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

Hale SMR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual