, fluid pressure increases.

❑ PRESSURE Pressure is usually measured in Pounds Per

Square Inch (PSI or BAR).

If pressure changes with speed held constant, the flow, measured in gallons or liters per minute (GPM/LPM), changes inversely; that is, if pressure increases, flow decreases.

❑ FLOW Flow is usually measured in the number of gallons of

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

A centrifugal pump is preferred by the fire protection service due to its ability to fully utilize any positive suction inlet pressure, reducing the amount of work done by the pump.

For example, if the required discharge pressure is 120 PSI (8.3 BAR), and the inlet pressure is 45 PSI (3.1 BAR), the pump must only produce the difference in pressure or 75 PSI (5.2 BAR). This contributes to low engine and pump speeds with reduced maintenance. Decreased maintenance is aided by the fact a centrifugal pump has few moving parts; such as the impeller, shaft and seal.

Note: SM Series pumps are single stage pumps, meaning there is a single impeller on a common shaft.

As the impeller rotates, the water moving outward in the impeller creates a vacuum in the suction eye allowing the pump to lift the fluid into the volute (or body).

As water is evacuated from the suction passage atmospheric pressure pushes the water through the suction passage.

Pump Stages

The number of impellers on a common shaft determines the number of pump stages.

2-2 Stainless Max Series Pumps

Hale SM series pumps use a single impeller to develop the required volume and pressure. (See Figure 2-2: “Pump Impeller.”)

During operation water enters the suction eye of the impeller. The rotating impeller vanes develop discharge pressure and direct the water to the discharge opening.

The cut water is a wedge that divides the water between the volute (pump body) and the pump discharge. (See Figure 2-3: “SM Pump Water Flow.”)

Introduction

Figure 2-2: Pump Impeller

There are three model SM series pumps available. The anticipated position on the apparatus determines the model selected as well as the drive unit.

SMM - midship series of

Discharge

pump. Driven by split shaft X-series gearbox,

Diffuser

the SMM-X Series is a fully manifolded package.

SMR - rear mount series pump. Pedestal mounted.

Impeller

Vanes

Suction Eye

(Intake)

Available as direct drive (-U version) or with a two gear PTO gearbox (-A version).

SMD - midship series of

Figure 2-3: SM Pump Water Flow

pump. Driven by a split shaft HG or X-series gearbox, with optional 6” (152mm) suction Victaulic flange or weld Rams Horn. Single-stage end suction, centrifugal pump connected to split-shaft PTO transmission.

Cavitation

Cavitation occurs when a centrifugal pump is attempting to discharge more fluid than it is receiving. When cavitation occurs, bubbles are created under the vacuum, near the eye of the impeller. Cavitation is often referred to as “the pump running away from the fluid supply.”

Stainless Max Series Pumps 2-3

Introduction

This means that the operator is trying to

Cavitation

Region

pump more water out of the pump than is going into the pump. The formation of bubbles in the low pressure regions of the impeller cause the impeller to "slip" in the water since the impeller is designed to move liquid, not the air in the

Cavitation

Region

bubbles.

Figure 2-4: Cavitation Regions

To eliminate cavitation, the operator must be aware of the warning signs and immediately correct the situation or serious damage to the pump and impeller will occur. The most reliable indication that a pump is approaching cavitation is when an increase in engine RPM does not cause an increase in pump discharge pressure. A low barometer, high elevation, or elevated fluid temperature will also contribute to cavitation.

Pumps are rated at standard temperatures and barometric pressures. When conditions vary from standard, the maximum capacity of the pump from draft can be affected.

The operator must not depend entirely on the vacuum gauge (if one is installed in the application) to indicate when a pump is nearing cavitation.

The vacuum gauge is usually tapped into the intake chamber several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The most common way to eliminate cavitation is to decrease the amount of fluid being discharged. This is accomplished by decreasing engine speed or closing discharge valves.

This will allow pressure to increase, however this will result in a reduction of flow.

Cavitation can also be eliminated be increasing the pressure on the pump inlet. This is accomplished with reduced vertical lift, reduced inlet losses, or running from positive pressure supplies.

Also see Section 3: “Operating Procedures,” heading CAVITATION, beginning on page 3-13 for additional information on the dangers of cavitation.

2-4 Stainless Max Series Pumps

PUMP COMPONENTS - SM SERIES

Stainless Max pumps are made up of:

Introduction

❑ Pump Body ❑ Impeller and Shaft

Mechanical

Seal

Impeller

Assembly

❑ Mechanical Seal ❑ Gearbox

Figure 2-5: “Overview of Hale SM Pump,” on the next page, shows these basic pump parts. These parts are briefly described in this section.

Pump Body

(Volute)

Pump Body

from

Gearbox

The Hale SM series pump body consists

Figure 2-5: Overview of Hale SM Pump

of a volute body pump head and front clearance ring. The pump body is constructed from corrosion resistant stainless steel.

The pump body is a single piece. Service of the impeller, clearance rings, and mechanical seal is accomplished by removing the pump body. This can often be accomplished without removing the entire pump and gearbox assembly from the apparatus.

The pump has a suction inlet on the front. The incoming fluid is directed to the impeller through the suction piping.

Impeller and Shaft Assembly

A high quality, stainless steel impeller provides velocity to the water. This part is mounted on a stainless steel shaft that is rotated by the gearbox. (See Figure 2-2: “Pump Impeller” on preceding page 2-3.) The water enters the rotating impeller at the intake (or eye), and is confined by the shrouds and the impeller vanes to build pressure. The vanes guide the water from the inlet to the discharge. Vanes curve away from the direction of rotation so the water moves toward the outer edge. The shrouds form the sides of the impeller and keep the water confined to centrifugal acceleration.

Stainless Max Series Pumps 2-5

Introduction

The impeller is mounted so that the discharging tube is widest at the pump outlet. The volute collects the water. A further increase in pressure and a decrease in velocity take place in the diffuser which is cast into the pump body.

Bearings

Bearings support and align the impeller shaft for smooth operation.

Mechanical Seal

The mechanical seal is common to Hale SM series pumps. (See Figure 2-6: “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-temperature operations.

Pump

Head

Stationary

Seat

Seal Ring

Diaphragm

Retainer

Impeller

Shaft

Priming

Figure 2-6: Mechanical Seal

The SM series pumps requires a priming system to evacuate air in the suction hose and pump. See separate heading “Priming System,” on page 2-11.

WARNING !

IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. THIS MAY DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.

Gearbox - SMM and SMD Series

The gearbox is dependent on the pump model selected. See Figure 2-7: “SMM/SMD Pump and Gearbox Configuration,” on page 2-7 for a sample configuration.

Within the gearbox a gear set and input drive shaft, made of heattreated nickel steel, transfers engine power to the impeller.

2-6 Stainless Max Series Pumps

Hale offers a variety of pump gear ratios to accommodate a wide range of end-user and apparatus manufacturer requirements based on the pump's intended use, horsepower and speed rating of the engine, and the torque rating of the transmission PTO.

Also see subheading “X Series Gearbox” on page 2-8 for additional information about the gearbox.

Pedestal - SMR Series

Introduction

SMM/ SMD

Pump

G / HG Series

Gearbox

Figure 2-7: SMM/SMD Pump and

Gearbox Configuration

SMR series pump shafts run through a bearing housing that acts as a mounting

SMR Pump

pedestal. See Figure 2-8 for a sample configuration.

This pedestal is constructed of fine grain cast iron, and consists of bearings and a shaft. Additionally the SMR-

Pedestal

Mount

A pump is driven through a 26 ear helical gear box.

Figure 2-8: SMR Pump and Pedestal

Configuration

PUMP DRIVES

There are four common SM pump drives used on fire fighting apparatus:

❑ Operation from the truck chassis drive shaft (split-shaft gearbox). ❑ Operation from a separate engine. ❑ Operation from the front of the truck chassis engine (front engine

PTO) crankshaft.

❑ Operation from a PTO from the truck transmission, a PTO before

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

Hale SM pumps are built to produce the volumes and pressures shown on their respective performance curves.

Stainless Max Series Pumps 2-7

Introduction

However, the volumes and pressures safely obtainable are dependent on the torque capacity of the apparatus transmission or transfer case, power takeoff and the pump drive line. In most cases, the torque rating of the PTO determines maximum pump performance.

The apparatus builder can give various pump performance spots that will define the torque limit of the PTO in terms of GPM and PSI. When pumping continuously, care should be taken not to overheat the apparatus' PTO, transmission or transfer case.

SMM-X Series Pump

Mechanical Seal

Gearbox

Assembly

Spacer

Pump Shaft

Tachometer

Cable

Connection

Input Shaft

Power Shift

Cylinder

G-Series Gearbox

Shift Shaft

Figure 2-9: Overview X-Series Gearbox

Pump Gear

Intermediate

Gear

Cooling

Tube

Sliding Gear

Shift Fork

Gear Body

Housing

The most common pump drive is the split-shaft gearbox. The Hale G-Series split-shaft gearbox is available as an extra long (X) model.

2-8 Stainless Max Series Pumps

Introduction

Hale offers a variety of pump gear ratios to accommodate a wide range of apparatus manufacturer requirements based on engine speed and available horsepower. The gearbox can withstand the full torque of the engine in ROAD operating conditions up to 16,000 pound-feet (21,693N-m).

The gearbox consists of the outer housing, gear set, and input and shafts that are both made of heat-treated nickel steel to support the shaft loads. (See Figure 2-9: “Overview X-Series Gearbox,” on preceding page 2-8.)

Special care must be taken to properly set the clearances on these bearings. Also see Section 6: "Maintenance and Repair," beginning on page 6-1.

Mid-Ship Pumps

Midship pumps are so named because of their location on the fire apparatus. They are normally driven through an integral transmission that has a sliding gear shaft and sliding gear that selectively directs the engine power to the pump or the rear axle. Figure 210: “SMM Split-Shaft Drive Applications” shows the typical midship pump split-shaft arrangement on a chassis.

Hale “X” Gearbox Ratios: 1:1.96, 2.13, 2.32, 2.55, 2.83

Pump and

Transmission

Gearbox

Drive Shaft,

Split-Shaft

Drive Shaft

Drive Axle

Drive Shaft

Rear Mount Split-Line Drive PTO

Rear Mount PTO Drive

Figure 2-10: Typical Split-Shaft Drive Applications

Stainless Max Series Pumps 2-9

Introduction

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

Shifting

If the gearbox is equipped with a power shift system, an in-cab control valve is provided for mode selection.

This control locks in place for pump operation. Indicator lights are provided to alert the operator when the gearbox has fully shifted from ROAD to PUMP position. Additionally, manual shifting is provided due to failure of the power shift system.

Different pump models utilize different indicating switches. Some indicator switches are pneumatic while others are electric dependent on which pump model is selected and/or your operation requirements.

HALE Power Takeoff Pumps (PTO)

Hale Stainless Max pumps are available for either engine rotation or opposite engine rotation PTO operation. Additionally, the pump can be configured to discharge in a variety of positions. Since some PTOs match engine rotation and some turn opposite of the engine rotation, each pump model can be built to match the rotation of the PTO.

ACCESSORIES

In addition to the basic parts of Hale Stainless Max pumps, as described in the preceding sections, the following items are available to enhance operation:

❑ Cooling Systems ❑ Priming Systems ❑ Pressure Control Devices ❑ Anodes ❑ Suction and Discharge Manifolds

Auxiliary Cooling (Overheat Protection)

A cooler protects the gearbox, the apparatus engine, and the pump from an overheat condition.

2-10 Stainless Max Series Pumps

Introduction

The gearbox cooler circulates pump water to transfer heat from the gearbox oil to the pump discharge. It is standard equipment on pumps with a capacity of 750 GPM (2,839LPM) or greater and optional equipment on all other pumps.

Priming Systems

Priming pumps are used to evacuate air in the suction hose and the pump. The vacuum created allows atmospheric pressure to push water from the static source through the suction hose and into the pump.

Note: Hale SM series pumps use Rotary Vane Positive Displacement type pumps for priming. (See Figure 2-11: “ESP Priming Pump.”) Also see Figure 2-12: “Rotary Vane Priming Pump.”

Figure 2-11: ESP

Priming Pump

A priming pump draws air out of the pump body and discharge piping allowing water to enter. The priming pump has a rotor mounted off-center (eccentric) to the pump body housing. The vanes in the rotor slide in grooves and are held against the body housing

Suction

Ground to

Chassis

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

Rotor

vane advances outward from the groove and against the body housing. During this cycle, the

Vanes

space between the rotor and housing case fills with

Discharge

air. The vanes, acting as wipers, force air out of the

Figure 2-12: Rotary Vane Priming Pump

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.

Stainless Max Series Pumps 2-11

Introduction

A ESP series priming pump also uses a single control to open the priming valve between the pump and the priming pump, 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 for Remote Mounting

(SPVR)

From Priming Port

PRIME

To Priming Pump

Remote Push Button

(mounted on Operator Panel)

Figure 2-13: SPVR Priming Valve

A hose is connected from the SPVR to the priming tap on the Stainless Max pump body. A single push-button on the operator’s panel starts the priming pump motor. When a vacuum is created, the SPVR opens. (See Figure 2-13: “SPVR Priming Valve.”) Releasing the push-button stops the priming pump and the SPVR closes.

❑ The Hale PVG Priming Valve

The PVG is mounted on the pump operator’s panel. The PVG is a combination valve and switch.

PRIME

Figure 2-14: PVG Priming Valve

2-12 Stainless Max Series Pumps

Introduction

When the handle on the PVG is pulled out, the valve opens and the switch energizes the primer motor. See Figure 2-14: “PVG Priming Valve” on page 2-12. Pushing the handle de-energizes the motor and closes the valve.

Pressure Control

The P Series relief valve system is a bronze, variable-pressure setting relief valve that prevents undue pressure per the requirements of NFPA Standard 1901. An indicator light on the operator control panel signals when the valve is open.

The P Relief Valve System

The P relief valve system consists of a panel mounted control valve (PM) and, depending on the pressure rating of the pump, a P30 or P35 relief valve. The valve is mounted in the discharge piping and plumbed back to the pump suction. See Figure 2-15: “P Relief Valve System Arrangement.”

PM Control Panel

Victaulic

Flange

Figure 2-15: Relief Valve System Arrangement

PM Control Valve

Valve connections are either flanged or Victaulic™. Both are shown in Figure 2-15: “Relief Valve System Arrangement.”

How the relief system works:

A bleeder line mounted in the pump discharge pressure tap provides pressure to the diaphragm in the PM control valve. The hand wheel on the PM control either increases or decreases the spring tension on the diaphragm. The seat of the Pseries relief valve is kept closed by pump discharge pressure.

As the pump pressure increases, more pressure is applied to the diaphragm in the PM Control valve.

Stainless Max Series Pumps 2-13

Introduction

As the pressure on the diaphragm increases beyond the set point, the stem will move off its seat, allowing pump pressure to push on the piston in the relief valve.

This causes the relief valve seat to lift allowing excess pressure to dump back to the pump suction side. After the pressure equalizes, the piston returns to the closed position.

An Amber indicator light on the PM control illuminates when the relief valve is open.

Thermal Relief Valve (TRV)

The Thermal Relief Valve protects the pump from overheating. (See Figure 2-16: “TRV System.”)

The optional TRV unit can be attached to the discharge piping either by flange mounting or 1-1/4”NPT threaded connection (38 mm for the TRVM).

The valve monitors the temperature of the water in the pump. When the temperature

°

exceeds 120°F (48.9

C), the valve automatically opens and depending on the installation,

Figure 2-16: TRV-L Kit

discharges a small amount of water either to the ground or into the water tank allowing cooler water to enter. After the temperature returns to a safe level, the valve closes.

The TRV produces a flow rate of up to 1 to 2 GPM (3.8 to 7.6 LPM).

TRV-L Kit

See Figure 2-16: “TRV-L Kit.”

The TRV-L kit includes a chrome panel placard with a warning lamp, a lamp test button, and a pre-assembled wiring harness. The light illuminates whenever the TRV is open and discharging water.

An optional buzzer provides audible warning. The buzzer mounts on the operator panel.

2-14 Stainless Max Series Pumps

Introduction

NOTES

________________________________________________________________________

Stainless Max Series Pumps 2-15

Introduction

APPENDIX A: GLOSSARY

Atmospheric ........ Pressure caused by the elevation of air above the earth. Air pressure is 14 pounds

Pressure per square inch at sea level. Pressure increases below sea level and decreases

above sea level. The weather also effects air pressure. Atmospheric pressure effects a pumps ability to pump from draft. Higher pressures increases a pumps performance, while lower pressures can cause a noticeable decrease in lift.

Auxiliary............... Permits water from a pump to cool the radiator water through a heat exchange.

Cooling Valve

Capacity .............. Pump flow rating.

Cavitation ............ Occurs when the pump attempts to deliver more fluid than is being supplied. This

causes the formation of bubbles in the pump. When the bubbles collapse, the liquid, under pressure, rushes in to fill the empty space. This damages the pump and must be corrected immediately.

Centrifugal ........... Force that tends to make rotating bodies move away from the center of rotation.

Force

Centrifugal ........... A pump that uses a rapidly spinning disk or impeller to create the pressure for fluid

Pump movement.

Certification ......... Pumper test in accordance with NFPA standards to determine if a pump can

deliver its rated volume and pressure.

Check Valve ........A one-way valve or non-return valve that allows flow in one direction, but shifts to

prevent flow in the reverse direction.

In two stage pumps, there are two swing check or flap valves in the suction passage of the second stage. They are located in each side of the pump between the suction tube and the pump body. These valves swing open when pumping in parallel for volume. They are closed by first stage pressure when pumping in series for pressure.

Clearance ............ Prevents discharge fluid from returning to the eye of the impeller.

Rings

Compound........... A compound gauge is graduated to read pressure in "pounds per square inch" and

Gauge "vacuum in inches of mercury."

Cut Water ............ Cut water is a wedge-shaped point between the volute (pump body) and the pump

discharge where the volume of fluid is directed to the victaulic discharge connection.

Dead Heading ..... Operating a pump without any discharge. The lack of flow causes temperatures to

rise inside the pump. See WARNING ! on next page (2-17).

2-16 Stainless Max Series Pumps

Introduction

WARNING !

IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. THIS COULD DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.

Double Suction .... Fluid enters on both sides of the impeller.

Impeller

Dry Prime Test ....Provides information on the ability of a priming pump to evacuate air from the main

pump. If the vacuum does not hold, it is an indication there is a leak in the system.

Eye, Impeller ....... Point where fluid enters the impeller.

Flow Meter .......... Measures the volume of fluid that is flowing.

Friction Loss ........ Loss of pressure in hose, fittings, standpipes, and other appliances because of the

resistance between the fluid molecules and the inside surfaces of the hoses, fittings, standpipes, piping, and other appliances.

Front-Mount ........ Pump mounted ahead of the vehicle’s engine – usually on the front of the radiator.

Pump

Gauge ................. Pressure read from a gauge (PSIG).

Pressure

Governor .............Minimizes pressure changes by controlling engine speed to maintain pump

discharge pressure.

Horsepower ......... A measure of mechanical work.

Impeller ............... The working part of a centrifugal pump that, when rotating, imparts energy to fluid.

Essentially, an impeller consists of two disks separated by vanes. The vanes force the fluid to move outward between the disks so that it is thrown outward at high velocity by centrifugal force. The water from the impeller discharges into a diverging passage known as a volute, converting the high velocity energy of the water into pressure.

Net Pump ............ The difference in pressure between discharge and suction pressure.

Pressure

Packing ............... Material that maintains an airtight seal at the point where the impeller shaft enters

and exits the pump body.

Parallel ................ Capacity position in which each impeller on a two-stage pump works independently

into the discharge – often termed "Volume Mode."

Pitot Gauge ......... Measures velocity head at the discharge of a nozzle and can be converted to flow

using a chart or simple calculation.

Stainless Max Series Pumps 2-17

Introduction

Positive................ A pump with a fixed flow delivered to the discharge with each revolution.

Displacement Pump

Positive................ Pressure above atmospheric.

Pressure

Power Valve ........A valve that uses hydraulic pressure to transfer two-stage pump operation from

volume mode to pressure mode, and vice versa.

Pressure .............. Force per unit area.

Pressure .............. The pressure gauge is usually graduated in pounds per square inch (PSI) only. It

Gauge is connected to the pump discharge manifold, thus indicating pump discharge

pressure.

Priming ................ Priming evacuates the air from the main pump and suction hose, thus creating a

vacuum. This allows atmospheric pressure on the source of the fluid to push the fluid up into the suction hose and pump.

Priming Pump...... An auxiliary positive displacement pump which pumps air out of the booster pump

that creates a vacuum to prime the main pump. The priming pump is a rotary vane type, electric motor driven. Once the main pump is primed and pumping, the priming pump is shut off.

Priming Pump...... A valve located in the priming line between the priming pump and the main pump.

Valve It remains closed at all times except when priming. The control is normally located

on the pump panel.

Pump Shift ........... A midship pump is usually mounted with a split gearbox installed in the drive shaft.

The pump shift moves a sliding gear in the gearbox that transmits power either to the pump or the rear axle. In ROAD position, power is shifted to the rear axle for driving; in PUMP position, the rear axle is disconnected, and power is shifted to the pump shaft.

Relay ................... Movement of water from an apparatus at a water source to additional apparatus

until water reaches the fire ground.

Relief Valve .........An automatic valve which, when activated by the relief valve control, will hold pump

pressure steady when discharge valves or shut-off nozzles are closed. The valve maintains its given pressure by dumping the pump discharge flow into the pump suction.

Relief Valve .........A handwheel adjustment valve which controls and/ or adjusts the relief valve to

Control (PM) maintain the working pressure (i.e., set to control the desired pressure).

Series ..................Pressure position in which the first impeller’s discharge is fed to the eye of the

second impeller in a two-stage pump which then discharges the fluid from the pump.

Service Test ........ Pump test performed to determine if the apparatus can deliver its rated volume and

pressure.

2-18 Stainless Max Series Pumps

Introduction

Shrouds ............... Sides of an impeller that confine the fluid.

Slinger Ring......... Prevents fluid from continuing to travel down a shaft to the gears and ball bearings.

Stages .................The number of impellers in a pump that are used in series; that is, one following

another in terms of flow. Each impeller develops part of the total pump pressure.

Tachometer ......... Indicates the speed of the engine crankshaft in revolutions per minute.

Torque ................. The force that acts to produce rotation.

Transfer Valve ..... A two-position valve in a pump that changes the operation from parallel (volume) to

series (pressure) operation and vice versa (not used on single stage pumps).

Vanes ..................Guides inside an impeller that direct fluid to the volute (pump body).

Volute ..................A gradually increasing discharge waterway. Its function is to collect the water from

the impeller and, depending on its design, it either increases pressure and decreases velocity or increases velocity and decreases pressure.

Water .................. Amount of energy in the water stream.

Horsepower

Wear Rings ......... See Clearance rings.

Stainless Max Series Pumps 2-19

Introduction

APPENDIX B: MEASUREMENTS

Water Horsepower .................................................................................................... (GPM x PSI)/ 1,714

One Gallon of Water Weighs ............................................................................................... 8.33 Pounds

One Gallon ................................................................................................................... 231 Cubic Inches

One Cubic Foot .................................................................................................................... 7.48 Gallons

One Pound per Square Inch of Head......................................................................... 2.31 Feet of Water

One Inch of Mercury ................................................................................................ 1.132 Feet of Water

One Pound per Square Inch ........................................................................... 2.0178 Inches of Mercury

equals 27.68 inches of Water

One Cubic Meter ................................................................................................................... 1,000 Liters

One Imperial Gallon ............................................................................................................... 1.2 Gallons

CONVERSIONS

TO CONVERT TO MULTIPLY BY

Feet Head ........................... Pounds Pressure ................................. 2.31

FT-LB (Torque) ................................. N-m ......................................... 1.3558

GALLONS .................................. LITERS ....................................... 3.785

HP (Horsepower) ........................ KW (Kilowatts) ................................. 0.7457

One Pound per Square Inch .................... One Bar ...................................... 0.0690

One Pound per Square Inch ....................... KPA .......................................... 0.001

Pounds per Square Inch ..................... Feed Head ..................................... 0.433

BAR ........................................... PSI ........................................... 4.504

PSI ........................................... BAR ........................................ 0.06895

2-20 Stainless Max Series Pumps

SECTION 3: OPERATING PROCEDURES

This section provides information and procedures for the operation of Hale SM series pumps. Included are post-operation procedures and procedures for pumping from:

❑ a hydrant ❑ draft ❑ an onboard tank

Unless otherwise indicated, these instructions apply to all Hale SM series pumps.

NOTICE !

Operating Procedures

THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES AND POLICIES ESTABLISHED BY YOUR COMPANY, NOR DO THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED BY THE APPARATUS MANUFACTURER'S MANUAL.

REFER TO COMPANY PROCEDURES ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES. ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.

STATIONARY PUMPING OPERATIONS

Pumping from a Hydrant (General Operation)

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

CAUTION!

REFER TO DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS AND LAYING OUT SUCTION AND DISCHARGE HOSES. ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.

2. Bring the truck to a complete stop before attempting to shift from ROAD to PUMP.

3. Apply the truck parking brake.

Stainless Max Series Pumps 3-1

Operating Procedures

4. Shift the truck transmission to the NEUTRAL position. See Figure 3-1: “Driver’s Com-

PTO Transmission

Switch Connection

PUMP ENGAGED

WHEN LIT

OK TO PUMP

WHEN LIT

PUMP ENGAGED

WHEN LIT

partment Indicator Lights.”

Ground

OK TO PUMP

WHEN LIT

CAUTION !

PTO Switch Connection

NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRUCK TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS ZERO “0” BEFORE MAKING PUMP TRANSMISSION SHIFT. (SEE FIGURE 3-1: “DRIVER’S COMPARTMENT INDICATOR LIGHTS.")

5. Engage the PTO. (Move the in-cab pump shift control valve from the ROAD position to the PUMP position. Within a few seconds the shift warning indicator lights, indicating a complete shift.)

Figure 3-1: Driver's Compartment Indicator

Lights

Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or has an electric switch, follow the instructions supplied with that valve.

6. After pump shift has completed, place the truck transmission in the proper pump operating range or gear.

For most operation conditions, this will be direct drive (1:1) ratio. In addition, the speedometer should read 5 MPH to 15 MPH (8 15 KMH) after the shift has been completed.

7. If the shift does not complete, shift truck transmission to “N” and repeat the entire procedure.

Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck’s chassis manual for details.

WARNING !

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

3-2 Stainless Max Series Pumps

Operating Procedures

8. Exit the driving compartment only after all the

NEUTRAL Safety Switch

PUMP ENGAGED

WHEN LIT

above steps are completed and you are sure

OK TO PUMP

WHEN LIT

WARNING DANGER

that the shift completed lights in the cab and panel are on.

CAUTION !

DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (ALSO SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL.”)

Ground

Throttle Control

Figure 3-2: Pump Operator's Panel

9. Verify that the pump panel shift indicator green “OK TO PUMP” light is on.

10. Open the hydrant. Bleed off the air from the suction hose.

11. If necessary, open the suction valve to allow fluid to flow into the pump.

12. If necessary to eliminate air pockets, open appropriate valve to expel air or prime the pump, if so equipped.

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

14. Set the automatic relief valve or governor control system according to your company policy, if so equipped.

CAUTION!

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

15. If the master intake gauge shows a high vacuum before the desired discharge pressure or flow is reached, it indicates that you are getting all the water the suction piping (hydrant) can supply.

Stainless Max Series Pumps 3-3

Operating Procedures

To increase the pressure when this occurs, reduce the pump flow.

16. The master intake gauge reading must be maintained at 5 PSI (0.3 BAR), minimum. If the gauge shows a vacuum the pump is attempting to draw more water than the hydrant can supply. When this occurs, reduce the pump flow to increase the pressure.

As the throttle is opened, the pressure gauge reading increases with engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. (See heading “Cavitation” on page 3-13.) In this case, 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.

17. Open the discharge valve(s).

IMPORTANT!

IF THE PUMP OVERHEATS AND IT IS NOT EQUIPPED WITH A HALE TRV VALVE, OPEN THE VALVE TO ACCESS THE BYPASS LINE, IF SO EQUIPPED, OR OPEN THE VALVE TO THE BOOSTER TANK (BOTH SUCTION AND DISCHARGE SIDES) TO CIRCULATE WATER.

18. After completion of pumping, gradually reduce the pump pressure until the engine is at an idle speed.

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

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

21. Move pump shift control valve lever to the ROAD position. The in-cab and panel pump indicator lights should go out when the pump transmission starts to shift into the ROAD position.

22. When pumping operations are completed, gradually reduce the pump pressure until the engine returns to idle speed. Disengage the PTO.

3-4 Stainless Max Series Pumps

Operating Procedures

Emergency Pump Shift Procedures

Before implementing manual override shift procedures, repeat recommended procedures as described in the previous section. If the shift fails to take place, follow these procedures.

1. Bring the truck to a complete stop.

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

3. Shift the truck transmission to the NEUTRAL position.

4. For PUMP or ROAD position, put the in-cab shift control in the NEUTRAL position. (Neutral position is exactly in the middle, between the road and pump positions.)

5. Shut down the engine.

WARNING !

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

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

Note: The shift stroke is approximately 1” (25 mm). Make sure the gearbox is fully shifted and shift indicators show proper mode.

7. An eyebolt is provided in the shift shaft to accept a drift punch or screwdriver. By inserting this tool into the hole provided, you are able to pull or push the shaft manually.

8. Pull the shift shaft OUT for PUMP position (after in-cab control valve selection), or push shift shaft IN for ROAD position (after incab control valve selection).

If the shift stroke cannot be completed manually, turn the drive shaft slightly by hand to realign the internal gears and repeat the manual shift effort.

9. Some units may be equipped with a manual shift device attached to the eye bolt. Refer to the manufacturer’s instructions when manual shift devices are installed.

Stainless Max Series Pumps 3-5

Operating Procedures

TPM Operation from a Hydrant

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

Draft Limiting Factors

Water Temperature

See Table 3-3: “Baseline NFPA Rating (Additional Loses).”

The effect of raised water temperatures when pumping from a positive pressure source (i.e., a hydrant) is negligible on fire pump performance. However, when pumping from draft, elevated water temperature does have a limiting effect.

F° (C°)

°06)°61(enilesaBABFN

°07 )°12( 3.0 )6.7(

°08)°72(6.0)2.51(

°09 )°23( 1.1 )0.82(

°001)°83(7.1)2.34(

°011 )°34( 5.2 )5.36(

Table 3-3: Baseline NFPA Rating

(Additional Loses)

Lift Loss

Head Ft. (mm)

°

Water temperature above 95

F (35°C) causes a noticeable decrease in lift when drafting. Another factor that can limit lift when drafting is barometric pressures below 29 In. of Hg.

It is important to be aware of environmental conditions when drafting.

Pumping from Draft

1. Get as close to the water source as possible. The pump can draw 100% of its rated capacity with less than a 10 foot (3.05 meters) vertical lift. As the lift increases to above 10 feet, the pump capacity is reduced.

CAUTION!

REFER TO DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS AND LAYING OUT SUCTION AND DISCHARGE HOSES. ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.

3-6 Stainless Max Series Pumps

Operating Procedures

2. Bring the truck to a complete stop before attempting to connect suction hoses or shifting from ROAD to PUMP.

3. Apply the truck parking brake.

4. Shift the truck transmission to NEUTRAL.

CAUTION !

NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRUCK TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS AT ZERO “0” BEFORE MAKING THE PUMP TRANSMISSION SHIFT. (SEE FIGURE 3-1: “DRIVER’S COMPARTMENT INDICATOR LIGHTS.”)

5. Engage the PTO. (Move the in-cab pump shift control valve from the ROAD position to the PUMP position. Within a few seconds the shift warning indicator lights, indicating a complete shift.)

Note: If the truck manufacturer has used another in-cab valve to achieve pump shift or has an electric switch, follow the instructions supplied with that valve.

6. After pump shift is complete, place the truck transmission in the proper pump operating range or gear.

For most operation conditions, this is the direct drive (1:1 ratio). In addition, the speedometer should read 5 MPH to 15 MPH (8 15 KMH) after the shift has been completed.

7. If the shift does not complete, shift truck transmission to “N” and repeat the entire procedure.

Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck manual for details.

WARNING !

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

8. Exit the driving compartment only after all the above steps are completed and the indicator lights in the cab and on the panel are ON.

Stainless Max Series Pumps 3-7

Operating Procedures

WARNING !

DO NOT ADVANCE THE THROTTLE UNLESS THE "OK TO PUMP" INDICATOR IS ON.

9. Verify the pump panel shift indicator light is on.

10. Activate the priming pump by pulling the control handle located on the pump panel or pressing the push button.

The departmental manual for pumping should specify the correct RPM for priming. In general, priming should be done at idle with an engine speed of about 1,000 to 1,200 RPM.

11. Monitor the intake and discharge master gauges. The pump is primed when the intake reading falls below zero (0), and the discharge pressure starts to increase. Water may also discharge to the ground.

Running the engine at speeds higher than 1,200 RPM during priming is not recommended. It will not improve the priming operation but may cause damage to the pump.

CAUTION

IF DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO, OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND 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.”

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

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

As the throttle is opened, increase the pressure gauge reading with engine speed. If the engine speed increases without an increase in pressure, the pump is nearing cavitation. Reduce the flow from the pump to maintain pressure or reduce the pressure (throttle) to maintain flow.

Note: Cavitation is discussed in detail under heading “Cavitation,” beginning on page 3-13.

3-8 Stainless Max Series Pumps

Operating Procedures

14. If a pump shutdown is desired while pumping from draft, reduce the engine speed to idle, and close the discharge valves.

To resume pumping, open the throttle and discharge valves. If the pump overheats from continued churning without water flow, open the discharge valves periodically to release hot water.

14. Set the automatic relief valve according to department policy. See heading “Relief Valve Procedures” on page 3-12.

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

16. After completing pumping procedures, gradually reduce the engine RPM to idle speed and disengage the PTO. See heading “Post-Operation Procedure” on page 3-16.

Pumping from Onboard Water Tank

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

NOTICE !

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

2. Bring the truck to a complete stop before attempting to shift from ROAD to PUMP.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRAL position.

5. Move the in-cab pump shift control valve from ROAD to PUMP. Within a second or two the shift warning indicator turns ON, indicating a completed shift.

If the truck manufacturer has used another in-cab valve to achieve pump shift, follow the instructions supplied with the valve.

6. After pump shift iscompleted, place the truck transmission in the proper pump operating range or gear.

Stainless Max Series Pumps 3-9

Operating Procedures

For most operating conditions, this is the direct drive (1:1 ratio). In addition, the speedometer should read 5 MPH to 15 MPH (8-15 KMH) after the shift has been completed.

7. If the shift does not complete, shift the truck transmission to “N” and repeat the entire procedure.

Note: Some vehicles operate the speedometer from the front wheels. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck manual for details.

WARNING !

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

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

WARNING!

DO NOT OPEN THE THROTTLE UNTILL THE GREEN INDICATOR IS ON. (ALSO SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 3-3.)

8. Verify that the green “OK TO PUMP” pump panel shift indicator is ON.

9. Open the tank suction valve.

10. Check the master discharge gauge to see if priming is necessary. If necessary, start the priming pump by either pulling the control handle located on the pump panel, pressing the prime push button or just slightly open the tank fill valve.

CAUTION!

IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO (0), OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND IN 30 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP. STOP THE PUMP AND CHECK FOR AIR LEAKS OR POSSIBLE PUMP PROBLEMS. SEE SECTION 5: “TROUBLESHOOTING.”

11. Watch the intake and discharge pressure gauges. When the pump is primed, the compound gauge falls below zero (0), and the pressure starts to increase. You may also hear water splashing on the ground, indicating that the pump is primed.

3-10 Stainless Max Series Pumps

Operating Procedures

12. Open the engine throttle gradually until the desired pressure or flow is reached. As the throttle is opened, the discharge pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating.

Note: Cavitation is discussed in detail under heading “Cavitation,” beginning on page 3-13.

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

WARNING!

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

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

14. Set the automatic relief valve according to your fire department policy. If your fire department does not have a policy to follow, see the “TPM or Relief Valve Procedures” beginning on page 3-12.

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

16. After completion of pumping procedures, gradually reduce the engine RPM until it is at an idle speed. See the heading “Post Operation Procedure” on page 3-16.

PUMP AND ROLL OPERATION

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.

Stainless Max Series Pumps 3-11

Operating Procedures

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.

4. Open the valve between the tank and pump suction.

5. Observe pump discharge pressure and verify the pump pressure increases.

6. Prime the pump if necessary.

7. Open the discharge valves and commence operations.

RELIEF VALVE PROCEDURES

TPM /P35 Relief Valve Procedures

These procedures cover the Hale “TPM” Relief Valve System. Be sure to select the correct procedure based upon how the truck is equipped.

See Figure 3-4: “PMD Relief Valve Control.”

1. Set the pressure indicator on the PMD control valve to a position slightly above the normal operating pressure (even before water starts to flow).

2. After normal operating pressure has been achieved (as indicated on the master pressure gauge while the pump is discharging water), slowly move the adjusting hand wheel counterclockwise until the relief valve opens.

Pressure Indicator

Indicator Light

(Amber)

The amber indicator light comes ON.

3. Turn the hand wheel slowly clockwise until the indicator light goes out. The relief valve will operate at the set pressure.

Figure 3-4: PMD Relief Valve

Control

3-12 Stainless Max Series Pumps

Operating Procedures

4. When the pump is not in operation, turn the hand wheel clockwise back to a position slightly above the normal operating pressure. More complete and detailed information can be found in the relief valve manual.

CAUTION!

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

CAVITATION

Cavitation can occur while pumping from draft, in relay, or from a hydrant. The operator must be aware of the warning signs and correct the situation, or serious damage to the pump and impeller will occur.

Cavitation can damage the impeller and other sensitive components, impair pump performance, and reduce flow capacity. The damage done during any one period of cavitation is not great, but the effects are cumulative. Implosions occurring during cavitation break away or erode tiny pieces of metal from the internal parts and the pump casing. When enough metal has been chipped away, the impeller becomes unbalanced causing a strain and vibration on bearings, bushings and shafts.

The way to eliminate cavitation is to increase the flow to the pump, decrease the amount of water being discharged from the pump, or reduce the pressure in the pump by decreasing engine speed.

Process of Cavitation

When increased discharge demand exceeds the intake, bubbles form in the low-pressure region (eye) of the impeller. The pressure of the water in the pump drops as it flows from the suction flange through the suction nozzle and into the impeller.

As flow from the pump increases, the vacuum at the impeller increases. As the vacuum increases, the boiling point of the water in that vacuum decreases until it reaches a point near the impeller eye where it boils and vaporizes.

Once the vapor pockets, or bubbles, enter the impeller, the process begins to reverse itself. As the vapor reaches the discharge side of the pump, it is subjected to a high positive pressure and condenses back to a liquid.

Stainless Max Series Pumps 3-13

Operating Procedures

This sudden change from vapor to liquid generates a shock effect that damages the impeller and pump housing. Usually there are thousands of tiny vapor pockets (bubbles) rather than a few large ones. It is the collapsing (or implosion) of these bubbles that causes the characteristic sound of cavitation that has been described as rocks tumbling in the pump.

Warning Signs of Cavitation (Discharge and Gauges)

Discharge Pressure

In a properly functioning pump, an increase in RPM increases the discharge pressure and volume. An increase in engine RPM that does not cause an increase in the pump discharge pressure, is the most reliable indication that a pump is approaching cavitation.

Vacuum Compound Gauge

Do not depend entirely on the vacuum (compound) gauge to indicate when a pump is nearing cavitation. The vacuum gauge is usually tapped into the intake chamber several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The vacuum gauge does not take into account ambient temperature nor atmospheric pressure and is not accurate near zero (0) on the vacuum scale.

How to Prevent Cavitation

A soft sleeve has an advantage over a hard sleeve when pumping from a hydrant because it will partially collapse providing an immediate indication to the operator that cavitation is imminent. A hard sleeve indicates problems only at the intake gauge, which is not the best or most reliable indicator.

Monitoring current operating conditions, knowing the capabilities of the equipment, and regular inspection are the best protection against cavitation.

During Operations

❑ Do not increase the pump speed beyond the speed at which the

pressure ceases to rise.

❑ Monitor that the water temperature baseline per NFPA

standards is 60° F (16° C).

3-14 Stainless Max Series Pumps

Operating Procedures

Table 3-3: “Baseline NFPA Rating,” on page 3-6, shows the amount of lift loss as temperatures rise. If there is a marked loss of suction capacity, the pump may be near cavitation.

Note: When water reaches 95° F( 35° C), you should notice a marked decrease in lift.

❑ Monitor barometric pressure. NFPA standards sets a baseline

of 29.9”Hg. See Table 3-5: “Lift Loss from Barometric Pressure.”

❑ Location: The higher the elevation above sea level, the lower

the atmospheric pressure and less lift. See Table 3-6: “Lift Loss from Elevation.”

Barometric Reading

in (mb)

9.92)5.210,1(enilesaBABFN

7.92 )8.500,1( 2.0 )6.0(

5.92)999(5.0)51.0(

3.92 )2.299( 7.0 )12.0(

1.92)4.589(9.0)72.0(

9.82 )7.789( 1.1 )33.0(

7.82)9.179(4.1)34.0(

Lift Loss

Head Ft. (mm)

Table 3-5: Lift Loss from Barometric

Pressure

❑ Open the throttle

gradually and watch the pressure gauge and the tachometer, if equipped. An increase in engine RPM without a corresponding increase in pressure indicates cavitation.

❑ Use a hard suction hose when pumping from draft and soft

suction hose when pumping from a hydrant.

Elevation

Feet (Meters)

000,2)016(enilesaBABFN

000,3 )419( 1.1 )33.0(

000,4)912,1(2.2)76.0(

000,5 )425,1( 3.3 )00.1(

000,6)928,1(4.4)43.1(

000,7 )431,2( 5.5 )76.1(

000,8)834,2(6.6)10.2(

000,9 )347,2( 7.7 )53.2(

000,01)840,3(8.8)86.2(

Lift Loss

Feet (Meters)

Table 3-6: Lift Loss from Elevation

Preventive Measures

❑ Regularly inspect discharge and suction hoses to check for air

leaks. Air leaks can also cause cavitation.

❑ Consider the size of the suction hose. Table 3-7: “Hose size for

Pump Rating Capacity,” on page 3-16, lists the NFPA preselected hose sizes for each pump-rating capacity. Using the appropriately sized hose minimizes the occurrence of cavitation.

Stainless Max Series Pumps 3-15

Operating Procedures

Hose Diameters

in. (mm)

Flow

gpm (lpm)

052

053

005

057

000,1

052,1

005,1

057,1

000,2

005,2

3”

(76)

)02(2.5

4”

(102)

4.5”

(114)

Lift Loss

)5.9(5.2

)91(0.5)6.31(6.3

)34(4.11 )03(0.8 )81(7.4 )2.7(9.1

)55(5.41)23(5.8)31(4.3

5”

(127)

)94(31 )02(2.5

Table 3-7: Hose Size for Pump Rating Capacity

6”

(152)

Dual

6” (152)

)92(6.7)2.7(9.1

)93(4.01 )01(6.2

)31(4.3

)02(2.5

❑ Consider the piping within the truck. Further suction losses may

result from additional suction piping added to the fire pump during assembly by the manufacturer.

❑ Follow the maintenance and inspection procedures. ❑ Cavitation can occur with large nozzle tips. Solve this problem

by reducing flow.

❑ Cavitation can also occur when air enters the pump. The pump

may be primed, however, air leaks can cause rough operation and an increase of engine speed without an increase in pressure or flow. If an air leak is suspected, discontinue pumping and refer to Section 5: Trobleshooting.

POST OPERATION PROCEDURE

1. Return the engine to idle.

2. Slowly close all valves.

3. Place the transmission in NEUTRAL or PARK.

4. Slowly shift from PUMP to ROAD to disengage the pump.

3-16 Stainless Max Series Pumps

Operating Procedures

5. Drain the pump (especially important in freezing weather):

❑ Open the discharge valves, remove suction tube caps, and

discharge valve caps.

❑ Open the pump body drain cocks or Hale multiple drain valve.

If a multiple drain valve is used, all pump drain lines should be connected to this valve.

❑ After the pump is completely drained, replace all caps and

close all valves,

7. If sea water, dirty water, alkaline water or foam solution, has been used, flush the pump with clean water.

8. Remove the wheel chocks only when preparing to leave the scene.

9. Fill out the Pump Run Log, indicating total pumping time and total out-of-station time.

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

11. Know and follow all local procedures.

Stainless Max Series Pumps 3-17

Operating Procedures

NOTES

_________________________________________________________________________

3-18 Stainless Max Series Pumps

SECTION 4: PREVENTIVE MAINTENANCE

OVERVIEW

Hale SM Series Pumps require minimal care and maintenance. Pre-

ventive maintenance tasks take little time to perform and consist primarily of leak testing, lubrication and cleaning.

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

This section provides recommended actions to be completed after each use, weekly, monthly and annually.

Preventive Maintenance

POST-OPERATION

Flush Pump

1. Inspect the suction hose and rubber washers, as well as the washers in the suction tube caps.

2. Remove any foreign matter from the hose and coupling.

3. Replace worn, damaged, or dry washers.

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

5. Tighten the suction caps.

EXTREME CONDITIONS

Extreme conditions occur when the pump has been operated during freezing weather or when pumping from a water source that contains material that is harmful to the pump if not purged.

Stainless Max Series Pumps 4-1

Preventive Maintenance

During Freezing Weather

In freezing weather, drain the pump as follows:

1. Open all discharge and suction valves, remove suction tube caps, and discharge valve caps.

2. Open pump body drain cocks and/or Hale multiple drain valve.

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

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

After drafting from sea water, contaminated, sandy or dirty water, flush the pump and suction hoses by using water from a hydrant or other clean water source.

After pumping foam through the pump, flush as above until all residues of foam are flushed.

AFTER EACH USE

❑ Check seals for leaks. ❑ Check piping for leaks. ❑ Close all valves and caps.

WEEKLY

❑ Test the relief valve system ❑ Test the priming system ❑ Test the pump shift warning indicator lights ❑ Valve Maintenance ❑ Check and clean the intake strainers ❑ Check any auxiliary engine. ❑ Verify all gauges are in working order ❑ Operate pump controls ❑ Inspect water and foam tanks ❑ Check roof and bumper turrets ❑ Check auxiliary fire suppression equipment

4-2 Stainless Max Series Pumps

Preventive Maintenance

Relief Valve Test

When the relief valve is not in operation, keep the hand wheel set above the normal operating pressure.

1. Prepare to pump from the onboard water tank, having the discharge flow back to the water tank.

2. Turn the relief valve hand wheel clockwise to the STOP position to prevent the valve from operating. See Figure 4-1: “PM Valve Control.”

3. Increase the pump pressure up to 150 PSI (10 BAR) as indicated on the master pressure gauge per normal operating procedures.

Figure 4-1: PM Valve Control

4. Turn the relief valve hand wheel counterclockwise until the relief valve opens. The relief valve is open when the AMBER indicator light is on and the pressure begins to drop.

5. Turn the relief valve hand wheel clockwise then counterclockwise a few times to ensure that the hand wheel turns freely. Observe the pressure gauge and indicator light for proper valve operation.

6. Return the relief valve hand wheel and the apparatus to normal operational condition.

Priming System Test

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

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

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

1901.

Governor Test

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

Stainless Max Series Pumps 4-3

Preventive Maintenance

Pump Shift Warning Indicator Lights

CAUTION!

MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS.

VERIFY THE PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT ANY MOVEMENT OF THE APPARATUS.

1. Follow the operating procedures in Section 3 to engage the pump if no local procedures exist.

2. Verify that the warning indicators in the cab and the pump control panel function properly.

3. Verify that the indicator lights on the control panel function properly and agree with the indicators in the cab.

4. Repair or replace any malfunctioning indicators.

Valve Maintenance

Properly functioning valves are integral to the operation of the pump. The relief valve operating control should be lubricated every 5 months. or sooner, depending on use. Also refer to the valve manual for proper valve maintenance procedures.

1. Lubricate all suction and discharge valves using an approved lubricant as stated in the valve manual.

2. Verify each valve operates easily and closes completely.

3. Inspect and lubricate all of the valve linkages.

4. Repair or replace any damaged or nonfunctional linkages.

Check and Clean the Intake Strainers

1. Remove the strainers.

2. Clean any debris from the intake.

3. Flush the pump, if required by department procedures.

4. Repair or replace any damaged strainers.

4-4 Stainless Max Series Pumps

Preventive Maintenance

Check Auxiliary Engine

If the pump is powered by a separate engine, check the engine, fuel tanks and drive for wear and proper operation.

Verify All Gauges are in Working Order

Any gauge that is repeated in the cab or another panel, must agree with the gauge on the operator's panel.

Gauges not reading within 10% of the calibrated test gauge must be removed from service and re-calibrated.

Operate Pump Controls

Operate the pump drive controls to verify the pump engages.

Verify the indicator lights work properly.

Inspect Water and Foam Tanks

Visually inspect water and foam tanks for proper level and gauge readings.

If any debris is present, flush the tanks to protect the pump from wear caused by dirty water or foam concentrate.

Check Roof and Bumper Turrets

If the apparatus is so equipped, verify that the turrets function properly, and no leaks are present. Make repairs immediately.

Check Auxiliary Fire Suppression Equipment

Visually inspect all piping and valves on the pump and auxiliary equipment for corrosion or damage.

MONTHLY

❑ Check the Gearbox Oil ❑ Perform the dry vacuum test ❑ Check the drive line bolts

Stainless Max Series Pumps 4-5

Preventive Maintenance

Gearbox Lubrication

Too much oil or the wrong type of oil will result in unnecessary loss of power and high oil temperature. Change the oil every 12 months, depending on pump usage. Refer to Table 4-2: “Recommended Lubricants” for Hale recommended oils and gearbox capacities.

1. Remove the gearbox oil fill plug, and check the level of the oil in the gearbox. See Figure 4-3: “Sample Fill Plug.”

The oil level should be up to the plug hole.

Gearbox

(Model)

X

GH

RMS

)latsedeP(

Table 4-2: Recommended Lubricants

Recommended Oil Capacity

05EAS

2. 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. Either of these conditions indicates maintenance is required on the unit.

qts. (liters)

,09-W08,09-PEEAS

08-W57citehtnySro

04-W51ot04-W01

liOenignEedargitluM

stnemeriuqeR5-LGIPA

)8.3(4

stnip5.1

)57.0(

fognitaRecivreSteeMtsuMsliOraeGllA

Figure 4-3: Sample Fill Plug

Fill

Plug

Priming System Test (Dry Vacuum Test)

(Refer to NFPA 1901 or NFPA 1911)

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

2. Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel.

3. Engage the priming pump until the gauge indicates at least 22 IN-hg vacuum. See Figure 4-4: “Prime Control.”

4-6 Stainless Max Series Pumps

Figure 4-4: Prime

Control

Preventive Maintenance

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 than 10 inches of Hg in 5 minutes, it is an indication of at least one air leak.

Vacuum leaks may often be detected audibly if the apparatus engine is turned off. Correct leaks immediately to return the pump to service.

6. Test the suction hose as follows:

a. Attach the suction hose to the pump.

b. Place a suction tube cap on the end of the hose in place of a

strainer.

c. Close all valves and drains. Cap all suction openings and the

outlet of the suction side relief valve (if so equipped).

d. Connect a calibrated vacuum gauge or manometer to the

intake test gauge connection on the pump panel.

e. Engage the priming pump until the gauge indicates at least

22 IN-hg vacuum.

f. Watch the gauge. If the vacuum falls more than 10 inches in 5

minutes, it is an indication of at least one air leak.

g. Verify that the test gauge and the apparatus gauge display the

same readings.

h. Repair or replace any gauges that do not display the correct

pressure.

IMPORTANT!

IF LEAKS CANNOT BE DETECTED BY FOLLOWING THE PROCEDURE, IT IS ADVISABLE TO TEST THE PUMP HYDROSTATICALLY. TO TEST:

❑ OPEN ALL THE VALVES ❑ PLACE CAPS ON ALL VALVES ❑ CONNECT A POSITIVE PRESSURE SOURCE ❑ INSPECT THE PUMP FOR LEAKS

Drive Line and Flange Bolts

Check all drive line and flange bolts to ensure:

1. No bolts are missing.

Stainless Max Series Pumps 4-7

Preventive Maintenance

2. All bolts are tight. Use a torque wrench to torque bolts to the drive train manufacturer's recommended specifications.

3. Bolts used are “Grade 8” strength. Be sure to use Hale genuine replacement parts before you attempt any repair maintenance.

Indicator Light Test

Operate the respective component having indicator lights and observe the indicator light operation. If the light fails to tunr ON, check and/or replace the bulb and test again.

ANNUALLY

Figure 4-5:

Grade 8 Bolt

Head

❑ Replace the pump gearbox oil. (See Table 4-2: “Recommended

Lubricants” on page 4-6.)

❑ Check individual drain lines from the pump to the multi-drain to

ensure proper drainage and protection from freezing.

❑ Test tank-to -pump flow rate. ❑ Clean ESP Primer if installed. ❑ Perform the yearly pump test to check performance levels. (See

NFPA Standard 1911 for more details.)

Replace Gearbox Oil

1. Drain the oil from the gearbox.

2. Remove the drain plug (magnetic) and drain the gearbox oil into a suitable container. See Figure 4-6: “Sample, Drain and Fill Plugs – RH Horizontal Installation.” Also See Figure 4-2: “Recommended Lubricants,” on page 46, for fluid quantities.

Oil Fill

Oil

Drain

Water Drain

Oil Fill

Level

Figure 4-6: Sample, Drain, Fill and Level

Detect Plugs - RH Horizontal Installation

4-8 Stainless Max Series Pumps

Preventive Maintenance

For the pedestal, see heading “Replace Pedestal Oil - SMR Series” for additional information.

Note: Assembly orientation determines which plugs are used for oil fill, drain and level detection. Also see Installation Drawings at the back of this manual.

3. Examine the oil for contamination (e.g., water – turns the oil a milky color or settles to the bottom). Properly dispose of the used oil.

4. Inspect the magnetic drain plug. If metal filings are present on the drain plug, remove the cooler or cover plate to visually inspect and clean the internal components.

Repair or replace as necessary.

5. Replace the cooler or cover, if necessary. Remove the oil fill plug, the level detect plug, and replace the drain plug (magnetic).

6. Fill the gearbox with an approved gear oil until oil just begins seeping from the level plug opening.

7. Replace the fill plug.

Replace Pedestal Oil - SMR Series

1. To check the oil, remove the fill / dipstick and check reading. (See Figure 4-7: “Pedestal Oil Change.”)

2. Add fresh oil through the oil fill/dipstick port until oil reaches the MAX line. Do not overfill. See Table 4-2: “Recommended Lubricants” on page 4-6.

Note: Oil is checked with the dipstick screwed down tight.

3. Replace the oil fill / dipstick securely and run the pump for a short period, then recheck the oil level.

Oil Fill /

Dipstick

Drain Plug

4. To change the oil, remove

Figure 4-7: Pedestal Oil Change

the drain plug, located at the rear of the housing, below the pump drive flange.

Stainless Max Series Pumps 4-9

Preventive Maintenance

5. Drain the oil from the pedestal into a suitable container (1.5 pints/

0.7 liters).

6. Remove the oil fill/dipstick and replace the drain plug. (See Figure 4-7: “Pedestal Oil Change” on page 4-9.)

7. Fill the pedestal with an approved oil per preceding Step 2 and run the pump for a short period, then re-check the oil level.

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 of these drains are piped together to a multi-drain to allow the entire system to be drained by one valve.

It is necessary to inspect each line of the multi-drain to ensure the entire system is draining when the valve is operated.

Inspect each connection and verify the individual lines to the multidrain are free of debris. Repair or replace any lines that are damaged, kinked, or corroded.

Tank to Pump Flow Rate Test

Note: This procedure is provided as a reference only. It does not

supercede any local procedures.

1. Fill the water tank until it overflows.

2. Close the tank fill line, bypass the cooling line, and all the pump intakes.

3. Attach sufficient hose lines and nozzles to pump the desired discharge rate.

4. With the pump in gear, open the discharge to which the hose is attached and begin pumping water.

5. Increase the engine throttle until the maximum consistent pressure is obtained on the discharge gauge.

6. Close the discharge valve without changing the throttle setting. Refill the tank through the top fill opening or a direct tank line. The bypass valve may be opened during this time to prevent pump overheating.

4-10 Stainless Max Series Pumps

Preventive Maintenance

7. Reopen the discharge valve, and check the flow through the nozzle using a Pitot tube or flowmeter. Adjust the engine throttle to bring the pressure to the amount previously determined.

8. Compare the flow rate measured to the NFPA minimum or the designed rate of the pump. If the flow rate is lower, a problem exists in the tank to pump line. The minimum flow rate should be continuously discharged until 80% of the tank is discharged.

The pump should not experience mechanical problems, power loss, or overheat during the test.

Performance Testing Overview

The yearly standard performance test consists of checking the pump (according to its rating) at three capacities and comparing the results to when the pump was first placed in service. This provides some measure of any performance deterioration. See Table 4-8: “Pump Rating (GPM/LPM).”

Capacity Pressure

PSI (Bar)

LLUF

07

%

%05

Pump Rating in GPM (LPM)

250

(946)

)01(051

)11(561

)41(002

)71(052

052

051

521

350

(1,325)

053

)649(

542

)865(

)374(

)729(

571

)366(

450

(1,703)

054

)523,1(

513

522

500

(1,893)

005

)307,1(

053

)291,1(

052

)258(

750

(2,839)

057

)398,1(

525

)523,1(

573

)649(

1,000

(3,785)

000,1

)938,2(

)789,1(

)024,1(

)587,3(

007

)056,2(

005

)398,1(

1,250

(4,732)

052,1

)237,4(

052,1

)237,4(

578

)213,3(

526

)663,2(

1,500

(5,678)

005,1

)876,5(

005,1

)876,5(

050,1

)579,3(

057

)938,2(

Table 4-8: Pump Ratings (GPM/LPM)

A pump must be able to pump full capacity at 150 PSI, 70% capacity at 200 PSI and 50% capacity at 250 PSI.

Performance Testing Equipment and Materials

To accurately test pumper performance, requires a Pitot Gauge, a calibrated pressure gauge, and a vacuum gauge or manometer.

All gauges must be carefully tested for accuracy. Testing is appropriately accomplished with a dead weight gauge tester, which is usually available at the local water works.

Stainless Max Series Pumps 4-11

Preventive Maintenance

Use smooth bore test nozzles of accurate size with the Pitot Gauge. The volume pumped is then determined by referring to the 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.

For Pitot Gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 6.0 BAR). See Tables 4-9a (below) and 4-9b (on page 4-13): “Nozzle Flow and Pressure Ratings.”

GPM (LPM) AT VARIOUS NOZZLE SIZES

elzzoN

erusserP

)RAB(ISP )31("2/1 )61("8/5 )91("4/3 )22("8/7 )4.52("1 )92("8/1-1 )23("4/1-1 )53("8/3-1

)1.2(03

)4.2(53

)7.2(04

)1.3(54

)5.3(05

)8.3(55

)1.4(06

)3.4(26

)4.4(46

)6.4(66

)7.4(86

)8.4(07

)0.5(27

)1.5(47

)2.5(67

)4.5(87

)5.5(08

)9.5(58

)2.6(09

)6.6(59

)9.6(001

)2.7(501

)6.7(011

)9.7(511

)3.8(021

)551(14)242(46)843(29)374(521)716(361)087(602)269(452)661,1(803

)761(44 )162(96 )573(99 )115(531 )666(671 )048(222 )140,1(572 )752,1(233

)871(74)692(37)104(601)545(441)117(881)109(832)311,1(492)433,1(553

)981(05 )592(87 )424(211 )975(351 )357(991 )459(252 )771,1(113 )734,1(773

)102(35)013(28)744(811)016(161)597(012)700,1(662)242,1(823)305,1(793

)802(55 )623(68 )964(421 )046(961 )338(022 )650,1(972 )203,1(443 )975,1(714

)022(85)143(09)294(031)666(671)178(032)201,1(192)363,1(063)746,1(534

)022(85 )543(19 )005(231 )876(971 )688(432 )121,1(692 )583,1(663 )376,1(244

)322(95)253(39)705(431)986(281)109(832)931,1(103)404,1(173)007,1(944

)722(06 )653(49 )515(631 )007(581 )219(142 )551,1(503 )724,1(773 )627,1(654

)132(16)363(69)225(831)117(881)729(542)471,1(013)054,1(383)357,1(364

)532(26 )763(79 )035(041 )917(091 )939(842 )291,1(513 )964,1(883 )977,1(074

)832(36)573(99)835(241)137(391)459(252)802,1(913)294,1(493)608,1(774

)242(46 )973(001 )545(441 )247(691 )569(552 )322,1(323 )015,1(993 )828,1(384

)642(56)283(101)355(641)057(891)089(952)242,1(823)335,1(504)558,1(094

)052(66 )093(301 )065(841 )167(102 )299(262 )752,1(233 )255,1(014 )878,1(694

)052(66)493(401)865(051)867(302)700,1(662)631(63)175,1(514)009,1(205

)752(86 )504(701 )385(451 )597(012 )730,1(472 )700,1(743 )026,1(824 )169,1(815

)562(07)614(011)206(951)818(612)760,1(282)700,1(753)666,1(044)810,2(335

)372(27 )824(311 )716(361 )048(222 )490,1(982 )700,1(663 )117,1(254 )170,2(745

)082(47)934(611)263(761)368(822)421,1(792)700,1(673)657,1(464)721,2(265

)882(67 )154(911 )746(171 )288(332 )151,1(403 )700,1(583 )208,1(674 )771,2(575

)592(87)264(221)366(571)509(932)771,1(113)700,1(493)448,1(784)032,2(985

)303(08 )374(521 )876(971 )429(442 )802,1(913 )700,1(304 )588,1(894 )972,2(206

)703(18)184(721)217(381)349(942)032,1(523)700,1(214)729,1(905)823,2(516

)sretemillM(sehcnIni,eziSelzzoN

Table 4-9a: Nozzle Flow and Pressure Ratings

4-12 Stainless Max Series Pumps

GPM (LPM) AT VARIOUS NOZZLE SIZES

Preventive Maintenance

elzzoN

erusserP

)RAB(ISP )83("2/1-1 )14("8/5-1 )54("4/3-1 )84("8/7-1 )15("2 )75("4/1-2 )46("2/1-2 )67("3

)1.2(03

)4.2(53

)7.2(04

)1.3(54

)5.3(05

)8.3(55

)1.4(06

)3.4(26

)4.4(46

)6.4(66

)7.4(86

)8.4(07

)0.5(27

)1.5(47

)2.5(67

)4.5(87

)5.5(08

)9.5(58

)2.6(09

)6.6(59

)9.6(001

)2.7(501

)6.7(011

)9.7(511

)3.8(021

)683,1(663)826,1(034)588,1(894)560,2(275)464,2(156)911,3(428)058,3(710,1)245,5(464,1

)594,1(593 )657,1(464 )730,2(835 )933,2(816 )166,2(307 )963,3(098 )651,4(890,1 )589,5(185,1

)106,1(324)878,1(694)771,2(575)894,2(066)348,2(157)006,3(159)444,4(471,1)104,6(196,1

)696,1(844 )789,1(525 )903,2(016 )056,2(007 )710,3(797 )028,3(900,1 )317,4(542,1 )787,6(397,1

)197,1(374)101,2(555)434,2(346)497,2(837)081,3(048)420,4(360,1)079,4(313,1)451,7(098,1

)878,1(694 )302,2(285 )555,2(576 )039,2(477 )533,3(188 )122,4(511,1 )312,5(773,1 )305,7(289,1

)169,1(815)203,2(806)966,2(507)260,3(908)384,3(029)014,4(561,1)444,5(834,1)048,7(170,2

)199,1(625 )933,2(816 )017,2(617 )211,3(228 )045,3(539 )284,4(481,1 )435,5(264,1 )869,7(501,2

)520,2(535)773,2(826)657,2(827)161,3(538)695,3(059)455,4(302,1)126,5(584,1)390,8(831,2

)650,2(345 )114,2(736 )797,2(937 )012,3(848 )356,3(569 )626,4(222,1 )807,5(805,1 )222,8(271,2

)680,2(155)944,2(746)938,2(057)952,3(168)017,3(089)496,4(042,1)697,5(135,1)343,8(402,2

)611,2(955 )384,2(656 )688,2(167 )903,3(478 )367,3(499 )267,4(852,1 )978,5(355,1 )464,8(632,2

)641,2(765)125,2(666)229,2(277)453,3(688)618,3(800,1)038,4(672,1)269,5(575,1)585,8(862,2

)771,2(575 )555,2(576 )469,2(387 )093,3(898 )968,3(220,1 )598,4(392,1 )540,6(795,1 )307,8(992,2

)702,2(385)985,2(486)200,3(397)544,3(019)229,3(630,1)369,4(113,1)521,6(816,1)028,8(033,2

)332,2(095 )326,2(396 )040,3(308 )094,3(229 )179,3(940,1 )720,5(823,1 )402,6(936,1 )739,8(163,2

)462,2(895)756,2(707)180,3(418)635,3(439)420,4(360,1)190,5(543,1)482,6(066,1)150,9(193,2

)233,2(616 )737,2(327 )671,3(938 )546,3(369 )541,4(590,1 )742,5(683,1 )774,6(117,1 )133,9(564,2

)004,2(436)618,2(447)662,3(368)157,3(199)662,4(721,1)204,5(724,1)666,6(167,1)006,9(635,2

)464,2(156 )698,2(567 )853,3(788 )858,3(810,1 )483,4(851,1 )945,5(664,1 )848,6(908,1 )168,9(506,2

)925,2(866)869,2(487)544,3(019)259,3(440,1)794,4(881,1)396,5(405,1)720,7(658,1)811,01(376,2

)395,2(586 )440,3(408 )925,3(239 )050,4(070,1 )706,4(712,1 )338,5(145,1 )002,7(209,1 )863,01(937,2

)456,2(107)511,3(328)116,3(459)541,4(590,1)717,4(642,1)079,5(775,1)073,7(749,1)116,01(308,2

)417,2(717 )481,3(148 )596,3(679 )042,4(021,1 )328,4(472,1 )601,6(316,1 )735,7(199,1 )358,01(768,2

)177,2(237)252,3(958)477,3(799)133,4(441,1)529,4(103,1)532,6(746,1)007,7(430,2)480,11(829,2

)sretemillim(sehcnIni,eziSelzzoN

Table 4-9b: Nozzle Flow and Pressure Ratings - continued

The amount of discharge hose required for the service tests is dependent on the flow requirements and capacity test point. The most common discharge hose used is 2-1/2” (63 mm) in diameter by 100 feet (30.5 meters) long.

The number of hoses and length should be sufficient to reduce nozzle pressure to between 30 and 85 PSIG (2.1 and 6 BAR).

Refer to Table 4-10: “Hose Friction Loss,” on page 4-14, for a determination of the friction loss over 100 feet of hose. Also see Tables 4-9a and 4-9b: “Nozzle Flow and Pressure Ratings” for service testing of common size pumps.

Stainless Max Series Pumps 4-13

Preventive Maintenance

FLOWING

GPM (LPM)

3/4” (19 mm)

01

02

03

04

05

06

07

08

59

5.31

)83(

44

)67(

99

)411(

671

)151(

)981(

)722(

)562(

)303(

)143(

Booster

)9.0(

)0.3(

)8.6(

)21(

Booster

1” (25 mm)

5.3 )42.0(

6

)4.0(

41

)69.0(

42

)7.1(

83

)6.2(

45

)7.3(

1-1/2” (38mm)

4

)3.0(

7

)5.0(

9

)6.0(

21

)8.0(

51

22

)5.1(

Hose

)30.1(

FLOWING

GPM (LPM)

1-3/4” (44 mm) Hose with

59

41

)063(

521

42

)374(

051

53

)865(

571

74

)266(

002

26

)757(

522

)258(

052

)649(

572

)140,1(

003

)631,1(

2” (38mm) Hose with

1-1/2” (38mm) Coupling

8

)69.0(

)7.1(

)4.2(

)2.3(

)3.4(

1-1/2” (38mm) Coupling

)6.0(

31

)9.0(

81

)2.1(

52

)7.1(

23

)2.2(

3” (76mm) Hose with

2-1/2” (64 mm) Hose

6

)4.0(

8

)6.0(

01

)7.0(

31

)9.0(

51

)30.1(

81

)2.1(

2-1/2” (64mm) Coupling

5

)4.0(

3” (76mm) Hose

4

)3.0(

FLOWING

GPM (LPM)

3-1/2” (89 mm) Hose

005

057

5.9

)398,1(

02

)938,2(

000,1

43

)587,3(

052,1

35

)237,4(

005,1

47

)876,5(

057,1

)526,6(

000,2

)175,7(

)7.0(

)4.1(

)4.2(

)7.3(

)1.5(

4” (102mm) Hose

3

)2.0(

11

)8.0(

02

)4.1(

13

)1.2(

54

)1.3(

16

)2.4(

5” (217mm) Hose

5

)4.0(

8

)6.0(

31

)9.0(

81

)2.1(

52

)7.1(

23

)2.2(

521

)374(

051

)865(

83

45

523

)6.2(

)7.3(

)032,1(

053

)523,1(

005

)398,1(

057

)938,2(

000,1

)587,3(

22

8

)5.1(

)6.0(

52

)7.1(

8

)6.0(

02

71

)4.1(

)2.1(

54

63

)1.3(

)5.2(

08

86

)5.5(

)7.4(

Note: Add 5 PSI (0.35 BAR) for each story of the building and each wye or Siamese. Friction Loss Calculations courtesy of IFSTA.

Table 4-10: Hose Friction Loss (PSI/Bar 100 Feet)

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

❑ For 1,250 GPM (4,731 LPM) and 1,500 GPM (5,677 LPM)

tests, four or more lines are required between the pumper and the nozzle.

4-14 Stainless Max Series Pumps

Preventive Maintenance

❑ Because deluge guns are not always available, other hose

layouts may be used, such as one 2-1/2” (0.8 mm) line to a 1-3/8” (0.42 mm) nozzle for 500 GPM (1892 LPM).

Generally, the nozzle used on one, 2-1/2” line should not be larger than 1-1/2 inches (0.46 mm) for accuracy in measuring GPM (LPM).

Another alternative when a deluge gun is not available consists of a 1-1/4” (0.38 mm) nozzle on one and a 1-1/2” (0.46 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 pilot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and

5.8 BAR).

❑ 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. However, depending on line loss alone would require a large amount of hose for some tests.

It is common practice to use 50 to 100 feet (15.2 to 30.1 meters) of hose and gate the discharge valves as required to maintain pressure.

Performance Testing

Note: The NFPA standards require a 10% reserve in pressure at

the capacity run when the apparatus is delivered.

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

2. Perform steps 2 and 3 of the Post-Operation Maintenance procedures, beginning on page 4-1.

3. Run the standard pump test in accordance with NFPA standards to check pump performance. Pumps rated below 750 GPM are tested for an hour per NFPA 1901, 14-13.2.3.2.

4. Run the engine for 20 to 30 minutes to stabilize the engine temperature, then run the pump for:

❑ 20 minutes at capacity ❑ 10 minutes at 70% capacity ❑ 10 minutes at 50% capacity

Stainless Max Series Pumps 4-15

Preventive Maintenance

5. If the apparatus does not reach performance levels, refer to Section 5, “Troubleshooting” in this manual.

6. Compare the results of this test to those from when the apparatus was delivered. The apparatus may not have shown the 10% reserve at delivery.

7. 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.

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 the 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 hundreds of hours of operation. In dirty or sandy water, the impeller hub and clearance rings will wear faster. The more wear, the greater the bypass and lower pump performance.

Clearance Ring Measurement Impeller Measurement

Figure 4-11: Clearance Ring and Impeller Measurement

When new, the radial clearance between the impeller hubs and the clearance ring is between 0.005” to 0.007” (0.0127 to 0.0178 mm) per side. Any increase will allow more bypass and result in lower performance.

4-16 Stainless Max Series Pumps

Preventive Maintenance

It should not be necessary to replace clearance rings and impellers until the average radial clearance exceeds 0.015” to 0.020” (0.381 to 0.508 mm) or more per side as measured with calipers. See Figure 4-11: “Clearance Ring and Impeller Measurement” on page 4-16.

If the clearance rings on the SM pump show significant wear but the impeller itself is within the size tolerance, "undersized " clearance rings can be installed to delay a complete rebuild. Contact Customer Service at Hale Products.

Often, replacement of the clearance rings will reduce the bypass and restore the pump to near original performance. A complete restoration requires that the impellers also be replaced. See Section 6 for maintenance and repair information if pump disassembly is required.

Anode Check

The zinc anodes should be inspected every 12 months. Replace when over 75% of the zinc has been consumed. Performance of the anode life will vary with water quality and pH. Anodes conform to MIL Spec. A180001.

EXTREME CONDITIONS, MAINTENANCE GUIDELINES

Freezing Weather

1. Drain the pump body and discharge valves.

2. If the gearbox is equipped with a water cooling line, also drain this line.

3. There should be drains for the gauge lines, the cooling line to the engine, and to the relief valve (if equipped). All of these should be opened until all water is drained, then close the drain valves.

4. In freezing weather, drain the pump as follows:

❑ Open the discharge and suction valves, remove suction tube

caps and discharge valve caps.

❑ Open the pump body drain cocks and drain valves ❑ After the pump is completely drained replace all caps and

close all valves.

Stainless Max Series Pumps 4-17

Preventive Maintenance

Contaminated Water

After pumping salt water, contaminated water or foam solution, or if water containing sand or other foreign matter has been used, connect the pump to a fresh water hydrant or other source of fresh clean water and flush the contaminants out of the pump.

NOTES

_________________________________________________________________________

4-18 Stainless Max Series Pumps

SECTION 5: TROUBLESHOOTING

Table 5-1 lists the Conditions, Possible Causes and Suggested Corrective Action measures. Before calling Hale Products or a Hale authorized parts service center for assistance, eliminate problem causes using the following table.

If you cannot correct a problem, please have the Model and Serial numbers ready prior to calling the Hale Customer Service Technician Department for assistance – Customer Service telephone number: 610-825-6300.

Note: The location of the serial number will vary depending on the pump model but it is generally displayed on the pump operator's panel and/or the side of the gearbox.

Troubleshooting

Figure 5-1: Sample, Serial Plate

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

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agnitpmettaerofebPOTSetelpmocaotemoctsumtfahsevirD

ninoissimsnarthtiwserudecorptfihsdednemmocertaepeR

.serudecorptfihsdednemmocertaepeR

taeperdnatesernehT.yliratnemommetsysekarbesaeleR

gnitarepO"3noitceSeeS(.serudecorpgnitfihsdednemmocer

).1-3egapnogninnigeb”,serudecorP

!

nodeunitnoctrahC

egaptxen

serudecorpedirrevolaunamyolpmE.metsysniskaelrofkcehC

ni,serudecorPtfihSpmuPycnegremEeeS.yrassecenfi

.5-3egapnogninnigeb,serudecorPgnitarepO:3noitceS

Table 5-2: Troubleshooting

Stainless Max Series Pumps 5-1

Troubleshooting

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

dradnatS

htiw,noissimsnart

-metsystfihsREWOP

metsys

deunitnoc

citamotuA

htiw,noissimsnart

metsystfihsREWOP

metsys

ylppusriatneiciffusnI

!

tfihsniskaelriaro

yam,lanretxefi,egakaeL.)s(kaelriaperdnaetacolottpmettA

satondnalanretniebdluocegakaeL.ylbiduadetcetedeb

.detcetedylisae

!

ninoissimsnartehthtiwserudecorptfihsdednemmocertaepeR

.LARTUEN

!

.1-3egapnogninnigeb”,serudecorP

)

ylppusriatneiciffusnI

!

tfihsniskaelriaro

taeperdnatesernehT.yliratnemommetsysekarbesaeleR

nitarepO"3noitceSeeS(.serudecorpgnitfihsdednemmocer

g

serudecorpedirrevolaunamyolpmE.metsysniskaelrofkcehC

ni,serudecorPtfihSpmuPycnegremEeeS.yrassecenfi

.5-3egapnogninnigeb,serudecorPgnitarepO:3noitceS

!

yam,lanretxefi,egakaeL.)s(kaelriaperdnaetacolottpmettA

satondnalanretniebdluocegakaeL.ylbiduadetcetedeb

.detcetedylisae

!NOITUAC

:etoN gnimirpylkeeW

NOISSIMSNARTFOSSELDRAGERYLSUOUNITNOCREDNILYCTFIHSEHTNORIANIATNIAMSELCIHEVEMOS

ESU.LARTUENNISINOISSIMSNARTELCIHEVEHTNEHWDEILPPARIAEVAHYLNOEMOSDNA,GNITTES

TFIHSEHTSSELNUPMUPEHTGNITFIHSRETFABACEHTEVAELTONOD.GNICIVRESNINOITUAC

.DETONSIGNIDAERRETEMODEEPSARO,NOSITHGILROTACIDNI

SESOLPMUP

TIROEMIRP

metsys

gnimirpcirtcelE

EMIRPTONLLIW

otdednemmocersi

:2noitceSeeS

.noitareporeporperusne

gnidaeh,noitcudortnI

.6-2egapno”gnimirP“

metsys

!

.6-2egapno”gnimirP“gnidaeh,noitcudortnI:2noitceS

!

gnimirpevitcefeD

hgihootstfilnoitcuS

!

cirtceleehtetarepootderiuqersideepsenignedednemmoceroN

metsyslacirtceleehtsniatniamMPRenigne000,1,revewoH.remirp

eesoslA.noitarepognipmuplaitinirofdeepshguonegnidivorpelihw

rep”tseTmuucaVyrD“agnimrofrepybmetsysgnimirpehtkcehC

nahtsselsllupremirptub,muucavsdlohpmupehtfI.sdradnatsAPFN

.remirpehtniraewevissecxeetacidnidluocti,muucavfo)mm955(”22

.6-2egapno”gnimirP“gnidaeh,noitcudortnI:2noitceSeesoslA

woltatpecxe)sretem7.6(teef22gnideecxestfiltpmettaTONOD

.noitavele

noitcusdekcolB

!

.reniartsesohnoitcusmorfnoitcurtsboevomeR

reniarts

noitcuS

snoitcennoc

enil

nodeunitnoctrahC

egaptxen

!

dnaesohnoitcuskcehC.snoitcennocnoitcusllanethgitdnanaelC

.ecalperro/dnariapeR.stcefedelbissoprofsteksagesoh

noitcusnideppartriA

!

noitcusehtnahtrehgihesohnoitcusehtfotrapynagnicalpdiovA

diulfotenilcedsuounitnochtiwdialebdluohsesohnoitcuS.ekatni

.ylppus

Table 5-2: Troubleshooting - continued

5-2 Stainless Max Series Pumps

Troubleshooting

SESOLPMUP

TIROEMIRP

EMIRPTONLLIW

deunitnoc-

.noitcusnideppartriA

POSSIBLE

CAUSE

hguonegnol

enil

denepo

SUGGESTED CORRECTIVE ACTIONCONDITION

detarepotongnimirP

!

ehtesaelertonoD.dewollofebdluohsserudecorpgnimirpreporP

egrahcsidehtnepO.emirpetelpmocagnirussaerofeblortnocremirp

.emirpetelpmocerusneotemirpfonoitelpmocgnirudylwolsevlav

!ECITON

54NIHTIWDEVEIHCATONSIEMIRPFI.SDNOCES54REVOREMIRPEHTNURTONOD )ESOHNOITCUSDEKCOLBROSKAELRIA(SESUACROFKOOLDNAPOTS,SDNOCES

!

.ylppus

!

.esohnoitcusnistekcopriaetanimile

ooterusserppmuP

!

sielzzonnehwwol

.ylwolsevlavegrahcsidehtgninepo

noitcusehtnahtrehgihesohnoitcusehtfotrapynagnicalpdiovA

retawotenilcedsuonitnochtiwdialebdluohsesohnoitcuS.ekatni

otyrassecenebyamgnimirpdetaeper,elbadiovanusiesohnipartfI

elihwerusserppmuprehgihniatniamdnaniagapmupehtemirP

skaelriA :erudecorpgniwollofehtgnisuskaelriatcerrocdnaetacolottpmettA

!

sehcni22htiwsdradnatsAPFNreppmupnotsetmuucavyrdmrofreP

muucavfosehcni01deecxeottonssolhtiwderiuqermuucavmuminim

.setunim5ni

!

gnimirpeht,deveihcaebtonnacmuucavfosehcni22fomuminimafI

remirpehtrofgibootsikaelehtro,evitcefedebyammetsysroecived

.)evlavneponasahcus(emocrevoot

!

netfosikaelafonoitcetedelbiduA.enigneehtffotuhs,gnimirpretfA

.elbissop

!

rehtonafoegrahcsidehtrotnardyhehtmorfesohnoitcusehttcennoC

egakaelelbisivrofkooldna,retawhtiwpmupehtezirusserpotrepmup

oD.tneiciffusebdluohs)RAB9.6(ISP001foerusserpA.tcerrocdna

gnipipro,seirossecca,pmupfosnoitatimilerusserpdeecxeton

.snoitcennoc

!

noitcennocteltuoevlavehtgulP.kaelnacevlavfeileredisnoitcusehT

.tseterdna

TNEICIFFUSNI

YTICAPACPMUP

rewop

enignetneiciffusnI

evlavfeileR

nodeunitnoctrahC

egaptxen

deppiuqe

!

dnaenignekaeprofderiuqerebyampuenutrokcehcrewopenignE

.ecnamrofreppmup

!

osfi-tesylreporpmi

!

.retawssapyb

.)8-5egapno(noitceSsihtniretalsmotpmySnoitatoReesoslA

dnanepootevlavehtswollatiwoloottessierusserpevlavfeilerehtfI

evitneverP:4noitceSeeS.ylgnidroccaerusserpevlavfeilerehtteseR

.2-4egapnogninnigeb”,tseTevlaVfeileR“gnidaeh,ecnanetniaM

Table 5-2: Troubleshooting - continued

Stainless Max Series Pumps 5-3

Troubleshooting

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

tesronrevogenignE

TNEICIFFUSNI

-YTICAPACPMUP

deunitnoc

osfi-yltcerrocni

deppiuqe

ro,raeggnorwni

gnippilssihctulc

esohnoitcuS

degrahcsid

ehtninoitcirtseR

!

sinoissimsnartkcurT

!

.ecnatsissaroflaunamkcurteeS.egnarraegro

!

llamsootsiretemaid

!

gniebemulovehtrof

!

.esohnoitcusregralaesU

.htgnelenofolavomerybhtgnellatotnetrohS

.egrahcsidfoemulovecudeR

ehttaenilnoitcus

reniarts

skaelriA TONLLIWROEMIRPSESOLPMUP"gnidaehrednu"skaelriA"eeS

.3-5egapno,EMIRP

enigneeht,citamotuanonehwwoloottessironrevogenigneehtfI

.dehcaersierusserpderisedehterofebsetareleceddeeps

noissimsnartdednemmocerehtrofserudecorpgnipmupehtkcehceR

deepskcehcotlenappmupehtnoretnuocdeepslacinahcemesU

etaruccanirognippilsnoissimsnartrohctulcelbissoptsniaga

).oitarretnuocdeepselbissoproflaunamkcurtehtkcehC(.retemohcat

.reniartsehttaretawfoecnartnegnitcirtsersirbedynaevomeR

ehtfoespalloclaitraP

!

noitcusehtnigninil

esoh

TNEICIFFUSNI

ERUSSERP

rewop

ETOMER

enignetneiciffusnI

noitacirbulfokcaL

!

.tseterdnaesohehtecalpeR

.espalloclaitrapagnisuacsgninilrenni

.yticapaCpmuPtneiciffusnI:noitcessuoiverpeeS

.liohtiwrallocdnasegaknillortnocetomerehtetacirbuL

dnaretuoehtneewtebniriawollayamgninilretuoehtotegamaD

LORTNOC

OTTLUCIFFID

ETAREPO

ninoissimsnartkcurT

SDEEPSENIGNE

ROFHGIHOOT

DERIUQER

ROYTICAPAC

!

raegroegnargnorw

).ecnatsissaroflaunam

!

.raegtcerrocehtnisinoissimsnartehtyfireV

.noitcelesnoissimsnarttcerrocrofserudecorpdednemmocerkcehC

kcurtruoydnalaunamsihtni"serudecorPgnitarepO":3noitceSeeS(

ERUSSERP

noitcus,hgihoottfiL

!

llamsootesoh

!

nodeunitnoctrahC

egaptxen

!

.noitarepohguordnamuucav

.esohnoitcusregralesU

ecruosretawehtotresolcpmupehtevoM

hgih,sdeepsenignerehgihsesuac)m1.3/'01(tfillamronnahtrehgiH

Table 5-2: Troubleshooting - continued

5-4 Stainless Max Series Pumps

Troubleshooting

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

esohnoitcusytluaF

SDEEPSENIGNE

ROFHGIHOOT

DERIUQER

ROYTICAPAC

-ERUSSERP

!

.elbatcetednu

!

.esohlanigiro

deunitnoc

noitcustaegakcolB

!

yrtneesoh

!

pmupnroW

!

ro)s(rellepmi

sgnirecnaraelc

egakcolbrellepmI

!

.erusserp

!

).riaperrojama

.esohnoitcusgniyalrofsecitcarp

.diulfehtfoecafrusehtwoleb

yllaususidnagnitfardnehwespallocyamesohnoitcusfogninilrennI

tsniaganosirapmocroftset;pmupemasnoesohnoitcustnereffidayrT

dednemmocerwollofdnanoitcurtsboforeniartsesohnoitcusnaelC

)sretem6.0(teef2tsaeltaybylppusdiulfehtfomottobehtffopeeK

dnaecnanetniaM:6noitceSeeS.dedeensaecalperro/dnariapeR

.01-6egapnogninnigeb",pmuPMSehtgnicivreS“gnidaeh,riapeR

dnayticapachtobfossoltneverpnacrellepmiehtniegakcolB

.egakcolbeerfyamnoitcusotegrahcsidmorfspmupfognihsulfkcaB

deredisnocsisihT(.deriuqerebyamydobpmupehtfoflahgnivomeR

gnihcaorppasipmuP

!

”noitativaC“

!

NOITATIVAC

otgninnigebpmuP(

eromgnigrahcsiD

nignikatsi

!

pmupehtnahtretaw

!

.wolfecuder

”.noitativaC“gnidaehgniwollofeesoslA

lliwsihT.esaercnioterusserpwollaotsevlavegrahcsidehtetaG

.gnitteserusserplanigiroehtotgninepoelttorhtehtecudeR

.senilekatniregralro/dnaeromhtiwpmupehtotniwolfehtesaercnI

.erusserpniatniamdnawolfecuderotsevlavegrahcsidehtetaG

).etativac

kaeLriA

hgihootgnitfarD

hgih

nodeunitnoctrahC

egaptxen

!

.nepotonsiebutnoitcusehtnoredeelbriayfireV

.ecnanetniamgnirudskaelriallaetanimilednaetacoL

gnitimiltfilrehtodnaerutarepmetretaw,noitcirfesoh,ssoltfilyfireV

.detanimilerodecudererasrotcaf

!

ooterutarepmetretaW

!

.ecruosretawehtotresolcpmupehtetacoL

ehtgnitagroMPRehtgnirewolybdegrahcsidemulovecudeR

.sevlavegrahcsid

!

.retawreloocfoecruosaetacoL

Table 5-2: Troubleshooting - continued

Stainless Max Series Pumps 5-5

Troubleshooting

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

fognittestcerrocnI

EVLAVFEILER

-ERTONSEOD ERUSSERPEVEIL

!

evlav)DMP(lortnoc

.21-3egapnogninnigeb”,serudecorP

SEVLAVNEHW

DESOLCERA

evlaVfeileR

evitareponi

EVLAVFEILER

-ERTONSEOD

DNAREVOC

!

.etacirbuldnanaelc,eltnamsid

!

rofsnoitcurtsniwollofdnalaunamevlavfeilerehtotrefeR

.gnitacirbuldnagninaelc,gnilbmessasid

gnisuacmetsysnitriD

!

noitcaerwolsroykcits

.21-3egapnogninnigeb”,serudecorP

OTNRUTER

-SERPLANIGIRO

GNITTESERUS

GNINEPORETFA

SEVLAV

evlaVfeileR

evitareponi

!

.pilcrepapdenethgiartsroeriwllamsahtiwevlavehtnaelC

rofsnoitcurtsniwollofdnalaunamevlavfeilerehtotrefeR

.gnitacirbulfnagninaelc,gnilbmessasid

.metsysevlavfeilergnittesrofserudecorpreporptaeperdnakcehC

evlaVfeileR“gnidaeh",serudecorPgnitarepO":3noitceSeeS

,pmupmorfevlavfeilerevomeR.noitacirbulfodeenniylbissoP

.metsysevlavfeilergnittesrofserudecorpreporptaeperdnakcehC

evlaVfeileR“gnidaeh",serudecorPgnitarepO":3noitceSeeS

,gnisuohnielohniarD

EVLAVFEILER

NEHWSNEPO

EVLAVLORTNOC

gnisnesronotsip

dekcolbevlav

TUODEKCOLSI

OTELBANU

REPORPNIATBO

gnorwehtgnisU

erudecorp

NOGNITTES

!

.gnitacirbuldnagninaelc,gnilbmessasid

!

.21-3egapnogninnigeb

.pilcrepapdenethgiartsroeriwllamsahtiwevlavehtnaelC

rofsnoitcurtsniwollofdnalaunamevlavgnisnes/feilerehtotrefeR

3noitceSeeS.teserdnaevlavfilierfognittesrofsnoitcurtsnikcehC

",serudecorPevlaVfeileR"gnidaeh",serudecorPgnitarepO"

EVLAVFEILER

reniartsdekcolB

,evlavlortnocytriD

lanretni

noitidnocgnitnuH

nodeunitnoctrahC

egaptxen

!

pmupehtmorfenilylppusehtnireniartsehtnaelcdnakcehC

tcaxeehtroflaunamkcurtehtkcehC.evlavlortnocehtotegrahcsid

.noitacol

!

.naelcdnaevlavlortnocehtevomeR

.evlavlortnocehtotpmupehtmorfylppusretawtneiciffusnI

.evlavlortnocehtnaelcdnaevomeR

.sevlavlortnocdnafeilerehtotdetalersenilgnibutnaelcdnakcehC

.snoitcirtserwolfrofmetsysevlavfeilerdnareniartsehtkcehC

Table 5-2: Troubleshooting - continued

5-6 Stainless Max Series Pumps

Troubleshooting

POSSIBLE

SUGGESTED CORRECTIVE ACTIONCONDITION

CAUSE

EGRAHCSID

noitacirbulfokcaL

SEVLAV

OTTLUCIFFID

ETAREPO

ecnaraelc

PMUPNIRETAW

XOBRAEG

laes

morfgnimockaeL

pmupevoba

!

esU.evlavnoitcusdnaegrahcsidfonoitacirbulylkeewdednemmoceR

.esaergenocilisesabmuelortepfoedargdooga

!

edarGdooFetihW®ezieS-reveNesu,sevlaVSVSstcudorPelaHroF

.EFTPhtiw

!

eromfodeennievlaV

!

.noitamrofnilanoitiddaroflaunamevlavotrefeR

dnaecnaraelceromrofsteksaglanoitiddaswollangisedteksag-itluM

.noitarepoeerf

:etoN .egakaelsesuacyllautneveevlavehtotsteksagynamootgniddA

!

.xobraegpmupehtotnoyltceridgnillaf

lacinahcemgnikaeL

!

.dedeensaecalperdnalaeslioehttcepsnI

.31-6egapnogninnigeb

egallipselbissoprofwolfrevoknatdnasnoitcennocgnipipllakcehC

laesliofI.skaelonebtsumereht,dellatsnisilaeslacinahcemafI

eeS.decalperebotdeenyamlaeslacinahcemehtneht,KOskcehc

”ylbmessAlaeSlacinahceM“gnidaeh,ecnanetniaM:6noitceS

NOITATOR

SMOTPMYS

dellatsni

rellepmignorW

-06erusserpdecudeR( ]RAB9.6-1.4[ISP001

!

rellepmidloehtsaemasehtdetneiroerasenavrellepmiwenehtyfireV

.8-5egapno”,noitatoRenignE“:3-5erugiFeeS.gnillatsnierofeb

!

rofsnoitcurtsniwollofdnalaunamevlavgnisnes/feilerehtotrefeR

.gnitacirbuldnagninaelc,gnilbmessasid

)wolfdecuderdna

noitacilppagnorW

detpmetta

!

,dednetnitonsawtihcihwrofnoitacilppananodellatsnisawpmupehT

.tnuomraer.svtnuomtnorf.e.i

!ECITON

GNORWEHTHTIWROYLTCERROCNIPMUPEHTELBMESSAEROTELBISSOPSITI

LANIGIROEHTHTIWSTRAPTNEMECALPEREHTERAPMOCSYAWLA.STRAP

REWSNAOTSTCUDORPELAHTAECIVRESREMOTSUCTCATNOC.ERAWDRAH

.SNRECNOCROSNOITSEUQ

Table 5-2: Troubleshooting - End

Stainless Max Series Pumps 5-7

Troubleshooting

NOTES

Opposite

Engine

Rotation

Figure 5-3: Engine Rotation

Engine

Rotation

_________________________________________________________________________

5-8 Stainless Max Series Pumps

SECTION 6: MAINTENANCE AND REPAIR

OVERVIEW

This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Stainless Max (SM) series pump components. To completely dismantle the pump, gearbox, and/ or pedestal, follow the disassembly instructions in the order which they appear in this text. At any point in the disassembly process, the unit may be reassembled by following the instructions in the reverse.

Note: Unless otherwise indicated, these instructions apply to all Hale SM series pumps.

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, the proper tools and Hale genuine replacement parts before you attempt any repair maintenance.

Maintenance and Repair

For an illustrated pump overview, see heading SM Series Overview, beginning on page 6-43.

GENERAL REPAIR GUIDELINES

Due to the nature of a Hale SM series pump, most service can be performed without removing the pump assembly from the apparatus. However, the availability of room, options included, other equipment in the area, etc., will determine whether the unit must be removed from the apparatus for servicing.

If a catastrophic failure to the pump assembly (e.g., cracked pump body, internal seal or bearing failure, etc.) requires removal of the assembly from the apparatus see section “Pump Head” on page 6-17.

Before you begin...

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.

Stainless Max Series Pumps 6-1

Maintenance and Repair

Gearbox

(Model)

X

GH

RMS

Bolt Size

81-61/5

Recommended Oil Capacity

qts. (liters)

,09-W08,09-PEEAS

08-W57citehtnySro

05EAS

04-W51ot04-W01

)latsedeP(

liOenignEedargitluM

stnemeriuqeR5-LGIPA

Table 6-1: Recommended Lubricants

Material Minimum Torque

leetSdetalP-cniZ)32(71

leetSdetalP-cniZ

)kcolnolyn°063htiw(

eznorBnocilliS)41(3.01

)8.3(4

stnip5.1

)57.0(

fognitaRecivreSteeMtsuMsliOraeGllA

ft-lb (N-m)

)62(91

61-8/3

41-61/7

leetSdetalP-cniZ )14(03

leetSdetalP-cniZ

)kcolnolyn°063htiw(

eznorBnocilliS )42(81

leetSdetalP-cniZ)86(05

leetSdetalP-cniZ

)kcolnolyn°063htiw(

eznorBnocilliS)93(92

)14(03

)27(35

Table 6-2: Torque Values

Clearance Ring

(Front)

Impeller

Measurement

Table 6-3: Critical Measurements

6-2 Stainless Max Series Pumps

Maintenance and Repair

3. Match mark, tag and/or note the orientation of all mechanical and electrical components and connections to the pump, gearbox and/or pedestal before disconnecting or removing them. This aids in proper reassembly.

CAUTION !

BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP BODY.

4. Drain the inlet (suction) side of the pump body per your required procedures.

5. Remove the 14” NPT pipe plug from the pump body to drain any remaining fluid. Have a suitable container available to collect access fluid, approximately one to two gallons (3.8-7.6 liters).

6. Disconnect the suction and discharge piping, for example -

❑ adapter ring ❑ priming pump ❑ foam inductor ❑ tank fill line ❑ suction tube ❑ rams horn suction option ❑ victaulic suction option

Also disconnect cooling tubes from the water manifold and pump as required.

7. Remove the 1/4” NPT pipe plug from the pump body to drain any remaining fluid. Have a suitable container available to collect access fluid, approximately one to two gallons (3.8-7.6 liters).

Have clean disposable shop rags and oil dry handy.

8. If the gearbox or pedestal are being serviced, see Section 4: “Preventive Maintenance,” heading “Annually,” beginning on page 4-8 and drain oil from the gearbox and/or the pedestal.

9. Determine best method for servicing, i.e.., servicing while in the apparatus or removal from the top or bottom of the apparatus.

10. Always use proper lifting and support apparatus (cranes, hoists, straps, etc.) when servicing the unit. Avoid using chains to protect finished surfaces from scratches.

Stainless Max Series Pumps 6-3

Maintenance and Repair

WARNING !

THE SM SERIES PUMP AND GEARBOX ARE HEAVY AND BULKY (WEIGHING UP TO 750 TO 850 LBS. / 340 TO 386KGS. (APPROXIMATE). BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING SM SERIES PUMP AND GEARBOX ASSEMBLIES.

11. For lifting, tapped holes for eyebolts are provided to secure the assembly to your lifting apparatus. Where applicable, include a lifting strap to balance the load.

❑ SMR Series Pedestal - provides access for M10 x 1.5

eyebolt in the pump body, next to the discharge opening.

❑ SMD-A Series (HG Series Gearbox) - provides access for

M10 x 1.5 eyebolt in the pump body, next to the discharge opening.

❑ SMD-X or SMM-x Series (“X” Series Gearbox) - provides

access for two 5/8-11 eyebolts in the top machined surface of the gearbox.

12. When dropping the assembly out from the bottom use appropriate supports to brace and stabilize the assembly when disconnected from the drive shafts.

13. Make sure there is sufficient clearance above and around the apparatus to perform your service requirements. Obtain access to the pump assembly by removing or disconnecting as needed:

❑ valve operators ❑ discharge and suction piping ❑ other valves that might interfere with pump removal ❑ drive shafts ❑ air lines ❑ electrical wiring ❑ tachometer cable ❑ cooling lines

14. Where grease is called for, use a Lithium-based grease with 1% to 3% Molybdenum Disulfate. The following examples are approved greases:

❑ Dow Corning BR2-PLUS ❑ Lubriplate-Fiske #3000 ❑ Shell Super Duty Grease

6-4 Stainless Max Series Pumps

Maintenance and Repair

❑ Imperial #777 ❑ Mobil Grease Special

❑ Sunoco Moly #2EP

Also see Table 6-1: “Recommended Lubricants” on page 6-2.

15. When replacing fasteners, use the proper nuts, bolts, and other hardware.

Many are specifically rated; that is, SAE Grade 5 or higher and must be replaced with the identical type. Apply a coating of Loctite 242 or 246 High Temperature Removable Thread Locker (or equal) before installing.

°

Replacement steel fasteners must be Grade 5, 360

nylon patch-

lock fasteners. Apply Loctite 242 or 246 (or equal) to all threads.

16. It is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators.

17. Before installing the mechanical seal, use alcohol swabs provided by Hale Products Inc. to clean all grease or oil from the pump shaft and bearing housing.

When installing the mechanical seal, apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) on the rubber seal parts to ease installation.

WARNING!

USE OF ANY OTHER LUBRICANT CAN DAMAGE THE MECHANICAL SEAL AND SEAT.

18. Use a brass drift or a bearing installation tool, when installing various gear bearings to avoid marking the bearing faces.

19. Before releasing the apparatus into operation, the pump assembly must be tested and checked for leaks. All leaks must be repaired immediately.

Cleaning and Inspection Guidelines

Wherever procedures call for cleaning and inspection, use the following guidelines:

❑ Inspect all components for excessive or abnormal wear.

Stainless Max Series Pumps 6-5

Maintenance and Repair

IMPORTANT!

WHEN REASSEMBLING, ALL COMPONENTS MUST BE CLEAN AND FREE OF DEFECTS.

❑ 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.

❑ Wherever gaskets are removed, the gasket must be replaced.

Clean all gasket material from mating surfaces before installing a new gasket. Be careful not to score the finished surfaces.

❑ Bearings and seals should be inspected whenever the parts are

disassembled.

● Bearings and other components should be cleaned using only

recommended solvents.

● Inspect bearings for wear, pitting, and damage.

● Lightly oil or grease the shaft, O-ring seals and bearings

before installing bearings and spacers, especially when pressed-in.

❑ Inspect the gear tooth surface for wear damage and pitting.

Replace all components that are worn, damaged, or pitted.

❑ When inspecting the impellers and clearance rings for wear,

measure the impeller hub diameter and the inner diameter of the clearance ring, using a digital caliper. If measurements indicate, replace clearance rings and impeller. See Figure 6-3: “Critical Dimensions” on page 6-2.

❑ It is recommended to replace O-ring seals to avoid unnecessary

downtime later on.

❑ Replace any hardware that shows signs of excessive wear.

Note: If either the impeller hub or clearance rings are out of tolerance, both rings and the impeller must be replaced, as well as the mechanical seal.

Recommended Cleaners

Hale Products recommends:

❑ Safety Kleen ❑ Stoddard Solvent

Tools Required

❑ Lifting gear-lever hoist or chain hoist, and short choker

6-6 Stainless Max Series Pumps

Maintenance and Repair

❑ Ball peen hammer ❑ Center punch ❑ Drift punch ❑ Allen wrenches ❑ Strap wrench ❑ Snap ring pliers ❑ Pry bars (2) ❑ Ratchets and wrenches for disassembly ❑ Torque wrench, capable of 40, 65, and 135 ft.-lb. (54, 88, and

183 N-m)

❑ Pan (to collect drip oil) ❑ Disposable rags ❑ Oil dry ❑ Wood wedges ❑ Bearing puller ❑ Pusher tube (a small section of PVC tubing to fit over the shaft)

PUMP AND GEARBOX ASSEMBLY

WARNING !

THE SM SERIES PUMP AND GEARBOX ARE HEAVY AND BULKY, WEIGHING UP TO 750 TO 850 LBS./ 340 TO 386KGS (APPROXIMATE). BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING SM SERIES PUMP AND GEARBOX ASSEMBLIES.

The following procedures frequently refer to Tables 6-1, 6-2 and 6-3 on page 6-2. Also, please review the General Repair and Cleaning and Inspection Guidelines before beginning these procedures.

Removing Pump Assembly from Apparatus

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. With the pump assembly properly supported and balanced, disconnect the mounting brackets that secure the pump and gearbox assembly to the apparatus.

3. Carefully remove the assembly from the apparatus.

Stainless Max Series Pumps 6-7

Maintenance and Repair

4. Place and support the pump assembly on a stable work stand / bench of suitable capacity (see WARNING ! on page 6-7). Have the air vent and covers exposed to provide easy and safe access to the internal parts.

Installing Pump Assembly to Apparatus

After completing repairs and /or maintenance, install the pump assembly to the apparatus before filling with oil.

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Attach proper supporting devices and stabilize the assembly for transport to the apparatus.

3. Place the pump assembly into position within the apparatus.

4. Connect the mounting brackets using the proper fasteners. Torque the fasteners to values provided in Table 6-2: “Torque Values” on page 6-2.

5. Connect the drive shaft to the gearbox/pedestal. Apply Loctite to the fasteners and torque to PTO manufacturer's specifications.

6. Fill the gearbox and / or pedestal, if included, to the proper oil level. See Section 4: “Preventive Maintenance,” heading “Annually,” beginning on page 4-8 and add oil to the gearbox and/or the pedestal.

Use only oil with an API GL-5 rating. See Table 6-2: “Recommended Lubricants” on page 6-2 for recommended oils and gearbox/pedestal capacities.

7. Reassemble and reconnect all components removed to gain access to the pump assembly, paying particular attention to your sketch and identification match markings/ tags.

8. Test the pump for proper operation per your departmental requirements. Note and repair any leaks.

9. Recheck and top off oil levels. See Section 4: “Preventive Maintenance,” heading “Annually,” beginning on page 4-8 and add oil to the gearbox and/or the pedestal.

10. Return the apparatus to normal operation.

6-8 Stainless Max Series Pumps

Maintenance and Repair

Pump Body

(Volute)

O-ring Seal

Water Drain

Suction Cover

Plate

O-ring Seals

( 1 each )

Adapter Ring

Options: Rams Horn Suction Victaulic Suction

Port

Sealing Screw

Pump Head

O-ring Seal

Suction Inlet

6” (152 mm)

Impeller Pump

Shaft

O-ring Seal

Mechanical Seal

Key

Pump Shaft

Seal Retaining

Washer

Rear Wear

Ring

Impeller Nut

O-ring Seal

Pump Body

(Volute)

O-ring Seal

Clearance

Ring

Impeller

O-ring Seal

Lock Washer (pair)

Figure 6-4: Stainless Max Pump Assembly

SERVICING THE SM PUMP

Note: Servicing the pump shaft is discussed later in this manual in the

appropriate gearbox/pedestal service sections.

Suction Tube and Front Clearance Ring

See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. With the suction components removed, exposing the clearance ring (bronze), thread three jacking screws (M10) into the tapped holes adjacent to the bolt-down holes.

Evenly tighten the jacking screws until the suction cover plate is free (removable by hand).

Stainless Max Series Pumps 6-9

Maintenance and Repair

Note: The front clearance ring includes two identical O-rings. One face-mounted towards the suction tube and the other mounted in a groove behind the flange.

Inspection

See Figure 6-3: “Critical Dimensions” on page 6-2. Also see Figure 6-5: “Clearance Ring Measurement.”

Inspect clearance ring ID for signs of wear. Using a digital caliper, measure the inside diameter of the clearance ring in several places. (See A in Figure 6-

5.)

Figure 6-5: Clearance Ring

❑ New clearance ring

diameter:

7.362" to 7.366" (187.0 -187.1 mm)

❑ Wear Limit:

7.38" (187.5 mm)

Measurement

If the measured dimensions do not fall within the acceptable ranges specified, the clearance ring must be replaced.

Installation Notes

To install, follow the preceding steps in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

Impeller

See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Repeat Step 2 of preceding section “Suction Tube and Front Clearance Ring,” beginning on page 6-9.

6-10 Stainless Max Series Pumps

Maintenance and Repair

3. Remove the twelve M12 bolts and hardware securing the suction cover plate (with O-ring) to the volute (pump body).

4. Insert three jacking screws (M12) into the tapped holes adjacent to the bolt-down holes. Evenly tighten the jacking screws until the suction cover plate is free (removable by hand).

5. Remove the tachometer sender, if equipped.

6. While holding the impeller with a strap wrench, remove the impeller nut, then the lock washer (pair). Note orientation of the lock washers for reassembly.

Note: Tap the pump shaft at the threads, using a dead blow hammer, to free the impeller from the pump shaft. It may be necessary to use a special tool, Hale p/n: 60275/04, to remove the impeller from the pump shaft.

CAUTION!

DO NOT STRIKE THE IMPELLER. IRREPARABLE DAMAGE COULD RESULT.

7. Slide the impeller from the pump shaft, then remove the impeller shaft key and set safely aside.

Inspection

See Figures 6-3: “Critical Dimensions” on page 6-2, and Figure 66: “Impeller Measurement.” Also see Table 6-7: “Impeller Specifications” on page 6-12.

Inspect the clearance ring ID for signs of wear. Measure the front (ID) and the rear (OD) diameters of the impeller in several places, using a digital caliper.

If the measured diameter is equal to or less than the worn range in Table 6-7, a

Figure 6-6: Impeller Measurements

new impeller must be installed.

Stainless Max Series Pumps 6-11

Maintenance and Repair

Front (A)

new/ limit

.7-"643.7"843

)mm56.681-6.681(

7.581("13.7)mm

Table 6-7: Impeller Specifications

Rear (B)

new/ limit

.7-"632.7"042

)mm9.381-8.381(

2.481("52.7)mm

Installation Notes

To install, follow the preceding instructions in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ Install the impeller shaft key into the slot on the pump shaft. ❑ Carefully slide the impeller over the pump shaft, aligning the

keyway with the impeller key.

❑ Make sure the “new” lock washers are installed with the

locking ridges facing each other.

❑ Torqued the impeller nut to 295 ft.-lb. (400 N-m).

Rear Wear Ring

See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Remove the front clearance ring and the impeller as described in the previous sections, beginning on page 6-8. The rear wear ring and mechanical seal assembly are now exposed.

3. Remove the six M8 socket head screws securing the rear clearance ring to the pump rear cover plate.

Inspection

See Figures 6-3: “Critical Dimensions” on page 6-2, and Figure 6-8: “Wear Ring Measurements” on page 6-13.

6-12 Stainless Max Series Pumps

Inspect wear ring OD for signs of wear. Measure the outside diameter) of the clearance ring in several places, using a digital caliper. (See X in Figure 6-8.)

Maintenance and Repair

❑ New clearance ring

diameter:

Figure 6-8: Wear Ring Measurements

7.220" to 7.222" (183.4-183.5mm)

❑ Wear Limit: 7.200" (182.8mm)

If the measured dimensions do not fall within the acceptable ranges specified, the wear ring must be replaced.

Installation Notes

To install, follow the preceding steps in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ Install the impeller shaft key into the slot on the pump shaft. ❑ Carefully slide the impeller over the pump shaft, aligning the

keyway with the impeller key.

❑ Make sure the “new” lock washers are installed with the

locking ridges facing each other.

❑ Torqued the impeller nut to 295 ft.-lb. (400 N-m).

Mechanical Seal Assembly

See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

IMPORTANT !

IF EXCESSIVE LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS NOTICED OR SUSPECTED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED.

Stainless Max Series Pumps 6-13

Maintenance and Repair

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Remove the front clearance ring, the impeller and the rear wear ring as described in the previous sections, beginning on page 6-9. The mechanical seal assembly is then exposed.

CAUTION!

MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICES. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE MATING FACES. ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION. SOLID FACES MUST BE CLEANED WITH AN APPROPRIATE DEGREASER AND A SOFT CLOTH.

3. Remove the seal head assembly from the pump body by removing the two nyloc-nuts and washers. To remove the washers, you must gently remove the seal head assembly at the same time, being careful not to lose the wave washer (spring). See Figure 6-9: “Mechanical Seal Assembly.”

Seal

Assembled

Mating

Ring

Disassembled

Seal Head Assembly

O-ring

Seal

Wave Washer

Seal

Seal Head Assembly

Mating

Ring

Nyloc-Nut

Seal

Retaining

Washer

O-ring

Seal

Seal Head Assembly

Rear Cover Plate

(Pump Body)

Pump/ Impeller Shaft

Wear Ring

Figure 6-9: Mechanical Seal Assembly

Impeller

Stud (2)

Mating Ring

Assembly

Impeller

Carbon

Face

Note: The stationary carrier may only by left in place if the wearing

faces are the only replacements being made.

6-14 Stainless Max Series Pumps

Maintenance and Repair

4. Remove the silicon carbide mating ring, fitted in the rear side of the impeller. A small screwdriver should be inserted between the ring and its rubber cap. The ring can then be carefully pried free. See Figure 6-9: “Mechanical Seal Assembly” on page 6-14.

5. Examine the carbon face and mating ring matching face. If either is scored you must replace the mechanical seal assembly. Order Hale p/n: 60022/01.

Installation

See Figure 6-9: “Mechanical Seal Assembly” on page 6-14.

1. See CAUTION! warning on preceding page (6-14).

2. 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. Solid faces must be cleaned with appropriate degreasing cleaner and soft rags.

3. Apply a generous coating of Pac-Ease Rubber Lubricant Emulsion (or equal) to the O-ring on the seal head assembly and the pump shaft and seal areas.

WARNING!

USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUAL) ON THE RUBBER MECHANICAL SEAL PARTS TO EASE INSTALLATION. USING ANY OTHER LUBRICANT CAN DAMAGE THE SEAL AND SEAT.

4. Without touching the carbon seal, slide the wave washer and the seal head onto the pump shaft.

Seat the seal head against the pump housing making sure the cutouts in the seal head align with the threaded studs.

5. Install the washer to the studs, followed by the nyloc-nuts – hand tightened only. See Figure 6-9: “Mechanical Seal Assembly” on page 6-14.

Continue tightening all the nyloc-nuts evenly, half-a-turn at a time, until the seal head is pulled squarely into the pump body. Ensure the nuts are fully secured.

6. Verify that the carbon face of the seal head is clean and free from grease. Apply clean water to the carbon face to ensure cleanliness.

Stainless Max Series Pumps 6-15

Maintenance and Repair

7. With the impeller bores and all surfaces of the mating ring assembly clean, carefully push the mating ring assembly into the impeller bore. A special “fitting tool” may be needed, order Hale p/n: 60275/08.

Make sure that the face of the mating ring assembly is squared to the impeller housing within 0.00393” (0.1 mm).

8. Carefully fit the impeller onto the pump shaft, then reassemble the pump per preceding heading “Installation Notes” of section “Rear Wear Ring,” beginning on page 6-12.

If binding occurs apply additional lubricant or clean water. Also see WARNING! note on preceding page.

Volute (Body)

See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

The volute is sandwiched between the suction cover plate and the rear pump plate. It is secured by twelve screws, washers and nuts. Both cover plates are sealed at the front and rear faces with O-ring seals. The O-ring seals must be replaced whenever a joint face is disturbed.

The volute is mounted for either standard (clockwise) rotation, as viewed from the suction inlet, or reverse (counterclockwise) rotation. Notice the ARROW in the volute casting, near the discharge outlet, for rotation direction.

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Remove the suction apparatus and front clearance ring as described in the previous heading “Suction Tube and Front Clearance Ring,” beginning on page 6-9. The impeller, rear wear ring and mechanical seal assembly do not need to be removed.

3. Remove the twelve M12 bolts and hardware securing the suction cover plate (with O-ring) to the volute (pump body). See Figure 6-4: “Stainless Max Pump Breakdown” on page 6-9.

4. Insert three jacking screws into the tapped holes adjacent to the bolt-down holes to assist in pulling the plate from the volute. Evenly tighten the jacking screws until the suction cover plate is removable by hand.

6-16 Stainless Max Series Pumps

Maintenance and Repair

5. Remove the twelve nuts and hardware to dismantle the volute from the rear cover plate. Pull the volute body from the assembly being careful not to damage the impeller or scratch the sealing surfaces of the volute.

Note: A dead blow hammer may be needed. Tap, in a crisscross pattern, around the volute until it is separated from the cover plate.

Installation Notes

To install, follow the preceding steps in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ Replace all O-ring seals in the suction and rear cover plates.

It is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators.

❑ If you are changing from standard to reverse rotation, flip the

volute 180° horizontally, having the cast ARROW pointing in the counterclockwise direction, as viewed from the suction inlet.

PUMP HEAD

To service the oil seal between the pump and gearbox or pedestal mount or to service the gearbox or pedestal mount, you must dismantle the pump head from either unit.

Removing the Pump Head

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. As described in the previous sections, remove the -

❑ front clearance ring (on page 6-9) ❑ impeller (on page 6-10) ❑ rear wear ring (on page 6-12) ❑ mechanical seal (on page 6-13)

3. Remove the six nuts and hardware securing the pump body to the bearing housing portion of the gearbox or pedestal.

Stainless Max Series Pumps 6-17

Maintenance and Repair

4. Using a soft faced (dead blow) hammer, carefully tap around the pump body until it is separated from the bearing housing.

Note: If the pump head is assembled to a pedestal mount, there are two guide pins affixed to the bottom portion of the rear pump cover. These pins slide free of the pedestal as the two parts are separated.

Installation Notes

To install, follow the preceding instructions in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ All critical internal components must be inspected to

tolerances. See heading “Inspection” in previous sections:

● front clearance ring (on page 6-9)

● impeller (on page 6-11)

● rear wear ring (on page 6-12)

● mechanical seal (on page 6-13)

❑ Replace all O-ring seals in the suction and rear cover plates

and the two primer feed tube bores.

It is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators.

❑ Align the pump body (two guide pins, where applicable) with

the feed connections and the six threaded studs.

PEDESTAL MOUNT

Front Oil Seal

See Figure 6-10: “Front Oil Seal Breakdown, Pedestal” on page 6-19.

Removal

The oil seal is located between the pump body and the pedestal assembly, within the bearing/seal housing. The pump head must be removed to gain access to this seal.

6-18 Stainless Max Series Pumps

Maintenance and Repair

O-ring Seal

(Seal Housing)

Oil Seal

Seal Housing

Seal Flinger

Oil Seal

Seal Housing

O-ring Seal

Seal Wear

Ring

Bearings

Pump Shaft

Seal Flinger

O-ring Seal

Bearing

Housing

Oil Seal

Seal Housing

Pump Head

Figure 6-10: Front Oil Seal Breakdown, Pedestal

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Drain oil into an appropriate container from the gearbox or pedestal. See Figure 6-1: “Recommended Lubricants” on page 6-2, for oil capacities. Also see Section 4: “Preventive Maintenance,” headings:

❑ Replace Gearbox Oil, on page 4-8 ❑ Replace Pedestal Oil - SMR Series, on page 4-9

3. Remove the pump head as described in the previous heading “Pump Head,” beginning on page 6-17.

This exposes the following parts between the pedestal seal housing and its roller bearings -

❑ Seal flinger ❑ Seal wear ring ❑ O-ring seal ❑ Seal housing ❑ Oil seal ❑ O-ring seal, under side of seal housing

Stainless Max Series Pumps 6-19

Maintenance and Repair

4. Remove the six nuts and hardware securing the oil seal housing to the bearing housing. Slide the housing from the pump shaft. See Figure 6-10: “Front Oil Seal Breakdown, Pedestal” on page 6-19.

5. Press the oil seal from the housing and discard.

6. Remove and examine the pedestal O-ring seal and the seal wear ring, mounted on the pump shaft. If either is defective, it must be replaced.

For O-ring, order Hale p/n: 55837; for seal wear ring, order Hale p/n: 60012.

Installation Notes

See Figures 6-10: “Pedestal Oil Seal Breakdown” on page 6-19.

To install, follow the preceding step in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ Evenly press-in a new oil seal in the housing until flush with

the housing lip. See Figure 6-10: “Front Oil Seal Breakdown, Pedestal” on page 6-19. Lightly tap the seal around the edges to ensure an “even” seat.

❑ Place the assembly onto the main bearing housing and thread

the six hex nuts and hardware finger-tight only.

❑ In a crisscross pattern, tighten the six hex nuts ensuring that

the seal housing seats flat against the face of the bearing.

❑ Torque the six nuts to 21 ft.-lb. (28 N-m) using 5 ft.-lb.

(6.8 N-m) increments.

❑ Insert the seal flinger, then reinstall the pump head. ❑ Add fresh oil. See Figure 6-1: “Recommended Lubricants” on

page 6-2, for oil capacities. Also see Section 4: “Preventive Maintenance,” headings:

● Replace Gearbox Oil, on page 4-8

● Replace Pedestal Oil - SMR Series, on page 4-9

❑ Reassemble the pump. See section “Pump Head,” heading

“Installation Notes” on page 6-17.

6-20 Stainless Max Series Pumps

Maintenance and Repair

Rear Oil Seal

See Figure 6-11: “Rear Oil Seal Breakdown, Pedestal.”

Lock Washers

(pair)

Nut, Pump

Shaft

Oil Seal

Tachometer

Option

Rear Oil Seal

Wear Ring

Drive Flange

Gasket, Seal Housing

Rear Seal

Housing

Wear Ring

Nut, Pump

Shaft

Lock Washers

(pair)

Pump (Impeller)

Seal Housing and

Gasket

Figure 6-11: Rear Oil Seal Breakdown, Pedestal

Bearing

Shaft

If the pedestal is installed to a gearbox or other apparatus, dismantle the attached apparatus from the pedestal before servicing its internal components.

For gearbox instructions, see separate sections later in this manual.

For attached apparatus, see separate manual provided by apparatus manufacturer.

The rear oil seal is located at the tail end of the pedestal assembly, within the rear seal housing.

Removal

1. First, review preceding section “Before You Begin...,” beginning on page 6-1.

2. Drain oil into an appropriate container from the pedestal and/ or gearbox. See Figure 6-1: “Recommended Lubricants” on page 6-2, for oil capacities.

Stainless Max Series Pumps 6-21

Maintenance and Repair

Also see Section 4: “Preventive Maintenance,” headings:

❑ Replace Gearbox Oil, on page 4-8 ❑ Replace Pedestal Oil - SMR Series, on page 4-9

3. Disconnect tachometer sender option, if equipped.

4. With the tail end of the pump (impeller) shaft exposed, remove the hex nut and lock washer pair. See Figure 6-11: “Rear Oil Seal Breakdown, Pedestal” on page 6-21. A strap wrench may be needed to hold the shaft while removing the nut.

5. Remove the drive flange and shaft key and set safely aside.

6. Remove the four screws and hardware securing the oil seal housing to the bearing housing. Slide the housing from the pump shaft. See Figure 6-11: “Rear Oil Seal Breakdown, Pedestal” on page 6-21.

7. Remove and examine the O-ring seal and the seal wear ring, mounted on the pump shaft. Both must be replaced.

For O-ring, order Hale p/n: 05682/02; for seal wear ring, order p/n: 60008.

Installation Notes

See Figures 6-11: “Rear Oil Seal Breakdown” on page 6-21.

To install, follow the preceding steps in the reverse order, paying attention to the following:

❑ Review preceding section “Before You Begin...,” beginning on

page 6-1.

❑ Pay attention to section “Cleaning and Inspection Guidelines,”

beginning on page 6-6 to ensure a thorough installation.

❑ Evenly press-in a new oil seal in the housing until flush with

the housing lip. See Figure 6-10: “Rear Oil Seal Breakdown” on page 6-21. Lightly tap the seal around the edges to ensure an “even” seat.

❑ Place the assembly onto the main bearing housing and thread

the four screws and hardware finger-tight only.

Note: The tapped boss for the tachometer sender option must be towards the top of the bearing housing, as viewed from the drive end.

❑ In a crisscross pattern, tighten the screws ensuring that the

seal housing seats flat on the face of the bearing.

6-22 Stainless Max Series Pumps

Hale SMR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual