Pump Ends (Series 20FS, 30FS, 40FB, 50FB, 50FB-U-U, 50FB-U-M, 60FB, FB50, FB75, FB100, 80FC) Installation, Operation and Service 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 Web......www.haleproducts.
NOTICE ! Hale Products, Inc. cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice. All Hale products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested.
Table of C ont ents ❑ Contents Page Pump Ends, Pumping Systems 1 Safety Precautions................................................................................................. 11 1.1 1.2 1.3 1.4 2 Definitions......................................................................................................................... 12 General .............................................................................................................................. 13 Fuel Safety ..................
❑ Ta ble of Contents Contents - continued 2.4 Page Pump Components - continued Mechanical Seal ............................................................................................................................... 34 Figure 2-14: Typical Mechanical Seal Overview ................................................................ 34 Ball Bearings .................................................................................................................................... 35 2.5 2.
Table of C ont ents ❑ Contents - continued 3.4 Page Pumping Operations ........................................................................................................ 46 Initial Start Up ...................................................................................................................................46 Pumping Operations .........................................................................................................................
❑ Ta ble of Contents Contents - continued 4.5 Page Monthly - continued Pump and Flange Bolts .................................................................................................................... 61 Priming System Test (Dry Vacuum Test) ......................................................................................... 61 Figure 4-3: PVG Priming Valve Handle .............................................................................. 61 4.6 Annually................................
Table of C ont ents ❑ Contents - continued 6 Page Repair ..................................................................................................................... 79 6.1 6.2 Overview ........................................................................................................................... 79 General Repair Guidelines .............................................................................................. 79 Before You Begin..............................................
❑ Ta ble of Contents Contents - continued Page Pump Head Assembly – 30 FS Series Only - continued Pump Shaft Oil Seal, 30 FS Series ............................................................................................ 98 Figure 6a-7: Replacing 30 FS Series Pump Shaft Oil Seal ................................................ 98 Installation Notes – Pump Head, 30 FS Series.........................................................................
Table of C ont ents ❑ Contents - continued Page 6c.3 50 / 60 / 80 FBG Series Gearbox - continued Installation Notes – Pump Shaft and Seal, 50/60/80 FBG.............................................................. 122 Gearbox and Bell Housing Assemblies .......................................................................................... 123 Bell Housing (Flywheel) Adapter.............................................................................................. 123 Drive Shaft Oil Seal..........
❑ Ta ble of Contents Contents - continued Page Appendix E: Nozzle Size vs. Pressure................................................................ 143 Chart E-1: Nozzle Flow and Pressure Ratings, Part 1 ..................................................... 143 Chart E-2: Nozzle Flow and Pressure Ratings, Part 2 ..................................................... 144 Appendix F: Cavitation.......................................................................................
❑ Saf ety 1 Safety Precautions IMPORTANT ! HALE PUMP ENDS (SERIES 20* THROUGH 80*) ENGINE MOUNTED PUMPING SYSTEMS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL. ALL SUPPLIED DOCUMENTATION (ENGINE, HALE PUMP MANUALS, ETC.
❑ Sa fet y NOTICE ! - continued ALSO REVIEW THE SAFETY INFORMATION FOUND IN THE ENGINE MANUFACTURER’S OPERATING AND MAINTENANCE MANUAL, PROVIDED WITH THE ENGINE. 1.1 DEFINITIONS DANGER ! DANGER - Immediate hazard which WILL result in severe personal injury or death if the warning is ignored. WARNING ! WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death if the warning is ignored.
❑ Saf ety Eye Protection required when operating equipment Flammable Fuel Hazard Hearing Protection required when operating equipment Hot Surfaces Hazard 1.2 GENERAL Read all instructions, including the Engine Manufacturer’s Operating and Maintenance Manual, thoroughly before beginning any installation, service or operation process. ❑ Use care when removing the pump assembly from its packaging to prevent personal injury and/or damage to the system.
❑ Sa fet y ❑ 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. ❑ Fluids - To meet various shipping regulations, oil is drained from the gearbox (or pedestal unit) reservoir prior to shipping from the factory. At installation and before operation, oil must be added to the appropriate levels. (See Section 4, heading “ Replace Gearbox Oil,” on page 59.
❑ Saf ety WARNING! NO MODIFICATIONS MAY BE MADE TO THE HALE PUMP END ASSEMBLY WITHOUT PRIOR WRITTEN PERMISSION FROM: Hale Products, Incorporated Fire Suppression Division 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ..........610-825-6300 Fax .....................610-825-6440 Web....................www.haleproducts.
❑ Sa fet y Large diameter hose, marked “Supply Hose 6” to 5” (152 mm) diameter” shall not be used at operating pressures exceeding 135 PSI (9 BAR). ❑ If leakage from the drain hole in the pump head is noticed or suspected, the mechanical seal must be inspected and/or replaced. ❑ If a pump is operated without water for extended periods, or without discharging water, it could overheat. This can damage the mechanical seal, impeller or the drive mechanism. ❑ Keep equipment, i.e.
❑ Saf ety WARNING ! - continued ❑ Gasoline is a highly combustible fuel. The improper use, handling or storage of gasoline can be dangerous. Prevent accidents by following these safety recommendations, plus those furnished by your regional safety ordinances or departmental procedures: ● Use gasoline as a fuel, NEVER as a cleaning fluid. ● Use only an approved container to hold or store gasoline. NEVER store gasoline in familiar containers, such as milk containers or soap bottles.
❑ Sa fet y WARNING ! ❑ Always assume the battery is emitting hydrogen and employ proper safety precautions. ❑ Do not smoke, use an open flame, or create arcs or sparks near the battery. ❑ Consult the label on your battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. ❑ Packaged with every battery are specific instructions for battery safety, care and use, and a Material Safety Data Sheet (MSDS).
Introduction 2 ❑ Overview 2.1 PUMP ENDS Figure 2-1: Typical Pump End Pumping Systems The Hale Pump End Series Pumping Systems fulfill many types of in-service fire fighting applications. The pumps are available in configurations providing a wide range of pressures and flows to suit most user requirements in a transportable unit. (See Figure 2-1: “Typical Pump End Pumping Systems.
❑ Introduction ❑ Pump delivers discharge pressures up to 800 PSI (55 BAR) and flow rates up to approximately 100 GPM (379 LPM / 6 LPS), NFPA 1901 performance rated. ❑ Suction — 2” (51 mm) female NPT flange ❑ Discharge — 1-1/2” (38 mm) female NPT 30FS2 / 30FS3 / 30FS4 Series, with Gearbox ❑ Standard centrifugal pump and gearbox assembly with universal mounting bracket designed to bolt directly to either SAE #8 or #10 engine flywheel housing and available for gasoline or diesel engines.
Introduction ❑ 60FBG Series, with Gearbox ❑ Standard centrifugal pump and gearbox assembly with universal mounting bracket designed to bolt directly to either SAE #2 or #3 engine flywheel housing and available for gasoline or diesel engines. ❑ Pump delivers discharge pressures up to 250 PSI (17 BAR) and flow rates up to approximately 1,500 GPM (5,678 LPM / 95 LPS), NFPA 1901 performance rated.
❑ Introduction NOTICE ! PERFORMANCE OF PUMP END PUMPING SYSTEMS MEET OR EXCEED NFPA 1921 REQUIREMENTS. FOR COMPLETE NFPA 1921 COMPLIANCE, THE PUMPING UNITS MUST BE MARKED WITH SPECIFIC LABELS. CONSULT FACTORY IF THESE LABELS ARE REQUIRED. 2.2 PUMPING SYSTEM OVERVIEW ❑ Typical 20FS Series — see Figure 2-2: “Typical 20FS Series Pump Sys- tem Overview” on page 23. ❑ Typical 30FS Series — see Figure 2-3: “Typical 30FS Series Pump Sys- tem Overview” on page 24.
Introduction ❑ Figure 2-2: Typical 20FS Series Pump System Overview Pump Ends p/n: 029-0020-61-0 23
❑ Introduction Figure 2-3: Typical 30FS Series Pump System Overview 24 Pump Ends p/n: 029-0020-61-0
Introduction ❑ Figure 2-4: Typical 40 / 50FB Series Pump System Overview Pump Ends p/n: 029-0020-61-0 25
❑ Introduction Figure 2-5: Typical FB50, FB75 and FB100 Series Engine Mount Pump End Overview 26 Pump Ends p/n: 029-0020-61-0
Introduction ❑ Figure 2-6: Typical 60FBG Series Pump System Overview (Shown with G Series Gearbox) Pump Ends p/n: 029-0020-61-0 27
❑ Introduction Figure 2-7: Typical 80FC Series Pump System Overview (Shown with Engine Mount Bell Housing) 28 Pump Ends p/n: 029-0020-61-0
Introduction ❑ Figure 2-8: Typical 80FC-U Series Pedestal Pump System Overview Pump Ends p/n: 029-0020-61-0 29
❑ Introduction Figure 2-9: Check Valve Option, Discharge (Size determined by pump discharge) 30 Pump Ends p/n: 029-0020-61-0
Introduction 2.3 ❑ PRINCIPLES OF OPERATION Centrifugal Force Hale pumps are centrifugal pumps that operate on the principle of centrifugal force created by a rapidly spinning disk. (See Figure 2-10: “Centrifugal Force - Rotating Disk.”) As the disk is rotated, it throws water from the center toward the outer circumference of the disk. The velocity at which the water travels from the center directly relates to the diameter of the disk and the speed of rotation.
❑ Introduction As the impeller rotates, the water moving outward in the impeller creates reduced pressure or a vacuum in the suction eye allowing atmospheric pressure to push water into the pump impeller, replacing the water discharged. (See Figure 2-11: “Pump Water Flow, Cutwater.”) During operation water enters the suction eye of the impeller. The rotating impeller vanes develop discharge pressure and via the “cutwater *,” directs the water to the discharge opening.
❑ Introduction This gradual increase in size maintains a constant average velocity through the volute. The volute is a single piece, and must be removed to service the impeller, clearance rings, and mechanical seal. Removal of the volute can often be accomplished without removing the pump and gearbox assembly from the apparatus. Figure 2-12: Typical Pump and Gearbox Overview Impeller The impeller provides velocity to the water.
❑ Introduction Clearance Rings Clearance rings prevent pressurized water that is leaving the pump volute from returning to the intake of the impeller. Clearance rings at the impeller intake also prevent leakage, accomplished by limiting the radial clearance between the spinning impeller and the stationary clearance ring. Also see Figure 2-12: “Typical Pump and Gearbox Overview” on page 33. Typically, a clearance ring has a radial clearance of about 0.0075” (0.191 mm) or between 0.015” to 0.020” (0.381-0.
❑ Introduction Ball Bearings Ball bearings support and align the impeller and input shafts for smooth operation. They are the most common anti-friction bearings used and offer a major contribution to the life of a fire pump. 2.5 GEARBOX OPTION Hale pumps can be equipped with an all ball bearing-type gearbox, utilizing helical gears to reduce operating noise. To accommodate a wide range of engines, this speed increasing gearbox is available in a variety of ratios.
❑ Introduction The pedestal is constructed of fine grain cast iron, and consists of bearings, an oil seal and an oil reservoir. 2.7 HALE ENGINE MOUNT BELL HOUSING Model pump ends are available with an adapter to accept #2, #3, #4 and #5 SAE bell housings. Elastomeric drive discs are also available for 10” (254mm) and 11.5” (292mm) clutch discs. (See Figure 2-16: “Bell Housing Mount,” on page 36.
❑ A cc es sorie s / O ptions 2a Accessories / Options The following accessories and /or options are available to complete a system installation: ❑ Anodes ❑ Auxiliary Cooling, standard on some equipment ❑ Pressure Control Devices (Relief Valves or Governors) ❑ Thermal Relief Valve (TRV) ❑ Priming Systems ❑ Torrent Stainless Steel SVS Valves 2A.1 ANODES The Hale Anode System helps prevent damage caused by galvanic corrosion in the pump.
❑ Ac ce ss orie s / O pt ions 2A.2 AUXILIARY COOLING Gearbox Manifold Coolers Figure 2a-2: Typical Gearbox Manifold Coolers For pumps not equipped with standard gearbox cooling, a cooler option is available. (See Figure 2a-2: “Typical Gearbox Manifold Coolers.”) The gearbox cooler circulates pump water to transfer heat from the gearbox oil to the pump discharge, thus maintaining proper operating temperatures. Heat Exchanger, “K” Series The Hale Model “K” heat exchangers, meet NFPA 1901 requirements.
❑ A cc es sorie s / O ptions Figure 2a-3: Model “K” Heat Exchanger P Series Relief Valve System The P Series relief valve system is a bronze, variable-pressure setting, relief valve that prevents undue pressure per the requirements of NFPA Standard 1901. An AMBER indicator light on the operator control panel signals when the valve is open. (See Figure 2a-4: “P Series Relief Valve Control.”) The P series relief valve system includes a panel mounted control valve (PM) and a relief valve (P25, P30 or P30V).
❑ Ac ce ss orie s / O pt ions Figure 2a-5: Thermal Relief Valve, TRV The valve monitors the water temperature in the pump. When temperatures exceed 120° F (49° C), the valve automatically OPENS. When the temperature returns to a safe level, the valve CLOSES. TRV-L Kit The TRV-L kit includes a chrome panel placard with a warning light, a light test button, and a pre-assembled wire harness. The RED light illuminates when the TRV is open and discharging water. (See Figure 2a-5: “Thermal Relief Valve, TRV.
❑ A cc es sorie s / O ptions 2A.4 PRIMING SYSTEMS Hale recommends and uses Rotary Vane Positive Displacement ESP pumps for priming. Priming pumps are used to evacuate air in the suction hose and pump. (See Figure 2a-6: “Rotary Vane ESP Priming Pump.”) Figure 2a-6: Rotary Vane ESP Priming 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.
❑ Ac ce ss orie s / O pt ions Figure 2a-7: SPVR Priming Valves ❑ The Hale PVG Priming Valve The PVG is a combination valve and switch and is mounted on the pump operator’s panel. (See Figure 2a-8: “PVG Priming Valves.”) Pulling the handle out OPENS the valve and energizes the primer motor. Pushing the handle in de-energizes the motor and CLOSES the valve. Figure 2a-8: PVG Priming Valves 2A.
A cc es sorie s / O ptions ❑ Figure 2a-9: Automatic Pump Shift Overview It uses available apparatus vacuum or air pressure for power and is activated by an in-cab pump shift control valve. (See Figure 2a-10: “Pump Shift Control Valve.”) The system includes a three-position pump shift control valve assembly and indicator lights (GREEN), mounted in the operator’s cab and on the operator’s panel. Figure 2a-10: Pump Shift Control Valve Section 2a: Accessories Hale Products, Inc.
❑ Ac ce ss orie s / O pt ions 2A.6 TORRENT SVS VALVES Torrent SVS valves control the flow to and from the full range of Hale pumps. SVS valves enable the operator to shut off flow completely, or throttle the flow rate from a trickle to full flow. (See Figure 2a-11: “Typical SVS Valve Primary Components.”) Figure 2a-11: Typical SVS Valve Primary Components Numerous adapters tailor the valve to almost any installation requirement.
Operation 3 ❑ Basic Operation WARNING ! THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES. NOT ALL PROCEDURES IN THIS SECTION MAY APPLY TO YOUR SPECIFIC OPERATIONAL REQUIREMENTS. REFER TO ONLY THOSE SECTIONS WHICH APPLY TO YOUR OPERATIONAL REQUIREMENTS. THESE PROCEDURES DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION.
❑ Operation IMPORTANT ! AT INSTALLATION AND BEFORE OPERATION, ALL FLUIDS MUST BE ADDED PER THE MANUFACTURER’S REQUIREMENTS AND TO THE APPROPRIATE LEVELS. SEE SEPARATE DOCUMENTATION PROVIDED WITH THE ENGINE AND PUMP END ASSEMBLIES FOR PROPER FLUIDS TO USE AND QUANTITIES REQUIRED. Before operation, refill ❑ Engine crankcase OIL. ❑ Engine WATER coolant (anti-freeze). ❑ Engine battery fluid (ELECTROLYTE). ❑ Pump, gearbox and pedestal OIL. 3.
Operation ❑ Engine battery ELECTROLYTE level (not required for live sealed high performance-type batteries). ❑ Pump, gearbox and pedestal OIL level, if supplied. ❑ Pumping Operations 1. Position the skid or trailer as close to the water source as practical. Pumps smaller than 1,500 GPM (5,678 LPM) can draw 100% of rated capacity with less than 10 feet (3.05 meters) vertical lift and 20 feet (6 meters) of suction hose. Pumps smaller than 3,000 GPM (11,356 LPM) have six (6) feet (1.
❑ Operation 8. Activate the priming pump - pull the control handle, or press the pushbutton. Your departmental manual for pumping should specify the correct RPM for priming. However, in general, priming should be operated at IDLE. Running the engine at speeds higher than 1,200 RPM during priming is not recommended. It does not improve the priming operation but can cause damage to the pump.
❑ Operation CAUTION ! DO NOT CAUSE A WHIRLPOOL AT THE STRAINER. THIS ALLOWS AIR INTO THE PUMP, CAUSING ROUGH OPERATION AND PULSATION. REPOSITION THE STRAINER OR REDUCE FLOW. 13. If the pump is cavitating, warn personnel that the flow is being REDUCED. Close the throttle and / or discharges slowly until you operate without cavitation. The following can also lead to cavitation: ❑ Large nozzle tips - use smaller nozzle to reduce flow.
❑ Operation Water temperatures above 95°F (35°C) cause a noticeable decrease in lift when drafting. Also see Figure F-2: “Lift Loss from Temperature” on page 147. Barometric pressures below 29” Hg. can also limit lift when drafting. High elevations and storm conditions can affect maximum flow available from any pump. Also see Figure F-3a: “Lift Loss from Barometric Reading” on page 147. 3.5 RELIEF VALVE PROCEDURES Be sure to select the correct procedure based on how the skid or trailer is equipped.
❑ Operation 4. Turn the handwheel slowly clockwise until the light goes out. 5. When the pump is not in operation, turn the handwheel clockwise to a position slightly above the normal operating pressure. More complete and detailed information is found in the relief valve manual. CAUTION ! THE PRESSURE INDICATOR ON THE PANEL IS ONLY A ROUGH INDICATION OF TPM SETTING. ALWAYS USE THE PRECEDING PROCEDURE TO PROPERLY SET THE TPM RELIEF VALVE SYSTEM. Figure 3-2: TPM / PMD Relief Valve Control 3.
❑ Operation 52 7. Fill out the Pump Run Log, indicating total pumping and out-of-station time. 8. Report all pump, engine and equipment malfunctions, and irregularities to the proper authority. 9. Know and follow all local procedures. See WARNING ! note on page 45.
❑ Prev entive Mainte nance 4 Preventive Maintenance 4.1 OVERVIEW Hale Pump End Systems require minimal care and maintenance. Preventive maintenance tasks take little time to perform and consist primarily of leak testing, lubrication and cleaning. The following procedures are for normal use and conditions. Extreme conditions may indicate a need for increased maintenance.
❑ Prev entiv e Mainte nance ❑ Spark arrestor screen — clean or replacement ❑ Fuel requirements and adding fuel If required, separate Engine Service Repair Manuals are available from the engine manufacturer by contacting the engine manufacturer directly. All engine related service and parts requests should first be directed to the engine manufacturer. If additional information is needed, contact Hale Customer Service at telephone number: 610-825-6300.
❑ Prev entive Mainte nance 5. Make sure the pedestal oil reservoir is full to correct level - see heading “To Check / Add Oil” on page 57. Also ensure that the engine has the proper amount oil and coolant. See separate engine operation and maintenance manual provided. 4.3 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.
❑ Prev entiv e Mainte nance ❑ Test the priming system - see page 59. Establish and HOLD prime control for about three (3) to five (5) seconds to flush fresh water through the priming pump. Note: DO NOT apply lubricant the primer pump vanes or vane slots. Lubricant and cold water produces a gummy residue that renders the unit defective.
❑ Prev entive Mainte nance Figure 4-1: Typical Drain, Fill and Level Plugs 3. 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. Note: If water leak / contamination is suspected, see heading “Troubleshooting” on page 49. 4. Either of these conditions indicates maintenance is required on the unit. See Section 6 “Repair” on page 77.
❑ Prev entiv e Mainte nance Have clean disposable shop rags and oil dry handy and a suitable container to collect the fluid. 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. Note: If water leak / contamination is suspected, see heading “Troubleshooting” on page 49. Figure 4-2: Typical Pedestal Oil Servicing 3.
❑ Prev entive Mainte nance 2. Increase the pump pressure up to normal operating pressure as indicated on the master pressure gauge per normal operating procedures. 3. Turn the relief valve hand wheel counterclockwise until the valve opens. The relief valve is open when the AMBER indicator light is ON and the pressure begins to drop. (See Figure 3-2: “TPM / PMD Relief Valve Control” on page 51.) 4. Turn the relief valve hand wheel clockwise. The pressure should return.
❑ Prev entiv e Mainte nance For example, lubricate all moving parts of the suction, discharge, hose drain, and multi drain valves and valve linkage with a good grade, lithium base grease. Note: The PMD valve should be lubricated every six (6) months. Verify All Gauges are in Working Order Any gauge that is repeated in 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.
❑ Prev entive Mainte nance Valve Lubrication 1. On handwheel-type valves, including PM, PMD, and Transfer Valve Controls, if necessary, first remove old grease and paint, use a dry lubricating spray on gears. 2. Lubricate suction threads with a light coat of grease. Check Gearbox or Pedestal Lubrication ❑ To check the gearbox, see heading “Gearbox Option” on page 56. ❑ To check the pedestal reservoir, see heading “Pedestal Option” on page 57.
❑ Prev entiv e Mainte nance 5. STOP the priming pump and observe the gauge. If the vacuum falls more than 10” Hg. in 5 minutes, it is an indication of at least one air leak. Vacuum leaks can often be detected by ear if the apparatus engine is turned OFF. Correct leaks immediately before returning the pump to service. 6. Test the suction hose as follows: ❑ Attach the suction hose to the pump. ❑ Place a suction tube cap on the end of the hose in place of a strainer. ❑ Close all valves and drains.
Prev entive Mainte nance ❑ ❑ Relief valve system, check and repair - see page 65. ❑ Checking individual drain lines from the pump to the multi-drain to ensure proper drainage and protection from freezing - see page 65. ❑ Test tank-to-pump flow rate - see page 67. ❑ Disassembly of priming pump to clean vanes - - see page 66. (Also see separate manual provided.) IMPORTANT ! DO NO USE A LUBRICANT ON THE PUMP VANES AND VANE SLOTS.
❑ Prev entiv e Mainte nance 2. Remove the Oil FILL and DRAIN (magnetic) plug and drain the gearbox oil into a suitable container. For container size based on gearbox capacity, see “Appendix C1: Lube and Sealant Specifications” on page 139. Have clean disposable shop rags and oil dry handy. 3. Examine the oil for contamination (e.g., water – turns the oil a milky color or settles to the bottom). Also see Section 5 Troubleshooting, heading “Water/Moisture in Pump Gearbox.” on page 65 4.
❑ Prev entive Mainte nance 4. Add fresh oil through the oil FILL port until oil reaches the bottom of the hole (just begins sweeping out of the hole). DO NOT OVERFILL. Pedestal reservoir holds approximately three (3) pints (1.4 liters) of approved SAE EP90 oil or equivalent. 5. Replace the oil FILL plug securely, using suitable thread sealant, and run the pump for a short period, then recheck the oil level. Relief Valve System Check 1.
❑ Prev entiv e Mainte nance It is necessary to inspect each line of the multi-drain to ensure the entire system is draining when the valve is operated. Inspect each connection and verify the individual lines to the multi-drain are free of debris. Repair or replace any lines that are damaged, kinked, or corroded. Clean Priming Pump Disassemble the priming pump and clean the housing and vanes. Inspect the vanes for wear and replace as needed. Reassemble the pump and test for proper operation.
Prev entive Mainte nance ❑ Tank-to-Pump Flow Rate Test Note: This procedure is provided as a reference only. It does not supersede 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.
❑ Prev entiv e Mainte nance For Pitot gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 6.0 BAR / 0.21 and 0.6 MPa). Also see “Appendix E: Nozzle Size vs. Pressure” on page 143. The amount of discharge hose required for the service tests is dependent on the flow requirements and capacity test point. Provide adequate hose to discharge the rated capacity with a flow velocity less that 35 ft./sec. Also see “Appendix D: Hose Friction Loss” on page 141 at the back of this manual.
❑ Prev entive Mainte nance 3. Run the standard pump test in accordance with NFPA standards to check pump performance. 4. “Silencer” Series Pumps rated below 750 GPM (2,839 LPM / 47 LPS) are tested fifty (50) minutes per NFPA 1901, 14-13.2.3.2. Run the engine to stabilize engine temperature, then run the pump for: 5. ❑ Thirty (30) minutes at FULL capacity and at 150 PSI (10 BAR / 0.4 MPa) ❑ Ten (10) minutes at 70% capacity and at 200 PSI (14 BAR / 1.
❑ Prev entiv e Mainte nance In dirty or sandy water, the impeller hub and clearance rings wear faster. The more wear, the greater the bypass and lower pump performance. It should not be necessary to replace clearance rings until a loss in pump performance is noticed during the annual test – see heading “Performance Testing” on page 68. For clearance ring and impeller service, proceed to Section 6, heading “Impeller” on page 93.
❑ Troubles hooting 5 Troubleshooting 5.1 ENGINE AND TRAILER ❑ For Engine, see the engine manufacturer’s documentation, supplied with your unit. ❑ For Trailer, see the trailer manufacturer’s documentation, supplied with your unit, for the trailer assembly, axle, brake system, tires, etc. 5.2 PUMP Table 5-2 lists conditions, possible causes and suggested corrective action measures.
❑ Troubles hooting Condition Possible Cause Suggested Corrective Action Note: Using lubricant on the vanes and vane slots during disassembly Pump Loses Prime Inoperative priming and cleaning eventually causes a gummy residue to develop, rendering or Will Not Prime - system or possible continued. clogged priming pump. the system inoperative. DO NOT LUBRICATE VANES AND VANE SLOTS. • Check the priming system by performing a “Dry Vacuum Test” per Inoperative priming NFPA standards.
❑ Troubles hooting Condition Possible Cause Suggested Corrective Action Pump Loses Prime Air leaks. or Will Not Prime continued. • Attempt to located and correct air leaks using the following procedures: • Perform “Dry Vacuum Test” on pump per NFPA standards with 22” Hg. minimum vacuum required with loss not to exceed 10” Hg. in five (5) minutes. • If a minimum of 22” Hg.
❑ Troubles hooting Condition Insufficient Pump Capacity continued. Possible Cause Suggested Corrective Action Air leaks. • See heading “Air leaks.” under condition “ Pump Loses Prime or Will Not Prime” on page 73. Partial collapse of the • Damage to the outer lining may allow air between the outer and lining in a suction hose. inner linings causing a partial collapse. • Replace hose and retest. Engine governor set incorrectly.
❑ Troubles hooting Condition Possible Cause Suggested Corrective Action Engine Speeds Too Pump is approaching HIGH for Required “Cavitation.” Capacity or Pressure - continued. • Gate the discharge valves to allow pressure to increase. This reduces the flow. • Reduce the throttle opening to the original pressure setting. • See “Appendix F: Cavitation” on page 145. Worn pump impeller(s) • Repair and/or replace as needed. See Section 6 “Repair” on page or clearance rings. 77. Impeller blockage.
❑ Troubles hooting Condition Possible Cause Suggested Corrective Action Relief Valve Does Not Relieve Pressure When Relief Valves are Closed - continued. Relief valve inoperative. • Possibly in need of lubrication. Remove valve from pump, dismantle, clean and lubricate. Relief Valve Does Not Recover and Return to Original Pressure Setting After Opening Valves. Dirt in system causing • Check and repeat proper procedures for setting the relief valve sticky or slow reaction. system.
❑ Troubles hooting Condition Discharge Valves Are Difficult to Operate continued. Possible Cause Suggested Corrective Action Valve in need of more clearance for operation. Water/Moisture in Leak coming from Pump Gearbox. above the pump. • Multi-gasket design allows additional gaskets for more clearance and free operation. • Note: Adding too many gaskets to the valve eventually causes leakage.
❑ Troubles hooting Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ _____________________________________________
Correc tive Mainte nance 6 ❑ Repair 6.1 OVERVIEW This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Hale pump, gearbox and pedestal components. Follow the disassembly instructions in the order in which they appear in this section. At any point in the disassembly process, the unit can be reassembled by following the instructions in the reverse.
❑ Corre ctiv e Ma int enanc e WARNINGS ! BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP. THE PUMP, GEARBOX AND PEDESTAL ASSEMBLIES CAN BE HEAVY AND BULKY. ADDING ACCESSORIES ALSO INCREASES THE WEIGHT. CHECK YOUR BILL OF LADING FOR THE APPROXIMATE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES (I.E., OVERHEAD CRANE, JACK, CHAINS, STRAPS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THESE ASSEMBLIES.
❑ Correc tive Mainte nance Also ensure screws/bolts are properly torqued. (See Table 6-1: “Typical Torque Values Chart.”) Bolt Size Lock Nut size Material Minimum Torque Ft.-Lb. (N-m) 5/16”18 Zinc-plated steel 17 (23) 5/16”18 Zinc-plated steel, with 360° nylon lock 19 (26) 5/16”18 Silicon bronze 10.
❑ Corre ctiv e Ma int enanc e 12. Before placing apparatus into operation, the pump assembly must be tested and checked for leaks. Gearbox and Pedestal Assemblies 1. Drain oil from the gearbox. Also see Section 4 Preventive Maintenance, heading “Change Gearbox Oil” on page 63. 2. Drain oil from the pedestal. Also see Section 4 Preventive Maintenance, heading “Change Pedestal Oil” on page 64. 3. Have clean disposable shop rags and oil dry handy and a suitable container to collect the fluid.
❑ Correc tive Mainte nance 4. Lightly oil or grease the shaft, O-ring seals and lip seals with a coating of general-purpose grease before reinstalling, especially when pressedin. 5. For Hale recommended cleaners, see “Appendix C1: Lube and Sealant Specifications” on page 139. 6. Replace any hardware that shows signs of excessive wear. Bearings Bearings and other components should be cleaned using only recommended solvents. Bearings must always be replaced in matching sets by manufacturer.
❑ Corre ctiv e Ma int enanc e ❑ Disposable rags ❑ Oil dry ❑ Wedges ❑ Bearing puller ❑ Pusher tube (a small section of PVC tubing to fit over the shaft) ❑ N-06 or N-07 bearing nut socket or spanner wrench, available from: Whittet-Higgins at www.whittet-higgins.com or, 35 Higginson Avenue P O Box 8 Central Falls, RI 02863 Phone ................
❑ Correc tive Mainte nance 6a Servicing the Pump This section details servicing the pump for all models listed in this manual. Refer to the sections for you particular pump only. Before beginning the removal process, you may want to sketch (or photograph) the plumbing and component configuration to aid in easy re-assembly. 6A.1 GENERAL PREPARATION ❑ Review heading “Before You Begin...” on page 79. Also review heading “Cleaning and Inspection Guidelines” on page 82.
❑ Corre ctiv e Ma int enanc e Figure 6a-1: 20FS Series, Pump and Bearing Housing Overview 2. If installed, disconnect the primer hose from the bearing housing fitting (3/8” NPT). 3. Remove the eight (8) 3/8”-16 screws holding the housing to the volute (pump body). Slide the bearing housing from the pump / impeller shaft. 4. Examine the housing bearings and spring pins. Replace accordingly. Note: If bearings (2) are being replaced, they are press-fit and both must be replaced. 5.
Correc tive Mainte nance 6. ❑ Using Loctite, install and tighten the eight (8) 3/8”-16 screws EVENLY and in a criss-cross pattern to assure an even seal. For sealant specifications, see heading “Appendix C1: Lube and Sealant Specifications” on page 139. Removing the Pump WARNING ! THE LOWER AND UPPER PUMP BODY HALVES ARE BULKY AND HEAVY. SUPPORT EACH HALF WITH THE PROPER LIFTING DEVICE. FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL INJURY, OR PROPERTY DAMAGE.
❑ Corre ctiv e Ma int enanc e WARNING ! DO NOT STRIKE THE IMPELLER. IRREPARABLE DAMAGE COULD RESULT. MAKE CERTAIN THE WEDGES OR PULLER IS PLACED AT THE IMPELLER VANES TO AVOID IRREPARABLE DAMAGE. 3. To avoid damaging the impellers, use wedges (3) or a bearing puller to remove the impellers from the pump shaft. Place the wedges or puller at the impeller vane area where the metal is the heaviest. Also see Figure 6a5: “Placing Edges for Impeller Removal” on page 95.
❑ Correc tive Mainte nance ❑ Apply Loctite and install the 3/4”-16 washer and impeller nut and torque the impeller nut to approximately 200 ft.-lbs. (271 N-m). ❑ Install the dowel pins (2) into the UPPER and LOWER pump body halves before installing them. ❑ Apply Loctite to all screws and tighten in a criss-cross pattern to ensure an EVEN seal. Refer to Table 6-1: “Typical Torque Values Chart” on page 79 for recommended torque values, fastener size and material.
❑ Corre ctiv e Ma int enanc e WARNING ! SECURE THE PUMP HEAD ASSEMBLY TO AN APPROPRIATE HOIST TO PREVENT POSSIBLE INJURY OR DAMAGE. 3. Remove the oil seal from the housing and discard. To replace, order Hale p/n: 296-2140-00-0. (See Figure 6a-2: “Oil Seal, Pump Shaft” on page 89.) 5. Insert (or press) a new oil seal into the bore of the pump head, flush with the front face of the housing. Apply a coating of general-purpose grease to the seal to ease installation.
Correc tive Mainte nance 1. Review heading 6a.1 “General Preparation” on page 85. 2. Disconnect the suction, discharge and cooling lines, and any electrical wiring, if applicable. 3. Match mark the volute and flange to ensure proper alignment at reassembly. 4. Remove the eight (8) 3/4”-10 screws and washers holding the flange option to the volute. (See Figure 6a-3: “Typical Suction Flange Option.”) ❑ Support the weight of the flange. It can be heavy and bulky.
❑ Corre ctiv e Ma int enanc e Figure 6a-4: Typical Pump Disassembly Overview 92 2. Remove the suction flange (if installed) - see heading “Suction Flange” on page 90. 3. Disconnect the water line compression fittings and the gearbox water cooling lines from the volute. 4. Also disconnect primer lines, if included. 5. Volutes are mounted for various pump discharge positions.
❑ Correc tive Mainte nance 7. ❑ For 30 FS series pump - eight (8) 3/8”-16 screws ❑ For 60 FB series pump - twelve (12) 7/16”-14 screws ❑ For all other pumps - sixteen (16) 7/16”-14 screws Separate the volute from the pump head being careful not to damage the clearance rings, impeller or mechanical seal. If necessary, tap the volute free using a soft hammer, i.e., rawhide, rubber, etc. Support the weight of the volute as it is heavy and bulky.
❑ Corre ctiv e Ma int enanc e ❑ Replace all gaskets. Apply a small amount of grease to the gasket(s). ❑ If the clearance rings are removed, use a press to install them back into the volute. ❑ When installing the volute and suction flange, DO NOT damage the clearance rings or impeller. ❑ Reconnect all cooling lines, piping and tubing. ❑ Set up apparatus for pumping and test pump. Check for leaks at the piping and seal areas before returning apparatus to operation. Impeller 1.
❑ Correc tive Mainte nance Figure 6a-5: Placing Edges for Impeller Removal WARNING ! DO NOT STRIKE THE IMPELLER. IRREPARABLE DAMAGE COULD RESULT. MAKE CERTAIN THE WEDGES OR PULLER IS PLACED AT THE IMPELLER VANES TO AVOID IRREPARABLE DAMAGE. 4. Inspect the clearance ring seated within the pump head - see heading “Clearance Rings, Impeller Measurement.” 5. Removing the impeller may disturb the mechanical seal. A new seal must be installed - see heading 6b “Mechanical Seal Assembly” on page 111.
❑ Corre ctiv e Ma int enanc e Figure 6a-6: Clearance Ring and Impeller ID / OD Measurement The impeller hub diameter can be cut (turned down) and “undersized” clearance rings can be ordered to compensate for a new impeller diameter. Contact Customer Service at Hale Products at 610-825-6300. CAUTION ! WHEN TURNING IMPELLERS TO FIT UNDERSIZED RINGS, CAUTION MUST BE EXERCISED TO ENSURE THAT THE SEAL RING SURFACE RUNS TRUE WITH THE BORE TO WITHIN 0.002” (0.051MM).
❑ Correc tive Mainte nance ❑ ❑ To install the volute and suction flange, for: ● Volute - see heading “Volute (Pump Body)” on page 91. ● Suction flange, in included - see heading “Suction Flange” on page 90. Inspect the system for proper operation before returning the apparatus to service. 6A.4 PUMP SHAFT OIL SEALS, WITH BELL HOUSING On bell housing (flywheel) adapter engine mounts, THAT DO NOT INCLUDE A GEARBOX, replacing the pump shaft oil seal is determined by your pump model, i.e.
❑ Corre ctiv e Ma int enanc e Pump Head Assembly – 30 FS Series Only Review heading 6a.1 “General Preparation” on page 85. Also refer to the appropriate plate drawing of your specific pump model. See Section 8, heading “Drawing Package” on page 151. Pump Shaft Oil Seal, 30 FS Series 1. Dismantle the pump head assembly, and gasket from the gearbox - remove the upper four (4) 5/16”-18 screws and the two (2) lower 5/16”-18 screws of the pump head.
❑ Correc tive Mainte nance Installation Notes – Pump Head, 30 FS Series ❑ Review heading 6a.1 “General Preparation” on page 85. ❑ Insert (or press) a new oil seal (Hale p/n: 296-2110-00-0) into the pump housing bore. Apply a coating of general-purpose grease to the seal to ease installation. (See Figure 6a-7: “Replacing 30 FS Series Pump Shaft Oil Seal” on page 98.) ❑ When sliding the pump head over the pump shaft, be careful not to damage the oil seal. ❑ Replace all gaskets.
❑ Corre ctiv e Ma int enanc e Figure 6a-8: Replacing 40FB - 100FB Series Pump Shaft Oil Seal 2. Pull the pump head assembly, including the pump shaft from the bell housing, using appropriate hoist, and move the assembly to a suitable work area. Safely support the assembly. WARNING ! SECURE THE PUMP HEAD ASSEMBLY TO AN APPROPRIATE HOIST TO PREVENT POSSIBLE INJURY OR DAMAGE. 3.
❑ Correc tive Mainte nance 4. Remove (pull) the pump shaft assembly, with both bearings, from the pump head. This exposes the oil seal. 5. Remove (press out) the oil seal and discard. Oil seals cannot be reused. To replace, order Hale p/n: 296-2060-00-0. 6. Inspect all parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly. Pump Shaft Bearings, FB40 – FB100 Series 1.
❑ Corre ctiv e Ma int enanc e ❑ Install a “new” mechanical seal - see heading see heading 6b.2 “Installing Seal” on page 112. ❑ Install the impeller, see heading “Installation Notes – Impeller,” on page 96. ❑ Install the volute - “Installation Notes – Volute (Pump Body),” on page 93. Also install the suction flange, if included - see heading “Installation Notes – Suction Flange” on page 91. ❑ Set up apparatus for pumping and test pump.
Correc tive Mainte nance ❑ Figure 6a-9: Replacing 80 FC Series Pump Shaft Oil Seal 4. Reach in and remove the bearing extension cover from the pump head assembly - four (4) 1/4”-20 screws. It is not necessary to disassemble the bell housing from the pump head to service the bearings or oil seal. 5. Remove (pull) the pump shaft assembly, with both bearings, from the pump head. This exposes the oil seal. 6. Remove (press–out) the oil seal and discard. Oil seals cannot be reused.
❑ Corre ctiv e Ma int enanc e Pump Shaft Bearings, 80 FC Series Only 1. If the bearings are being replaced, remove the shaft retaining ring, then press the bearings from the pump shaft. (See Figure 6a-9: “Replacing 80 FC Series Pump Shaft Oil Seal” on page 103.) Also see heading “Bearings” on page 81. 2. Install (press–on) one bearing, bearing shim, then the other bearing onto the pump shaft. Then install the bearing retaining ring.
❑ Correc tive Mainte nance ❑ Install a “new” mechanical seal - see heading see heading 6b.2 “Installing Seal” on page 112. ❑ Install the impeller, see heading “Installation Notes – Impeller,” on page 96. ❑ Install the volute - “Installation Notes – Volute (Pump Body),” on page 93. Also install the suction flange, if included - see heading “Installation Notes – Suction Flange” on page 91. ❑ Set up apparatus for pumping and test pump.
❑ Corre ctiv e Ma int enanc e Figure 6a-10: Pedestal Mount Pump Shaft Oil Seals (2), 40 / 5- FB-U and 80 FC-U Series 106 Pump Ends p/n: 029-0020-61-0
❑ Correc tive Mainte nance WARNING ! SECURE THE PEDESTAL AND PUMP HEAD ASSEMBLY TO AN APPROPRIATE HOIST TO PREVENT POSSIBLE INJURY OR DAMAGE. Note: On certain splined shaft assemblies you may need to remove a retaining ring at the base of the pedestal, near the oil seal. (See Figure 6a-10: “Pedestal Mount Pump Shaft Oil Seals (2), 40 / 5- FB-U and 80 FC-U Series” on page 106.) 3.
❑ Corre ctiv e Ma int enanc e Pump Shaft Bearings 1. If either set of bearings are being replaced, remove the shaft retaining rings (2), then press the bearings from the pump shaft. (See Figure 6a-9: “Replacing 80 FC Series Pump Shaft Oil Seal” on page 103.) It is recommended to replace both sets to avoid unnecessary downtown. Also see heading “Bearings” on page 81. 2. Examine the oil slinger and replace as needed. Order Hale p/n: 242-006000-0.
❑ Correc tive Mainte nance ❑ Slide the assembly into the engine mount and bolt the pedestal to the frame. ❑ Apply grease to the grease fitting in the pump head to lubricate the bearing chamber - see heading “Pump Head Bearing Lubrication” on page 63. ❑ Apply oil to the pedestal reservoir - see Section 4 Preventive Maintenance, heading “Change Pedestal Oil” on page 64. ❑ Install a “new” mechanical seal - see heading see heading 6b.2 “Installing Seal” on page 112.
❑ Corre ctiv e Ma int enanc e Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ __________________________________
Me chanic al Se al Re pla ce me nt ❑ 6b Mechanical Seal Assembly IMPORTANT ! IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE VOLUTE IS NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED. (SEE FIGURE 6B-1: “TYPICAL MECHANICAL SEAL ASSEMBLY.”) WHENEVER A MECHANICAL SEAL IS REMOVED, IT MUST BE REPLACED WITH A “NEW” SEAL. Before the mechanical seal can be replaced, the pump volute (pump body) and impeller must be removed.
❑ Me chanica l Sea l Re pla ce me nt Then, using steady gentle pressure, pull on the hex key with a screw driver to push the stationary seat out of the pump head. Removing the mechanical seal renders it inoperative and it must be replaced. 4. Carefully inspect clearance rings and other internal parts for excessive wear or damage. Replace accordingly. It is recommended to always use Hale genuine replacement parts for optimum safety of the equipment and its operators and to avoid unnecessary downtime. 6B.
Me chanic al Se al Re pla ce me nt ❑ 5. Apply a generous coating of Pac-Ease lubricant to the seal diaphragm assembly. Without touching the seal faces, slide the diaphragm assembly over the pump shaft, with the polished face toward the stationary seat. 6. Using a mechanical seal insertion tool, in Figure 6b-2: “Typical Mechanical Seal Insertion Tool.” push the diaphragm assembly in until the two running faces contact. 7. The seal insertion tool is available from Hale - order p/n: 029-0760-00-0.
❑ Me chanica l Sea l Re pla ce me nt Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ___________________________
❑ Gea rbox R epair 6c Gearbox Service This section details servicing the gearbox and pump shaft assemblies for the Hale series pump ends. Refer to the sections for you particular pump only. Before beginning the removal process, you may want to sketch (or photograph) the plumbing and component configuration to aid in re-assembly. 6C.1 GENERAL PREPARATION ❑ Review heading “Before You Begin...” on page 79. Also review heading “Cleaning and Inspection Guidelines” on page 82.
❑ Gea rbox R epair ❑ In every case, to expose the pump shaft assembly and service the gearbox, you must first remove the following: ● Suction Flange, if included - see heading “Suction Flange” on page 90. ● Volute - see heading “Volute (Pump Body)” on page 91. ● Impeller - see heading “Impeller” on page 94. ● Mechanical Seal - see Section 6b, “Mechanical Seal Assembly” on page 111. 6C.
Gea rbox R epair ❑ Figure 6c-1: 20 / 30 FS Series Gearbox and Bell Housing Overview 3. Slide the unit straight back to remove the splined drive shaft from the engine mount and drive disk (SAE #8 or SAE #10). Place and support the assembly on a suitable work area. Note: If required, remove the eight (8) 3/8”-16 screws and washers securing the drive disk to the engine mount. Examine, repair and/or replace the rubber disks as required.
❑ Gea rbox R epair Drive Shaft Oil Seal 1. Remove the four (4) 5/16”-18 and the two (2) 7/16”-14 screws to dismantle the bell housing from the gearbox. (See Figure 6c-1: “20 / 30 FS Series Gearbox and Bell Housing Overview” on page 117.) 2. Slide the housing from the drive shaft. 3. Remove (press–out) the oil seal and discard. Oil seals cannot be reused. To replace, order Hale p/n: 296-2220-00-0. Apply a coating of general-purpose grease to the seal to ease installation.
❑ Gea rbox R epair Pump Shaft 1. With the drive shaft removed, use a drift punch and begin pushing the pump shaft assembly from the pump side of the gearbox housing. (See Figure 6c1: “20 / 30 FS Series Gearbox and Bell Housing Overview” on page 117.) 2. Remove the retaining ring from the pump shaft, then press both bearings from the shaft. 3. Remove the pump gear and shaft key. 4. Clean and inspect all parts for excessive wear, chips, scoring or other damage. Repair and/or replace accordingly.
❑ Gea rbox R epair ❑ Apply Loctite and install the four (4) 5/16”-18 and two 7/16”14 screws to assemble the bell housing to the gearbox housing. Tighten screws in a criss-cross pattern and torque accordingly - see Table 6-1: “Typical Torque Values Chart” on page 79. ❑ Install a “new” mechanical seal - see heading see heading “Installing Seal” on page 112. ❑ Install the impeller, see heading “Installation Notes – Impeller,” on page 96 .
❑ Gea rbox R epair Figure 6c-2: Pump Shaft Oil Seal, 50/60/80 FBG Series, with Gearbox Pump Ends p/n: 029-0020-61-0 3. Lift the drive unit housing from the gearbox housing, then remove the entire pump housing, with the pump shaft assembly. 4. Place and safely support the assembly on a suitable work area. 5. Press the pump shaft assembly (shaft, bearings and shim and gear) out the back of the pump housing. 6.
❑ Gea rbox R epair Installation Notes – Pump Shaft and Seal, 50/60/80 FBG ❑ Review heading 6c.1 “General Preparation” on page 115. ❑ Make sure a new oil seal (Hale p/n: 296-2090-00-0) is installed into the pump housing. Apply a coating of general-purpose grease to the seal to ease installation. (See Figure 6c-2: “Pump Shaft Oil Seal, 50/60/80 FBG Series, with Gearbox” on page 121.
Gea rbox R epair ❑ Gearbox and Bell Housing Assemblies To service the intermediate and/or drive shaft assemblies you must remove the gearbox from the bell housing (flywheel) adapter and disassemble the pump housing. (See Figure 6c-3: “Gearbox and Bell Housing Overview, 50/60/80 FBG Series Pump End” on page 124.) Also see Figure 6c-2: “Pump Shaft Oil Seal, 50/60/80 FBG Series, with Gearbox” on page 121. Review heading 6c.1 “General Preparation” on page 115.
❑ Gea rbox R epair Figure 6c-3: Gearbox and Bell Housing Overview, 50/60/80 FBG Series Pump End 124 2. Slide the housing from the drive shaft. 3. Remove (press–out) the oil seal and discard. Oil seals cannot be reused. To replace, order Hale p/n: 296-2090-00-0.
Gea rbox R epair ❑ 4. Insert a new seal – see Figure 6c-3: “Gearbox and Bell Housing Overview, 50/60/80 FBG Series Pump End” on page 124. Apply a coating of generalpurpose grease to the seal to ease installation. 5. Remove the rear bearing from the bell housing. 6. Clean and inspect all parts for excessive wear, chips, scoring or other damage. Also see “Ball Bearings” on page 35. Repair and/or replace accordingly. Gearbox, Intermediate and Drive Shafts Pump Ends p/n: 029-0020-61-0 1.
❑ Gea rbox R epair Installation Notes – Gearbox and Bell Housing, 50/60/80 FBG ❑ Review heading 6c.1 “General Preparation” on page 115. ❑ Make sure a new oil seal (Hale p/n: 296-2090-00-0) is installed into the bell housing. Apply a coating of general-purpose grease to the seal to ease installation. (See Figure 6c-3: “Gearbox and Bell Housing Overview, 50/60/ 80 FBG Series Pump End” on page 124.
❑ Insta llation 7 Installation 7.1 OVERVIEW This section provides general guidelines and recommendations for installing the pump and bell housing (flywheel) assembly into your engine and chassis. 7.2 FRAME MOUNTING See separate Section, “Drawing Package” on page 133, located at the back of this manual, for the required mounting specifications. The installation drawing provides mounting configurations with bolt down specifications.
❑ Insta llation Wherever there is a requirement for new parts, it is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators and to reduce unnecessary “downtime.” General Mounting Tapped holes of various sizes and depths are provided, dependent on pump model and layout requirements. Mounting also varies depending on assembly configuration, i.e.
❑ Insta llation IMPORTANT ! AT INSTALLATION AND BEFORE OPERATING FOR THE FIRST TIME, OIL MUST BE ADDED TO THE GEARBOX OR THE PEDESTAL TO THE APPROPRIATE LEVELS. FOR THE PROPER OIL TO USE AND QUANTITY REQUIRED: ❑ SEE SECTION 4, HEADING “CHANGE GEARBOX OIL” ON PAGE 63. ❑ SEE SECTION 4, HEADING “CHANGE PEDESTAL OIL” ON PAGE 64. 7.5 CHECK FLYWHEEL RUN OUT Before mounting any Hale S.A.E.
❑ Insta llation S.A.E. Housing Mounting Face 1. Use the same procedure as above EXCEPT orient the indicator pointer perpendicular to the mounting face - see heading “S.A.E. Housing Pilot Bore” on page 129. 2. The RUNOUT limits are the same as those for the bore. Flywheel Pilot Bearing Bore 1. Rigidly mount the base of a dial indicator to the S.A.E. housing and orient the pointer perpendicular to the pilot bearing bore. 2.
G loss ar y a nd Mea surem ents ❑ Appendix A: Glossary Atmospheric .......Pressure caused by the elevation of air above the earth. Atmospheric pressure is 14 Pressure .............pounds per square inch at sea level. Pressure increases below sea level and decreases above sea level. The weather also effects atmospheric pressure. Atmospheric pressure effects a pumps ability to pump from draft. Higher pressures increase a pumps performance, while lower pressures can cause a noticeable decrease in lift.
❑ Glos sa ry and Mea sureme nts 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. Flow Meter ..........
G loss ar y a nd Mea surem ents ❑ 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 ressure. Priming ...............
❑ Glos sa ry and Mea sureme nts 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 ...
G loss ar y a nd Mea surem ents ❑ Appendix A-1: Measurements Water Horsepower ........................................................................................................ (GPM x PSI)/1,714 One Gallon of Water Weighs ..................................................................................................8.33 Pounds One Gallon...................................................................................................................... 231 Cubic Inches One Cubic Foot.............
❑ Glos sa ry and Mea sureme nts Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone..............1-610-825-6300 Fax ........................1-610-825-6440 Web ........ www.haleproducts.com 136 Appendix A: Glossary / Measurements Hale Products, Inc., July 2006, Rev.
❑ A lternate Lubrica nt Manufac ture rs Appendix C: Alternate Lubricant Manufacturers In addition to the Hale recommended lubricants: ❑ FULL SYNTHETIC SAE 50 Transmission Lubricant (Cognis 2924/2833) ❑ DEXRON III SYNTHETIC (Cognis 2803) for temperatures below 32°F (0°C) the following list of alternate oils and suppliers is provided . Oil / Lubricant Manufacturer Alternate STANDARD-Temperature Lubricant (Cognis 2923/2833) See Service Manual for additional information.
❑ Alt erna te Lubric ant Ma nufa ct urers Oil / Lubricant Manufacturer Alternate STANDARD-Temperature Lubricant (Cognis 2923/2833) See Service Manual for additional information. Monarch Syntran Plus SAE-50 Trans. Royal Manufacturing Company, Inc. P O Box 3308 516 South 25th West Avenue Tulsa, OK 75127 Mystik Synguard SX-7000 SAE-50 Trans. Cato Oil and Grease Company P O Box 26868 1808 NE 9th Street Oklahoma City, OK 73126 Peterbilt SAE-50 Original Factory Fill Fluid, Trans.
❑ Lubric ant Spe cific ations Appendix C1: Lube and Sealant Specifications Approximate Capacity Pump Gearbox Recommended Oil Quarts Liters 5 4.7 SAE 50 - above 0° F (above -18° C); Dextron III or Cognis 2803 - between -40°F to 0°F (-40° to -18°C) 2 1.9 SAE 50 80W-90; 75W-80 Synthetic B (Horizontal) 1.5 1.4 SAE 50 80W-90; 75W-80 Synthetic 4DK APS APSM MBP MBPM 4DB SBP B (Vertical) B (Inverted) 1.75 1.
❑ Lubric ant Spe cific ations Pump Gearbox Approximate Capacity Recommended Oil Quarts Liters APM / AP / CBP 2CBP / CBP2 / CBP3 2CBP2 / 2CBP3 1.75 1.7 SAE EP90 80W-90; 75W-140 Synthetic (Lubricants must meet service rating API GL-5.) 20FS 30FS 1.75 1.7 SAE EP90 80W-90; 75W-140 Synthetic (Lubricants must meet service rating API GL-5.) 3 2.8 SAE EP90 80W-90; 75W-140 Synthetic (Lubricants must meet service rating API GL-5.
❑ Hos e Fric tion Loss 2.0” (38) Hose with 1-1/2” (38mm) Coupling GPM (LPM) 3-1/2” (89mm) Hose 4.0” (102mm) Hose 14 (0.96) 8 (0.6) 500 (1,893) 9.5 (0.7) 3 (0.2) 20 (76) 44 (3.0) 6 (0.4) 125 (473) 24 (1.7) 13 (0.9) 750 (2,839) 20 (1.4) 11 (0.8) 5 (0.4) 30 (114) 99 (6.8) 14 (0.96) 150 (568) 35 (2.4) 18 (1.2) 1,000 (3,785) 34 (2.4) 20 (1.4) 8 (0.6) 40 (151) 176 (12.0) 24 (1.7) 4 (0.3) 175 (662) 47 (3.2) 25 (1.7) 6 (0.4) 1,250 (4,732) 53 (3.7) 31 (2.1) 13 (0.
❑ Hos e Fric tion Loss Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ..............1-610-825-6300 Fax.........................1-610-825-6440 Web ........ www.haleproducts.com 142 Appendix D: Hose Friction Loss Hale Products, Inc.
❑ Nozzle vs . P re ss ur e R ating Appendix E: Nozzle Size vs. Pressure GPM (LPM) at Various Nozzle Sizes Nozzle Pressure Nozzle Size in Inches (millimeters) PSI (BAR) 1/2” (13) 5/8” (16) 3/4” (19) 7/8” (22) 1.0” (25.4) 1-1/8” (29) 1-1/4” (32) 1-3/8” (35) 30 (2.1) 41 (155) 64 (242) 92 (348) 125 (473) 163 (617) 206 (780) 35 (2.4) 44 (167) 69 (261) 99 (375) 135 (511) 176 (666) 222 (840) 254 (962) 308 (1,166) 275 (1,041) 332 (1,257) 40 (2.
❑ Nozz le vs . Pre ss ure R at ing GPM (LPM) at Various Nozzle Sizes Nozzle Pressure PSI (BAR) Nozzle Size in Inches (millimeters) 1-1/2” (13) 1-5/8” (16) 1-3/4” (19) 1-7/8” (22) 2.0” (25.4) 2-1/4” (57) 2-1/2” (64) 3.0” (76) 30 (2.1) 366 (1,386) 430 (1,628) 498 (1,885) 572 (2,065) 651 (2,464) 824 (3,119) 1,017 (3,850) 1,464 (5,542) 35 (2.4) 395 (1,495) 464 (1,756) 538 (2,037) 618 (2,339) 703 (2,661) 890 (3,369) 1,098 (4,156) 1,581 (5,985) 40 (2.
❑ C av it ation Appendix F: Cavitation (See Figure F-1: “Sample, Cavitation Regions.”) Cavitation can occur while pumping from draft, in relay, or from a hydrant (although it is more likely from draft conditions). The operator must be aware of the warning signs and immediately correct the situation. Cavitation can damage the impeller and other sensitive components, impair pump performance, and reduce flow capacity.
❑ Ca vit ation 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 (or bubbles). 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.
❑ C av it ation During Operations Water Temperature F° (C°) Lift Losses Head Ft. (Meters) ❑ Do not increase pump speed NFPA Base Line - 2.38 (0.73mm) 60° (16°) beyond the speed at which 70° (21°) 0.3 (0.09) the pressure ceases to rise. The higher the elevation 80° (27°) 0.6 (0.18) above sea level, the lower 90° (32°) 1.1 (0.34) the atmospheric pressure 100° (38°) 1.7 (0.52) and less lift. Lift loss is in (43°) 110° 2.5 (0.76) addition to NFPA Baseline of 2.38 ft. (0.
❑ Ca vit ation ❑ Consider the piping within the truck. Suction losses can result from additional suction piping added to the fire pump during assembly. Hose Diameter in. (mm) 3” (76) 4” (102) Flow - gpm (lpm) 250 (946) 6” (152) Dual 6” (152) 5.2 (20) 2.5 (9.5) 500 (1,893) 5.0 (19) 750 2,839) 11.4 (43) 1,250 (4,732) 5” (127) Lift Loss (gpm (lpm) 350 (1,325) 1,000 (3,785) 4.5” (127) 3.6 (13.6) 8.0 (30) 4.7 (18 1.9 (7.2) 14.5 (55) 8.5 (32) 3.4 (13) 13 (49) 5.2 (20) 1,500 (5,678) 7.
Limite d W arra nty Express Warranty EXPRESS WARRANTY: Hale Products, Inc. (HALE) hereby warrants to the original Buyer that products manufactured by Hale are free of defects in material and workmanship for two (2) years or 2,000 hours usage, whichever shall first occur. The “Warranty Period” commences on the date the original Buyer takes delivery of the product from the manufacturer.
Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone..............1-610-825-6300 Fax ........................1-610-825-6440 Web ........ www.haleproducts.
Pump Ends (Series 20FS, 30FS, 40FB, 50FB, 50FB-U-U, 50FB-U-M, 60FB, FB50, FB75, FB100, 80FC) Drawing Package 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 Web......www.haleproducts.
Contents 8 Drawings.................................................................................. Plate Number Pump Ends 20 FS Series Engine Mount Pump Installation and Parts Identification ....................................... 504C 30 FS Series Engine Mount Pump Installation and Parts Identification ....................................... 530D 40 / 50 FB Series Engine Mount Pump Installation and Parts Identification ................................
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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 Web. ............www.haleproducts.