APS/MBP Silencer Series Booster 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 Web: www.haleproducts.
NOTICE ! Class1 cannot assume responsibility for product failure resulting from improper maintenance or operation. Class1 is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice. All Class1 products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested.
Table of Contents ❑ Contents Page Silencer Series Booster Pumps 1 Safety Precautions.................................................................................11 1.1 Guidelines ............................................................................................................. 11 2 Introduction...........................................................................................15 2.1 Overview .........................................................................................
❑ Table of Contents Contents - continued Page 2.5 Accessories - continued Pressure Control ............................................................................................................... 23 The P Relief Valve System .......................................................................................... 23 Figure 2-10: P Series Relief Valve System Arrangement ........................................... 23 How the Relief System Works ......................................................
Table of Contents ❑ Contents - continued Page 3.4 Cavitation - continued To Eliminate Cavitation ...................................................................................................... 38 During Operations ............................................................................................................. 38 Table 3-6: Lift Loss from Elevation .............................................................................. 38 Table 3-7: Lift Loss from Elevation .....................
❑ Table of Contents Contents - continued Page 4.5 Monthly..................................................................................................................45 Gearbox Lubrication .......................................................................................................... 45 Figure 4-2: Gearbox Capacity / Recommended Lubricants ........................................ 45 Figure 4-3: Typical Drain, Fill and Level Plugs............................................................
Table of Contents ❑ Contents - continued Page Figure 5-2: Troubleshooting Charts - continued Relief Valve Does Not Recover and Return to Original Pressure Setting After Opening Valves .................................................................. 59 Relief Valve Opens When Control Valve is Locked Out......................................... 59 Unable to Obtain Proper Setting on Relief Valve ................................................... 59 Discharge Valves Difficult to Operate...................
❑ Table of Contents Contents - continued Page 6.5 Mechanical Seal Assembly..................................................................................74 Figure 6-8: Mechanical Seal Overview / Replacement ............................................... 74 Removing the Seal............................................................................................................. 74 Installing Seal.......................................................................................................
Table of Contents ❑ Contents - continued Page 7.3 DRIVELINE ISSUES .............................................................................................. 90 Drive Line and Flange Bolts ............................................................................................... 90 Issues ................................................................................................................................. 90 Table 7-1: Maximum Recommended Driveline Lengths.............................
❑ Table of Contents Contents - continued Page Drawings .......................................................................................... Plate # Installation / Parts APS Silencer Series Booster Pump Installation and Identification...............................1027A MBP Silencer Series Booster Pump Installation and Identification..............................1026A Available Options Anti-Corrosion Anode, Plate #869A...............................................................................
❑ Safety Precautions 1 Safety Precautions IMPORTANT ! THE HALE SILENCER SERIES BOOSTER PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL. ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE SILENCER SERIES BOOSTER PUMP.
❑ Safety Precautions WARNING ! THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY, WEIGHING UP TO 145 LBS. (54 KGS.). ADDING ACCESSORIES INCREASES THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE SILENCER SERIES BOOSTER PUMP AND GEARBOX ASSEMBLIES.
Safety Precautions ❑ ❑ DO NOT operate the system at pressures higher than the maximum rated pressure. (Also see Table 2-1: “Booster Pump Capacity” on page 13.) ❑ 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.
❑ Safety Precautions Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ___________________________________________
❑ Introduction 2 Introduction 2.1 OVERVIEW Hale Products currently offers the Silencer Series Booster Pumps in two models: ❑ APS – Single-Stage, Centrifugal Attack Pump (250-500 GPM/1,000- 2,000 LPM), with three primary drive options: truck transmission PTO, hydraulic drive or direct engine mount. ❑ MBP – Single-Stage, Centrifugal, “High Volume” Attack Pump (500- 1,000 GPM/2,000-4,000 LPM), also with three primary drive options: truck transmission PTO, hydraulic drive or direct engine mount.
❑ Introduction 2.2 PRINCIPLES OF OPERATION Centrifugal Force Hale booster pumps are centrifugal pumps that operate on the principle of centrifugal force created by a rapidly spinning disk. (See Figure 2-2: “Centrifugal Force, from 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. 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 cutwater is a wedge that divides the water between the volute (pump body) and the pump discharge.
❑ Introduction Pump Body (See Figure 2-4: “Overview of Hale Booster Pump and Gearbox.”) As water discharges from the impeller, it enters the volute (pump body). The volute is shaped so that its area increases from the cutwater to its full capacity at the volute throat. This gradual increase in size maintains a constant average velocity through the volute. Figure 2-4: Overview of Hale Booster Pump and Standard APS and MBP Gearbox volutes are constructed from fine-grain cast iron.
Introduction ❑ Note: Mechanical seals do not drip like older pump packing. A Hale Booster Pump with a drip from the seal requires service. WARNING ! IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT COULD OVERHEAT. THIS CAN DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM. Gearbox Hale Silencer Series Pumps are equipped with a B Series Gearbox that utilizes helical gears to reduce operating noise.
❑ Introduction Hale booster pumps are available for either engine rotation (clockwise), or opposite engine rotation (counterclockwise) PTO operation. (See Figure 25: “Mechanical Seal Overview,” on page 18.) WARNING ! NEVER OPERATE A BOOSTER PUMP ABOVE THE DERATED CONTINUOUS TORQUE RATING FOR ITS TRANSMISSION OR PTO, OR ABOVE THE RECOMMENDED PTO OUTPUT SPEED AS RECOMMENDED BY THE PTO MANUFACTURER.
❑ Introduction Priming Systems Priming pumps are used to evacuate air in the suction hose and pump. `The vacuum created allows atmospheric pressure to push water from the static source through the suction hose and into the pump. Hale booster pumps use Rotary Vane Positive Displacement type pumps for priming. (See Figure 2-7: “Rotary Vane and ESP Priming Pumps.”) Figure 2-7: Rotary Vane and ESP Priming Pumps The priming pump has a rotor mounted off-center (eccentric) to the pump body housing.
❑ Introduction An ESP series priming pump also uses a single control to open the priming valve between the booster and the priming pumps, and start the priming motor. (See Figure 2-7: “Rotary Vane and ESP Priming Pumps,” on page 21.) Priming Valves Hale priming valves open when the priming pump is operated to allow the air to escape from the pump.
Introduction ❑ Figure 2-9: PVG Priming Valves 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 a P25, P30 or P30V relief valve. (See Figure 2-10: “P Series Relief Valve System Arrangement.
❑ Introduction The valve is mounted in the discharge piping and plumbed back to the pump suction. Valve connections are either flanged or Victaulic™. (See Figure 2-10: “P Series Relief Valve System Arrangement,” on page 23.) How the Relief System Works A pressure line mounted in the pump discharge pressure tap provides pressure to the diaphragm in the PM control valve. The handwheel on the PM control either increases or decreases the spring tension on the diaphragm.
❑ Introduction After the temperature returns to a safe level, the valve closes. TRV-L Kit (See Figure 2-11: “Thermal Relief Valve, TRV,” on page 24.) The TRV-L kit includes a chrome panel placard with a warning lamp, a lamp test button, and a pre-assembled wire harness. The light illuminates when the TRV is open and discharging water. An optional buzzer provides audible warning. The buzzer mounts on the operator panel. Anodes (See Figure 2-12: “Hale Anode.
❑ Introduction Manifolds (See Figure 2-13: “Typical Manifold Assembly Option.
❑ Operation 3 Operation This section provides information and procedures for the operation of Hale silencer series booster pumps. Included are post-operation procedures and procedures for pumping from: ❑ a hydrant ❑ draft ❑ an onboard tank NOTICE ! THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES.
❑ Operation Figure 3-1: Driver’s Compartment Indicator Lights 3. Engage the PTO (power take-off) per the PTO manufacturer’s instructions. The GREEN shift warning indicator light illuminates, indicating a complete shift. (See Figure 3-1: “Driver’s Compartment Indicator Lights.”) WARNING ! DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB ARE ON. 4.
❑ Operation Figure 3-2: Pump Operator’s Panel 7. If necessary, open the suction valve to allow water to flow into the pump. 8. To eliminate air pockets, open appropriate valve to expel air or prime the pump, if so equipped. Also see heading “Pumping from Draft” on page 31. 9. Note the discharge pressures and intake pressures as applicable, then open the engine throttle gradually until the master discharge gauge indicates the desired pressure. 10.
❑ Operation If you need to increase pressure when this occurs, the pump flow must be reduced or the water supply improved. 12. As the throttle is increased, the pressure gauge reading increases with engine speed. If the engine speed increases without an increase in pressure, the pump could be cavitating. See Section 3.4 “Cavitation” on page 36. Cavitation can occur on a hydrant and it indicates the need to reduce the flow or improve the water supply. 13.
❑ Operation Another factor that can limit LIFT when drafting is barometric pressures below 29 in.Hg. High elevations and storm conditions can affect maximum flow available from any pump. Pumping from Draft 1. Get as close to the water source as practical. The pump can draw 100% of its rated capacity with less than a 10 foot (3.05 meters) vertical lift and 20 feet (6 meters) of suction hose. Water Temperature F° (C°) Lift Losses Head Ft. (mm) 60° (16°) NFPA Base Line 70° (21°) 0.3 (7.
❑ Operation WARNING ! DO NOT ADVANCE THE THROTTLE UNLESS THE “OK TO PUMP” INDICATOR IS ON. 7. Verify the pump panel shift indicator light is ON. 8. Activate the priming pump by pulling the control handle located on the pump panel or pressing the push-button. 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 12. Set the automatic relief valve, or governor according to department policy. See Section 3.3 “Relief Valve Procedures” on page 35. 13. After completing pumping procedures, gradually reduce the engine RPM to IDLE speed. See heading “Post Operation procedure” on page 40. 14. Disengage the PTO per the PTO manufacturer’s instructions. Pumping from Onboard Water Tank 1. Bring the truck to a complete stop and apply the truck parking brake.
❑ Operation 7. Open the tank suction valve (tank-to-pump). 8. Check the master discharge gauge to see if priming is necessary. If necessary, start the priming pump by either pulling the control handle located on the pump panel or pressing the prime push-button. CAUTION ! IF THE DISCHARGE GAUGE READING DOES NOT INCREASE, THE INTAKE GAUGE READING DOES NOT FALL BELOW ZERO (0), OR THE PRIMING PUMP DOES NOT DISCHARGE WATER TO THE GROUND IN 30 SECONDS, DO NOT CONTINUE TO RUN THE PRIMING PUMP.
❑ Operation 14. After completion of pumping procedures, gradually reduce the engine RPM until it is at an IDLE speed. See heading “Post Operation procedure” on page 40. 15. Disengage the PTO per the PTO manufacturer’s instructions. 3.2 PUMP AND ROLL OPERATION During pump and roll operation, it is necessary to slow the forward motion of the apparatus to the PTO (Power Take-Off) manufacturer's recommended engagement speed. The following outlines a general pump and roll procedure: 1.
❑ Operation The amber indicator light illuminates. (See Figure 3-4: “TPM Relief Valve Control.”) 3. Turn the hand wheel slowly clockwise until the indicator light goes out. The relief valve will operate at the set pressure. 4. When the pump is not in operation, turn the hand wheel clockwise back to a position slightly above the normal operating pressure. More complete and detailed information can be found in the relief valve manual.
Operation ❑ Process of Cavitation Cavitation occurs when a centrifugal pump attempts to discharge more water than it is receiving. When cavitation occurs, bubbles are created under the vacuum, formed near the eye of the impeller. Cavitation is often referred to as “the pump running away from the fluid supply.” This means the operator is trying to pump more water out of the pump than is going into the pump.
❑ Operation Vacuum Compound Gauge Do not depend entirely on the vacuum (compound) gauge to indicate when a pump is nearing cavitation. The vacuum gauge is usually tapped into the intake chamber several inches away from the leading edge of the impeller eye where the greatest amount of vacuum occurs. The vacuum gauge does not take into account ambient temperature nor atmospheric pressure and is not accurate near zero (0) on the vacuum scale.
Operation ❑ Monitor the water temperature. Table 3-3: “Base Line NFPA Ratings” on page 31 shows the amount of lift loss as temperatures rise. ❑ ❑ Barometric Reading in. (mb) Monitor barometric pressure. NFPA standard sets a baseline of 29.9”Hg. (See Table 3-7: “Lift Loss from Elevation.”) Lift Loss Head Ft. (mm) 29.9 (1,012.5) NFPA Base Line 29.7 (1,005.8) 0.2 (0.6) 29.5 (999) 0.5 (0.15) 29.3 (999.2) 0.7 (0.21) 29.1 (985.4) 0.9 (0.27) 28.9 (987.7) 1.1 (0.33) 28.7 (971.9) 1.
❑ Operation ❑ 3.5 Cavitation can also occur when air enters the pump. The pump could be primed, however, air leaks can cause rough operation and an increase of engine speed without an increase in pressure or flow. If an air leak is suspected, refer to Section 5 “Troubleshooting” on page 55. POST OPERATION PROCEDURE 1. Return the engine to idle. 2. Slowly close all valves. 5. Place the transmission in NEUTRAL or PARK. 3. Slowly shift from PUMP to ROAD to disengage the pump. 4.
Preventive Maintenance 4 ❑ Preventive Maintenance 4.1 OVERVIEW Hale Silencer Series Booster Pumps require minimal care and maintenance. Preventive maintenance tasks take little time to perform and consist primarily of leak testing, lubrication and cleaning. The procedures provided in this section are for normal use under normal operating conditions. Extreme conditions require additional maintenance to ensure lengthened pump life and continuing dependability. 4.2 POST-OPERATION Drain Pump 1.
❑ Preventive Maintenance During Freezing Weather In freezing weather, drain the pump as follows: 1. Open all discharge and suction valves, remove suction tube caps and discharge valve caps. 2. Open pump body drain cocks and/or Hale multiple drain valve. 3. After the pump is completely drained, replace all caps and close all valves. Pumping from Salt Water, Contaminated Water, or with Foam Solution Thoroughly flush the pump and suction hoses using fresh water from a hydrant or other clean water source.
❑ Preventive Maintenance 1. Prepare to pump from the onboard water tank, having the discharge flow directed back to the water tank. 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 4-1: “TPM Relief Valve Control.”) 4.
❑ Preventive Maintenance 2. Verify that the warning indicators in the cab and the pump control panel function properly. 3. Verify that the indicator lights on the control panel function properly and agree with the indicators in the cab. 4. Repair or replace any malfunctioning indicators. Valve Maintenance Properly functioning valves are integral to the operation of the pump. Refer to the separate valve manual for proper valve maintenance procedures.
Preventive Maintenance ❑ Inspect Water and Foam Tanks Visually inspect water and foam tanks for proper level and gauge readings. If any debris is present, flush the tanks to protect the pump from wear caused by dirty water or foam concentrate. Check Roof and Bumper Turrets If the apparatus is so equipped, verify that the turrets function properly, and no leaks are present. Make repairs immediately. Visually inspect all piping and valves on the pump and auxiliary equipment for corrosion or damage. 4.
❑ Preventive Maintenance Incorrect oil types or amounts of oil result in unnecessary loss of power and high oil temperature. Change the oil every 12 months, depending on pump usage. All lubricants must meet service rating API GL-5 requirements. (See Figure 4-2: “Gearbox Capacity / Recommended Lubricants,” on page 45.) Note: Hale recommends using an SAE EP-90, 80W90 Lubricant or “RoadRanger” Full Synthetic SAE 50 Transmission Lubricant, manufactured by the Eaton® Corporation, or equivalent. 1.
❑ Preventive Maintenance 2. Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel. 3. Engage the priming pump until the gauge indicates at least 22” Hg vacuum. (See Figure 4-4: “PVG Priming Valve Handle.”) 4. Compare the readings of the test gauge and the apparatus gauge. Note any difference. Figure 4-4: PVG Priming Valve Handle 5. STOP the priming pump and observe the gauge. If the vacuum falls more than 10” Hg.
❑ Preventive Maintenance 4.6 ANNUALLY ❑ Replace the pump gearbox oil. (See Figure 4-2: “Gearbox Capacity / Recommended Lubricants,” on page 45.) ❑ Check individual drain lines from the pump to the multi-drain to ensure proper drainage and protection from freezing temperatures. ❑ Test tank-to-pump flow rate. (See page 49.) ❑ Clean ESP Primer, if installed. (See separate manual provided.) ❑ Perform the yearly pump test to check performance levels. (See NFPA Standard 1911 for more details.
❑ Preventive Maintenance Most of these drains are piped together to a multi-drain to allow the entire system to be drained by one valve. It is necessary to inspect each line of the multi-drain to ensure the entire system is draining when the valve is operated. Inspect each connection and verify the individual lines to the multi-drain are free of debris. Repair or replace any lines that are damaged, kinked, or corroded. Tank-to-Pump Flow Rate Test Note: This procedure is provided as a reference only.
❑ Preventive Maintenance Performance Testing Overview The yearly standard performance test consists of checking the pump (according to its rating) at three capacities and comparing the results to when the pump was first placed in service. This provides some measure of any performance deterioration. (See Figure 4-5: “Pump Ratings (GMP/ LPM),” on page 50.) A pump must be able to pump FULL capacity at 150 PSI, 70% capacity at 200 PSI and 50% capacity at 250 PSI.
❑ Preventive Maintenance 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 103 at the back of this manual. Since NFPA standards specify both GPM and pressure, it is usually necessary to restrict the flow somewhat to build up the pump pressure.
❑ Preventive Maintenance GPM (LPM) at VARIOUS NOZZLE SIZES Noz z le Pressure Noz z le Siz e, in Inches (Millimeters) PSI (BAR) 1/2" (13) 5/8" (16) 3/4" (19) 7/8" (22) 1" (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) 254 (962) 308 (1,166) 35 (2.4) 44 (167) 69 (261) 99 (375) 135 (511) 176 (666) 222 (840) 275 (1,041) 332 (1,257) 40 (2.
Preventive Maintenance ❑ GPM (LPM) at VARIOUS NOZZLE SIZES Noz z le Pressure Noz z le Siz e, in Inches (Millimeters) PSI (BAR) 1-1/2" (38) 1-5/8" (41) 1-3/4" (45) 1-7/8" (48) 2" (51) 2-1/4" (57) 2-1/2" (64) 3" (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.
❑ Preventive Maintenance Worn Clearance Rings and Impeller Hubs Before assuming that clearance ring wear is at fault or that clearance ring replacement requires pump disassembly, it is advisable to thoroughly check other possible causes of low performance. Clearance rings limit the internal bypass of water from the discharge side of the pump back to suction. The radial clearance between the impeller hub and the clearance rings is only a few thousandths of an inch when new.
Troubleshooting 5 ❑ Troubleshooting Table 5-2 lists conditions, possible causes and suggested corrective action measures. Before calling Hale Products or a Hale authorized parts service center for assistance, eliminate problem causes using the following table. If you cannot correct a problem, please have the Model and Serial numbers ready prior to calling the Hale Customer Service Technician Department for assistance. Customer Service telephone number: 610-825-6300.
❑ Troubleshooting Condition PUMP LOSES PRIME OR WILL NOT PRIME continued Possible Cause Suggested Corrective Action Blocked suction strainer • Remove obstruction from suction hose strainer. Suction connections • Avoid placing any part of the suction hose higher than the suction intake. • Thoroughly clean strainer screen. • Suction hose should be laid out with continuos decline to fluid supply. • Avoid placing any part of suction hose higher than the suction intake.
Troubleshooting Condition Possible Cause ❑ Suggested Corrective Action • Connect the suction hose from the hydrant or the discharge of another pumper to pressurize the pump with water and look for visible leakage and correct. A pressure of 100 PSI (6.9BAR) should be sufficient. DO NOT exceed pressure limitations of pump, accessories or piping connections. PUMP LOSES PRIME OR WILL NOT PRIME continued • The suction side relief valve can leak.
❑ Troubleshooting Condition ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE continued Possible Cause Suggested Corrective Action Faulty suction hose • Inner line of suction hose may collapse when drafting and is usually undetectable. • Try a different suction hose on the same pump. • Test for comparison against original hose. Blockage at suction hose entry • Clean suction hose strainer of obstruction. See Section 4 Preventive Maintenance, heading “Intake Strainers” on page 44.
Troubleshooting Condition RELLEF VALVE DOES NOT RELIEVE PRESSURE WHEN VALVES ARE CLOSED Possible Cause ❑ Suggested Corrective Action Incorrect setting of control (PDM) Valve • Check and repeat proper procedures for setting relief valve system. • See Section 3 Operation, heading “Relief Valve Procedures” on page 35. • Possibly in need of lubrication. Remove valve from pump, dismantle, clean and lubricate.
❑ Troubleshooting Condition DISCHARGE VALVES DIFFICULT TO OPERATE Possible Cause Suggested Corrective Action Lack of lubrication • Recommended weekly lubrication of discharge and suction valve. • Use a good grade petroleum based silicone grease. • Foe Hale Products, SVS Valves, etc., use Never-Seize® White Food Grade with PTFE. • Refer to separate valve manual for addition information.
Preventive Maintenance 6 ❑ Repair Figure 6-1: Silencer Series Booster Pump Silencer Series Booster Pump, p/n: 029-0020-83-0 61
❑ Preventive Maintenance Gearbox Approximate Orientation Capacity Vertical 2 Quarts (1.9 Liters) Horizontal (Right or Left Hand) 1.5 Quarts (1.4 Liters) Inverted 1.75 Quarts (1.7 Liters) All lubricants must meet service rating API GL-5 requirements Figure 6-2: Gearbox Capacity / Recommended Lubricants Bolt Size Lock Nut size Material Minimum Torque Ft.-Lb.
Preventive Maintenance ❑ It is recommended to use Hale genuine replacement parts for optimum safety of the equipment and its operators and to avoid unnecessary downtime. For an illustrated pump and gearbox overview, see Figure 6-1: “Silencer Series Booster Pump” on page 61. 6.2 GENERAL REPAIR GUIDELINES Before You Begin... Figure 6-1: Silencer Series Booster Pump, on page 61, for a pump and gearbox overview. READ ALL INSTRUCTIONS THOROUGHLY BEFORE BEGINNING ANY SERVICE REPAIR. 1.
❑ Preventive Maintenance 5. Make sure there is sufficient clearance above and around the apparatus to perform your service requirements. Obtain access to the pump assembly by removing or disconnecting other equipment as needed: 6. Where grease is called for, use a Lithium-based grease with 1% to 3% Molybdenum Disulfate.
Preventive Maintenance ❑ 9. Use a pusher tool or a bearing installation tool when installing bearings and seals to avoid cocking the bearings or marking the bearing faces. 10. BEFORE PLACING THE APPARATUS INTO OPERATION, THE PUMP ASSEMBLY MUST BE TESTED AND CHECKED FOR LEAKS. ALL LEAKS MUST BE REPAIRED IMMEDIATELY. Cleaning and Inspection Guidelines Wherever procedures call for cleaning and inspection, use the following guidelines: 1. Inspect all components for excessive or abnormal wear.
❑ Preventive Maintenance Hale Recommended Cleaners ❑ Safety Kleen ❑ Stoddard Solvent Tools Required ❑ Lifting gear-lever hoist or chain hoist, and short choker ❑ Ball peen hammer ❑ Center punch ❑ Drift punch ❑ Allen wrenches ❑ Strap wrench ❑ Snap ring pliers ❑ Pry bars (2) ❑ Ratchets and wrenches for disassembly ❑ Torque wrench capable of 40, 65, and 135 ft.-lb.
❑ Preventive Maintenance 6.3 PUMP AND GEARBOX ASSEMBLY WARNING ! THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY, WEIGHING UP TO 145 LBS. (54 KGS.). ADDED ACCESSORIES MAY INCREASE THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE SILENCER SERIES BOOSTER PUMP AND GEARBOX ASSEMBLIES. The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62.
❑ Preventive Maintenance 7. Carefully remove the assembly from the apparatus. 8. Place and support the pump assembly on a stable work stand/bench of suitable capacity (see “WARNING !” on page 67.). Have the air vent and covers exposed to provide easy and safe access to the internal parts. Installing the Assembly to Apparatus After completing repairs and/or maintenance, install the pump assembly to the apparatus before filling with oil. 1. First, review preceding Section “Before You Begin...” on page 63.
❑ Preventive Maintenance 6.4 SERVICING THE BOOSTER PUMP The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62. Also, please review section General Repair Guidelines, on pape 62, before beginning these procedures. Volute (Pump Body) (See Figure 6-4: “Booster Pump Parts Breakdown.”) Figure 6-4: Booster Pump Parts Breakdown The volute is secured by hex screws (quantity dependent on pump model). It is sealed with a gasket that must be replaced whenever the joint face is disturbed.
❑ Preventive Maintenance 2. Unthread the compression fittings and disconnect gearbox cooler hoses from the volute. (See Figure 65: “Typical Water Cooling Lines.”) 3. Remove the 7/16-14 bolts and hardware to dismantle the volute from the pump head. Pull the volute body from the assembly being careful not to damage the impeller or scratch the sealing surfaces of the volute. (See Figure 6-4: “Booster Pump Parts Breakdown,” on page 69.
❑ Preventive Maintenance ❑ Replace all gaskets. Apply a small amount of grease to the gasket(s) and align on the pump body. ❑ If the clearance rings are removed, use a press to install them back into the pump body. ❑ When installing the pump body to the pump head, DO NOT damage the clearance rings or impeller. ❑ Reconnect all cooling lines, piping and tubing. ❑ Inspect the system for proper operation. ❑ Return the apparatus to service.
❑ Preventive Maintenance 7. Removing the impeller may disturb the mechanical seal. A new seal must be installed. Inspection – Clearance Rings (See Figure 6-6: “Clearance Ring ID Measurement.”) Inspect both clearance ring IDs for signs of wear. Using a caliper, measure the inside diameter of each ring in several places. If the nominal dimension does not fall within the acceptable range specified below, the clearance ring must be replaced.
❑ Preventive Maintenance ❑ Minimum Outside Diameter APS - ........ 4.74” (120.4mm) MBP -......... 5.60” (142.2mm) If the measured diameter is equal to or less than the maximum outside wear limit a new impeller must be installed. When new, the radial clearance between the impeller hubs and the clearance rings are between 0.005” to 0.007” (0.127-0.78mm) per side. Maximum acceptable radial clearance on used pumps is between 0.015” to 0,020” (0.381-0.508mm) per side.
❑ Preventive Maintenance 6.5 MECHANICAL SEAL ASSEMBLY (See Figure 6-8: “Mechanical Seal Overview / Replacement.”) Also see Figure 6-4: “Booster Pump Parts Breakdown” on page 69. Figure 6-8: Mechanical Seal Overview / Replacement IMPORTANT ! IF WATER LEAKAGE FROM THE DRAIN HOLE IN THE PUMP HEAD IS NOTICED, THE IMPELLER MUST BE REMOVED AND THE MECHANICAL SEAL MUST BE INSPECTED. Removing the Seal 1. To expose the mechanical seal, remove the volute and the impeller as described in the following sections.
❑ Preventive Maintenance CAUTION ! MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICES. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE MATING FACES. ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION. SOLID FACES MUST BE CLEANED WITH AN APPROPRIATE DEGREASER AND A SOFT CLOTH. 2.
❑ Preventive Maintenance 5. Without touching the carbon seal, slide the stationary seat into the pump head. 6. Carefully push the stationary seat into the pump head bore using a soft clean pusher tube. Verify the stationary seat is firmly seated in the pump head. 7. Clean the pump shaft with alcohol swabs. 8. Apply a generous coating of PAC-EASE Rubber Lubricant Emulsion (or equal) to the seal diaphragm. (See Figure 6-8: “Mechanical Seal Overview / Replacement,” on page 74.
Preventive Maintenance 6.6 ❑ PUMP HEAD To service the oil seal between the pump head and gearbox or to service the gearbox, dismantle the pump head from both units. (See Figure 6-9: “Oil Seal Replacement / Pump Head Parts.”) Figure 6-9: Oil Seal Replacement / Pump Head Parts The following procedures frequently refer to Tables 6-2, and 6-3 on pape 62. Also, please review section General Repair Guidelines, on pape 62, before beginning these procedures.
❑ Preventive Maintenance Removing the Pump Head and Oil Seal (See Figure 6-9: “Oil Seal Replacement / Pump Head Parts,” on page 77.) 1. As described in the previous sections, remove the following ❑ Volute, on pape 69 ❑ Impeller, on pape 71 ❑ Mechanical seal, on pape 74 2. Remove the four (4) hex screws and hardware securing the pump head to the gearbox casing. 3. Using a soft faced (dead blow) hammer, carefully tap around the pump head until it is separated from the gearbox.
Preventive Maintenance 6.7 ❑ ❑ Replace all gaskets and pump head seal rings, where applicable. Apply a coating of general-purpose grease to the gasket and align to the pump head. (See Figure 6-9: “Oil Seal Replacement / Pump Head Parts,” on page 77.) ❑ Install a new seal ring into the bore of the pump head on the gearbox side. ❑ Install the pump head on the gearbox being careful not to damage the oil seal or pump shaft.
❑ Preventive Maintenance Figure 6-10: Oil Seal, Input Shaft Installation Notes (See Figure 6-10: “Oil Seal, Input Shaft.”) To install, follow the preceding steps in the reverse order, paying attention to the following: ❑ Review preceding sections “Before You Begin...,” on page 63 and “Cleaning and Inspection Guidelines,” on page 65 to ensure a thorough installation. ❑ Evenly press-in a new oil seal in the gearbox housing until flush against the bearing.
❑ Preventive Maintenance Figure 6-11: Typical Bearing and Seal Insertion Tools If the bearing tool is not available, cover the flange retaining ring groove with thin electrical tape to avoid cutting the oil seal as it is inserted. ❑ 6.8 Add fresh oil. (See Figure 6-2: “Gearbox Capacity / Recommended Lubricants,” on page 62.) See Section 4: Preventive Maintenance, heading “Gearbox Lubrication” on page 45. DISMANTLE THE B SERIES GEARBOX (See Figure 6-12: “B Gearbox Parts Identification,” on page 82.
❑ Preventive Maintenance Figure 6-12: B Gearbox Parts Identification Note: If your pump assembly includes the optional Hydraulic Dive Assembly it must be removed from the assembly. See heading “Hydraulic Drive Option” on page 87.
❑ Preventive Maintenance 2. Remove the volute, impeller, mechanical seal, pump head, and pump shaft oil seal. See heading “Servicing the Booster Pump” on page 69. 3. Unfasten the twelve hex screws and hardware securing the drive unit cover to the gearbox housing. Remove the drive unit cover and gasket. 4. Scrape all gasket material from mating surfaces, taking care not to scratch the machined finishes. The gasket must be replaced. 5.
❑ Preventive Maintenance 13. Using a brass drift, push the pump shaft out through the pump side of the gearbox. As the pump shaft is removed, it may cause the pump shaft spacer, pump gear key, and pump gear to fall off in the housing. Carefully remove these one at a time before they fall into the housing. Always protect these parts from being marred, scratched, etc. as they are removed. 14. If necessary, remove the roller bearing from the pump shaft using a press.
❑ Preventive Maintenance 2. Place the gearbox housing on a steady flat surface with drive shaft opening facing up. 3. Insert one of the two roller bearings into the bore of the gearbox housing. 4. Slide the input gear into the gearbox housing, aligning the bore of the drive gear with the bore of the housing. 5. Insert the key in input shaft and insert shaft into gearbox housing. Align the input shaft in the bearing. 6.
❑ Preventive Maintenance 13. Stand the gearbox housing on its base and install the gasket and bearing cover. Secure with 7/16-14 hex screws and hardware and torque to 50 ft.-lbs. (68 N-m). It is recommended to manufacture insertion tools to assure correct installation of the input shaft bearings and oil seal. (See Figure 6-11: “Typical Bearing and Seal Insertion Tools,” on page 81.) Also see Figure 6-13: “Typical Angular Bearing Insertion Tool” on page 84.
Preventive Maintenance 6.9 ❑ AVAILABLE OPTIONS Hydraulic Drive Option (See Figure 6-15: “Hydraulic Drive Option.”) Figure 6-15: Hydraulic Drive Option 17. If not already done, remove the hydraulic motor from the hydraulic adapter. 18. Remove the 7/16” hex screws and hardware securing the hydraulic adapter flange to the gearbox housing. 19. Slide (pull back) the coupling from the drive shaft. 20. Remove the drive shaft key and set safely aside.
❑ Preventive Maintenance Tachometer Drive Option (See Figure 6-16: “Tachometer Drive Option.”) Figure 6-16: Tachometer Drive Option 1. Disconnect the tachometer cable from the tachometer drive assembly. 2. Remove the tachometer drive assembly from the adapter fitting. 3. Unthread the adapter fitting from the bearing cover. Installation Notes (See Figure 6-16: “Tachometer Drive Option.”) To install, follow the preceding steps in the reverse order.
❑ Installation 7 Installation 7.1 OVERVIEW This section provides guidelines and recommendations for installing the silencer series pump assembly into your truck chassis. 7.2 FRAME MOUNTING Also see Section “Installation and Parts Drawings,” located at the back of this manual. ❑ Plate # 1027A ......APS Silencer Series Booster Pump Installation and Parts Identification ❑ Plate # 1026A ......
❑ Installation 7.3 DRIVELINE ISSUES Drive Line and Flange Bolts Ensure that: ❑ All bolts are tight. Use a torque wrench to torque bolts to the drive train manufacturer's recommended specifications. ❑ Bolts used are “Grade 8” strength. 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.
❑ Installation Shaft RPM 2.0 (51) 2.5 (64) 3.0 (76) 3.5 (89) 40. (102) 4.
❑ Installation ❑ Plate # 1026A ......MBP Silencer Series Booster Pump Installation and Parts Identification The Silencer Series Booster Pump offers the following suction and discharge arrangements: ❑ Suction (Inlet) – APS: ● Victaulic, Standard 5” (127mm) connection ● ISO 228/1-G4-1-1/2” female pipe thread ● 4-1/2” NST Suction/Discharge Manifold Kit (See Figure 2-13: “Typical Manifold Assembly Option,” on page 26.) MBP: ● Victaulic, Standard 6” (152.
❑ Maintenance Kits 8 Maintenance Kits Disassembly of the pump and/or gearbox is a major undertaking that can remove a pump from service for a considerable period of time. Gaskets and O-ring seals must be replaced to ensure the pump is fully operational when returned to service. It is never permissible to reassemble the pump without installing new gaskets and seals. Hale Products supplies repair kits designed specifically for each pump and gearbox.
❑ Maintenance Kits Model Number Kit Part Number APS-37 546-3000-02-0 MBP/APS (All Others) 546-3000-01-0 Table 8-3: Level 2 Kit Part Numbers Complete Overhaul A Level 3 kit includes the entire contents of the Level 1 and 2 kits, plus shafts, impeller, clearance rings and gears. Order Hale kits per Table 8-3: “Booster Pump Maintenance Kits, Level 3” below. Model Hale Part Number Ratio Rotation MBP 546-3000-03-0 1.64 N/A MBP 546-3000-04-0 2.33 N/A MBP 546-3000-05-0 2.
Appendix A Glossary/Measurements ❑ 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...........
❑ Appendix A Glossary/Measurements WARNING ! IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. THIS COULD DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM. Double Suction ..Fluid enters on both sides of the impeller. Impeller Dry Prime Test ...Provides information on the ability of a priming pump to evacuate air from the main pump. If the vacuum does not hold, it is an indication there is a leak in the system. Eye, Impeller.......
Appendix A Glossary/Measurements ❑ Positive ...............A pump with a fixed flow delivered to the discharge with each revolution. Displacement Pump Positive ..............Pressure above atmospheric. Pressure Power Valve........A valve that uses hydraulic pressure to transfer two-stage pump operation from volume mode to pressure mode, and vice versa. Pressure .............Force per unit area. Pressure ............The pressure gauge is usually graduated in pounds per square inch (PSI) only.
❑ Appendix A Glossary/Measurements Slinger Ring........Prevents fluid from continuing to travel down a shaft to the gears and ball bearings. Stages .................The number of impellers in a pump that are used in series; that is, one following another in terms of flow. Each impeller develops part of the total pump pressure. Tachometer ........Indicates the speed of the engine crankshaft in revolutions per minute. Torque.................The force that acts to produce rotation. Transfer Valve ...
Appendix A Glossary/Measurements ❑ 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...........
❑ Appendix A Glossary/Measurements 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.
❑ Alternate Lubricant Manufacturers 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 2924/2833) See Service Manual for more information. Brad Penn Full Synthetic Trans.
❑ Alternate Lubricant Manufacturers Oil / Lubricant Manufacturer Continued Alternate STANDARD-Temperature Lubricant (Cognis 2924/2833) See Service Manual for more information. Royal Manufacturing Co., Inc. P O B ox 3308 516 S 25th West Avenue Tulsa, OK 74127 Monarch Syntran Plus SAE 50 Trans. Mystik Synguard SX-7000 SAE 50 Trans. Cato Oil and Grease Company P O B ox 26868 1808 NE 9th Street Oklahoma City, OK 73126 Peterbilt SAE 50 Original Factory Fill Fluid Trans.
❑ Appendix D: Hose Friction Loss 3-1/2” (89mm) Hose 4” (102mm) Hose 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) 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 (0.9) 50 (189) 38 (2.6) 7 (0.5) 200 (757) 62 (4.3) 32 (2.2) 8 (0.
❑ Appendix D: Hose Friction 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.
Limited Warranty 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 ...................610-825-6300 Fax .. ...........................610-825-6440 Web. ............www.haleproducts.
