SMM / SMR / SMD Stainless Max Series Pumps Operation and Maintenance Manual HALE PRODUCTS, INC. ● A Unit of IDEX Corporation 700 Spring Mill Avenue ● Conshohocken, PA 19428 U.S.A.
NOTICE ! Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale Products is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice. All Hale products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested.
Table of Contents Contents SECTION Page 1: SAFETY PRECAUTIONS ...........................................................1-1 GUIDELINES ................................................................................................................................ 1 SECTION 2: INTRODUCTION.........................................................................2-1 OVERVIEW ...............................................................................................................................
Table of Contents Contents - continued Page ACCESSORIES - continued Pressure Control ................................................................................................................................... 13 The P Relief Valve System ............................................................................................................... 13 Figure 2-15: Relief Valve System Arrangement .........................................................................
Table of Contents Contents - continued SECTION 4: Page PREVENTIVE MAINTENANCE ...............................................4-1 OVERVIEW .................................................................................................................................. 1 POST-OPERATION ...................................................................................................................... 1 Flush Pump .........................................................................................
Table of Contents Contents - continued Page ANNUALLY - continued Performance Testing Overview ............................................................................................................. 11 Performance Testing Equipment and Materials ................................................................................ 11 Table 4-9a: Nozzle Flow and Pressure Ratings .........................................................................
Table of Contents Contents - continued Page PUMP AND GEARBOX ASSEMBLY ........................................................................................... 7 Removing Pump Assembly from Apparatus ............................................................................................ 7 Installing Pump Assembly to Apparatus .................................................................................................. 8 Figure 6-4: Stainless Max Pump Assembly .................................
Table of Contents Contents - continued Page HG SERIES GEARBOX - continued Dismantle the HG Gearbox ................................................................................................................... 28 Figures 6-14: HG Series Gearbox Breakdown .......................................................................... 29 Assemble HG Gearbox ......................................................................................................................... 29 “X” SERIES GEARBOX ......
Table of Contents Contents - continued SECTION 7: Page INSTALLATION ............................................................................. 1 OVERVIEW .................................................................................................................................. 1 FRAME MOUNTING .................................................................................................................... 1 Mounting Holes ....................................................................
Table of Contents NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ___________________________________________
Safety Precautions SECTION 1: SAFETY PRECAUTIONS IMPORTANT! THE HALE STAINLESS MAX TM SM SERIES PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL. THIS SECTION ON SAFETY MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE CAFSPRO PUMP SYSTEM.
Safety Precautions WARNING ! THE SM SERIES PUMP AND GEARBOX ARE HEAVY AND BULKY, WEIGHING UP TO 750 TO 850 LBS. / 340 TO 386KGS (APPROXIMATE). BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING SM SERIES PUMP AND GEARBOX ASSEMBLIES. ❑ Installation should be performed by a trained and qualified installer, or your authorized Hale Products service representative.
Safety Precautions Stainless Max Series Pumps ❑ Rotating drive line parts can cause injury. Be extremely careful that NO part of your body (head, feet, arms, legs, finger, hair) is in an area of rotating parts where you could be subject to injury. ❑ Make sure everyone is clear of the apparatus. Verify the parking brake is set and the wheels are chocked to prevent any movement of the apparatus. ❑ DO NOT operate the system at pressures higher than the maximum rated pressure.
Safety Precautions NOTES ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________
Introduction SECTION 2: INTRODUCTION OVERVIEW Hale Products currently offers the first and only all Stainless Steel SM Series Pumps in three (3) models: ❑ SMR – rear mounted fire pump ❑ SMM – fully manifolded midship pump ❑ SMD – unmanifolded midship pump Unless otherwise indicated, these procedures apply to all models of Hale SM Series Pumps. Any variations in operations and maintenance of the different models are addressed within the context of this manual.
Introduction The velocity at which the fluid travels from the center directly relates to the diameter of the disk and the speed of rotation. When water is confined in a closed container (such as the pump body or volute), the velocity is converted to pressure and this pressure rises to a level that depends on the speed of rotation.
Introduction Hale SM series pumps use a single impeller to develop the required volume and pressure. (See Figure 2-2: “Pump Impeller.”) During operation water enters the suction eye of the impeller. The rotating impeller vanes develop discharge pressure and direct the water to the discharge opening. The cut water is a wedge that divides the water between the volute (pump body) and the pump discharge. (See Figure 2-3: “SM Pump Water Flow.
Introduction This means that the operator is trying to pump more water out of the pump than is going into the pump. The formation of bubbles in the low pressure regions of the impeller cause the impeller to "slip" in the water since the impeller is designed to move liquid, not the air in the bubbles.
Introduction PUMP COMPONENTS - SM SERIES Stainless Max pumps are made up of: ❑ Pump Body ❑ Impeller and Shaft Assembly ❑ Mechanical Seal ❑ Gearbox Mechanical Seal Impeller Figure 2-5: “Overview of Hale SM Pump,” on the next page, shows these basic pump parts. These parts are briefly described in this section. Pump Body Pump Body (Volute) from Gearbox The Hale SM series Figure 2-5: Overview of Hale SM Pump pump body consists of a volute body pump head and front clearance ring.
Introduction The impeller is mounted so that the discharging tube is widest at the pump outlet. The volute collects the water. A further increase in pressure and a decrease in velocity take place in the diffuser which is cast into the pump body. Bearings Bearings support and align the impeller shaft for smooth operation. Mechanical Seal The mechanical seal is common to Hale SM series pumps. (See Figure 2-6: “Mechanical Seal Overview.
Introduction Hale offers a variety of pump gear ratios to accommodate a wide range of end-user and apparatus manufacturer requirements based on the pump's intended use, horsepower and speed rating of the engine, and the torque rating of the transmission PTO. SMM / SMD Pump G / HG Series Gearbox Also see subheading “X Series Gearbox” on page 2-8 for additional information about the gearbox.
Introduction However, the volumes and pressures safely obtainable are dependent on the torque capacity of the apparatus transmission or transfer case, power takeoff and the pump drive line. In most cases, the torque rating of the PTO determines maximum pump performance. The apparatus builder can give various pump performance spots that will define the torque limit of the PTO in terms of GPM and PSI.
Introduction Hale offers a variety of pump gear ratios to accommodate a wide range of apparatus manufacturer requirements based on engine speed and available horsepower. The gearbox can withstand the full torque of the engine in ROAD operating conditions up to 16,000 pound-feet (21,693N-m). The gearbox consists of the outer housing, gear set, and input and shafts that are both made of heat-treated nickel steel to support the shaft loads. (See Figure 2-9: “Overview X-Series Gearbox,” on preceding page 2-8.
Introduction The midship transmission is capable of handling full engine horsepower, allowing the pump to meet optimum performance levels as well as all torque requirements for over the road applications. Shifting If the gearbox is equipped with a power shift system, an in-cab control valve is provided for mode selection. This control locks in place for pump operation. Indicator lights are provided to alert the operator when the gearbox has fully shifted from ROAD to PUMP position.
Introduction The gearbox cooler circulates pump water to transfer heat from the gearbox oil to the pump discharge. It is standard equipment on pumps with a capacity of 750 GPM (2,839LPM) or greater and optional equipment on all other pumps. Priming Systems Priming pumps are used to evacuate air in the suction hose and the pump. The vacuum created allows atmospheric pressure to push water from the static source through the suction hose and into the pump.
Introduction A ESP series priming pump also uses a single control to open the priming valve between the pump and the priming pump, and start the priming motor. Priming Valves Hale priming valves open when the priming pump is operated to allow the air to escape from the pump.
Introduction When the handle on the PVG is pulled out, the valve opens and the switch energizes the primer motor. See Figure 2-14: “PVG Priming Valve” on page 2-12. Pushing the handle de-energizes the motor and closes the valve. Pressure Control The P Series relief valve system is a bronze, variable-pressure setting relief valve that prevents undue pressure per the requirements of NFPA Standard 1901. An indicator light on the operator control panel signals when the valve is open.
Introduction As the pressure on the diaphragm increases beyond the set point, the stem will move off its seat, allowing pump pressure to push on the piston in the relief valve. This causes the relief valve seat to lift allowing excess pressure to dump back to the pump suction side. After the pressure equalizes, the piston returns to the closed position. An Amber indicator light on the PM control illuminates when the relief valve is open.
Introduction NOTES ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ______________________________________________________
Introduction APPENDIX A: GLOSSARY Atmospheric ........ Pressure caused by the elevation of air above the earth. Air pressure is 14 pounds Pressure per square inch at sea level. Pressure increases below sea level and decreases above sea level. The weather also effects air pressure. Atmospheric pressure effects a pumps ability to pump from draft. Higher pressures increases a pumps performance, while lower pressures can cause a noticeable decrease in lift. Auxiliary...............
Introduction WARNING ! IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR WITHOUT DISCHARGING WATER, IT MAY OVERHEAT. THIS COULD DAMAGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM. Double Suction .... Fluid enters on both sides of the impeller. Impeller Dry Prime Test .... Provides information on the ability of a priming pump to evacuate air from the main pump. If the vacuum does not hold, it is an indication there is a leak in the system. Eye, Impeller .......
Introduction Positive................ A pump with a fixed flow delivered to the discharge with each revolution. Displacement Pump Positive................ Pressure above atmospheric. Pressure Power Valve ........ A valve that uses hydraulic pressure to transfer two-stage pump operation from volume mode to pressure mode, and vice versa. Pressure .............. Force per unit area. Pressure .............. The pressure gauge is usually graduated in pounds per square inch (PSI) only.
Introduction Shrouds ............... Sides of an impeller that confine the fluid. Slinger Ring......... Prevents fluid from continuing to travel down a shaft to the gears and ball bearings. Stages ................. The number of impellers in a pump that are used in series; that is, one following another in terms of flow. Each impeller develops part of the total pump pressure. Tachometer ......... Indicates the speed of the engine crankshaft in revolutions per minute. Torque .................
Introduction APPENDIX B: MEASUREMENTS Water Horsepower .................................................................................................... (GPM x PSI)/1,714 One Gallon of Water Weighs ............................................................................................... 8.33 Pounds One Gallon ................................................................................................................... 231 Cubic Inches One Cubic Foot ...........................................
Operating Procedures SECTION 3: OPERATING PROCEDURES This section provides information and procedures for the operation of Hale SM series pumps. Included are post-operation procedures and procedures for pumping from: ❑ a hydrant ❑ draft ❑ an onboard tank Unless otherwise indicated, these instructions apply to all Hale SM series pumps. NOTICE ! THE PROCEDURES IN THIS SECTION ARE GENERAL OPERATING PROCEDURES.
Operating Procedures 4. Shift the truck transmission to the NEUTRAL position. See Figure 3-1: “Driver’s Compartment Indicator Lights.” PTO Transmission Switch Connection PUMP ENGAGED WHEN LIT OK TO PUMP WHEN LIT PUMP ENGAGED WHEN LIT OK TO PUMP WHEN LIT Ground CAUTION ! PTO Switch Connection NEVER ATTEMPT TO Figure 3-1: Driver's Compartment Indicator SHIFT THE PUMP Lights TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR.
Operating Procedures 8. Exit the driving compartment only after all the above steps are completed and you are sure that the shift completed lights in the cab and panel are on. CAUTION ! NEUTRAL Safety Switch PUMP ENGAGED WHEN LIT OK TO PUMP WHEN LIT WARNING DANGER Ground Throttle Control DO NOT OPEN THE Figure 3-2: Pump Operator's Panel THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS ON. (ALSO SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL.”) 9.
Operating Procedures To increase the pressure when this occurs, reduce the pump flow. 16. The master intake gauge reading must be maintained at 5 PSI (0.3 BAR), minimum. If the gauge shows a vacuum the pump is attempting to draw more water than the hydrant can supply. When this occurs, reduce the pump flow to increase the pressure. As the throttle is opened, the pressure gauge reading increases with engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating.
Operating Procedures Emergency Pump Shift Procedures Before implementing manual override shift procedures, repeat recommended procedures as described in the previous section. If the shift fails to take place, follow these procedures. 1. Bring the truck to a complete stop. 2. Apply the truck parking brake and chock the wheels. 3. Shift the truck transmission to the NEUTRAL position. 4. For PUMP or ROAD position, put the in-cab shift control in the NEUTRAL position.
Operating Procedures TPM Operation from a Hydrant When operating from a positive inlet pressure, during some operational conditions, it may be necessary to adjust the TPM Relief Valve to a point where water is dumping to the ground. The internal relief valve will always open first, and if it cannot handle the pressure rise, the external relief valve will dump water on the ground.
Operating Procedures 2. Bring the truck to a complete stop before attempting to connect suction hoses or shifting from ROAD to PUMP. 3. Apply the truck parking brake. 4. Shift the truck transmission to NEUTRAL. CAUTION ! NEVER ATTEMPT TO SHIFT THE PUMP TRANSMISSION WHILE THE TRUCK TRANSMISSION IS IN GEAR. ALWAYS SWITCH THE TRUCK TRANSMISSION TO “N” AND VERIFY THE SPEEDOMETER IS AT ZERO “0” BEFORE MAKING THE PUMP TRANSMISSION SHIFT. (SEE FIGURE 3-1: “DRIVER’S COMPARTMENT INDICATOR LIGHTS.”) 5.
Operating Procedures WARNING ! DO NOT ADVANCE THE THROTTLE UNLESS THE "OK TO PUMP" INDICATOR IS ON. 9. Verify the pump panel shift indicator light is on. 10. Activate the priming pump by pulling the control handle located on the pump panel or pressing the push button. The departmental manual for pumping should specify the correct RPM for priming. In general, priming should be done at idle with an engine speed of about 1,000 to 1,200 RPM. 11. Monitor the intake and discharge master gauges.
Operating Procedures 14. If a pump shutdown is desired while pumping from draft, reduce the engine speed to idle, and close the discharge valves. To resume pumping, open the throttle and discharge valves. If the pump overheats from continued churning without water flow, open the discharge valves periodically to release hot water. 14. Set the automatic relief valve according to department policy. See heading “Relief Valve Procedures” on page 3-12. 15.
Operating Procedures For most operating conditions, this is the direct drive (1:1 ratio). In addition, the speedometer should read 5 MPH to 15 MPH (8-15 KMH) after the shift has been completed. 7. If the shift does not complete, shift the truck transmission to “N” and repeat the entire procedure. Note: Some vehicles operate the speedometer from the front wheels. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck manual for details.
Operating Procedures 12. Open the engine throttle gradually until the desired pressure or flow is reached. As the throttle is opened, the discharge pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. Note: Cavitation is discussed in detail under heading “Cavitation,” beginning on page 3-13. If the pump is cavitating, warn personnel that the pressure is being dropped.
Operating Procedures Note: Most PTOs must be engaged while the apparatus is stopped. Only a "Hot Shift" PTO can be engaged while the apparatus is rolling. 2. Engage the PTO. 3. Verify the PUMP ENGAGED light is ON. 4. Open the valve between the tank and pump suction. 5. Observe pump discharge pressure and verify the pump pressure increases. 6. Prime the pump if necessary. 7. Open the discharge valves and commence operations.
Operating Procedures 4. When the pump is not in operation, turn the hand wheel clockwise back to a position slightly above the normal operating pressure. More complete and detailed information can be found in the relief valve manual. CAUTION! THE PRESSURE INDICATOR ON THE PANEL IS ONLY A ROUGH INDICATION OF TPM SETTING. ALWAYS USE THE ABOVE PROCEDURE TO PROPERLY SET THE “TPM” RELIEF VALVE SYSTEM. CAVITATION Cavitation can occur while pumping from draft, in relay, or from a hydrant.
Operating Procedures This sudden change from vapor to liquid generates a shock effect that damages the impeller and pump housing. Usually there are thousands of tiny vapor pockets (bubbles) rather than a few large ones. It is the collapsing (or implosion) of these bubbles that causes the characteristic sound of cavitation that has been described as rocks tumbling in the pump.
Operating Procedures Table 3-3: “Baseline NFPA Rating,” on page 3-6, shows the amount of lift loss as temperatures rise. If there is a marked loss of suction capacity, the pump may be near cavitation. Note: When water reaches 95° F( 35° C), you should notice a marked decrease in lift. ❑ Monitor barometric pressure. NFPA standards sets a baseline of 29.9”Hg. See Table 3-5: “Lift Loss from Barometric Pressure.
Operating Procedures Hose Diameters in. (mm) 3” (76) 4” (102) 4.5” (114) Flow gpm (lpm) 250 5” (127) 6” (152) Dual 6” (152) Lift Loss 5.2 (20) 350 2.5 (9.5) 500 5.0 (19) 3.6 (13.6) 750 11.4 (43) 8.0 (30) 4.7 (18) 1.9 (7.2) 14.5 (55) 8.5 (32) 3.4 (13) 13 (49) 5.2 (20) 1,000 1,250 1,500 7.6 (29) 1.9 (7.2) 1,750 10.4 (39) 2.6 (10) 2,000 3.4 (13) 2,500 5.2 (20) Table 3-7: Hose Size for Pump Rating Capacity ❑ Consider the piping within the truck.
Operating Procedures 5. Drain the pump (especially important in freezing weather): ❑ Open the discharge valves, remove suction tube caps, and discharge valve caps. ❑ Open the pump body drain cocks or Hale multiple drain valve. If a multiple drain valve is used, all pump drain lines should be connected to this valve. ❑ After the pump is completely drained, replace all caps and close all valves, 7.
Operating Procedures NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ________________________________________
Preventive Maintenance SECTION 4: PREVENTIVE MAINTENANCE OVERVIEW Hale SM Series 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 supplied in this section are for normal use under normal operating conditions. Extreme conditions may indicate a need for increased maintenance and the additional measures needed to ensure lengthened pump life and continuing dependability.
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.
Preventive Maintenance Relief Valve Test When the relief valve is not in operation, keep the hand wheel set above the normal operating pressure. 1. Prepare to pump from the onboard water tank, having the discharge flow back to the water tank. 2. Turn the relief valve hand wheel clockwise to the STOP position to prevent the valve from operating. See Figure 4-1: “PM Valve Control.” Figure 4-1: PM Valve Control 3.
Preventive Maintenance Pump Shift Warning Indicator Lights CAUTION! MAKE SURE EVERYONE IS CLEAR OF THE APPARATUS. VERIFY THE PARKING BRAKE IS SET AND THE WHEELS ARE CHOCKED TO PREVENT ANY MOVEMENT OF THE APPARATUS. 1. Follow the operating procedures in Section 3 to engage the pump if no local procedures exist. 2. Verify that the warning indicators in the cab and the pump control panel function properly. 3.
Preventive Maintenance Check Auxiliary Engine If the pump is powered by a separate engine, check the engine, fuel tanks and drive for wear and proper operation. Verify All Gauges are in Working Order Any gauge that is repeated in the cab or another panel, must agree with the gauge on the operator's panel. Gauges not reading within 10% of the calibrated test gauge must be removed from service and re-calibrated. Operate Pump Controls Operate the pump drive controls to verify the pump engages.
Preventive Maintenance Gearbox Lubrication Too much oil or the wrong type of oil will result in unnecessary loss of power and high oil temperature. Change the oil every 12 months, depending on pump usage. Refer to Table 4-2: “Recommended Lubricants” for Hale recommended oils and gearbox capacities. 1. Remove the gearbox oil fill plug, and check the level of the oil in the gearbox. See Figure 4-3: “Sample Fill Plug.” The oil level should be up to the plug hole.
Preventive Maintenance 4. Compare the readings of the test gauge and the apparatus gauge. Note any difference. 5. Stop the priming pump and observe the gauge. If the vacuum falls more than 10 inches of Hg in 5 minutes, it is an indication of at least one air leak. Vacuum leaks may often be detected audibly if the apparatus engine is turned off. Correct leaks immediately to return the pump to service. 6. Test the suction hose as follows: a. Attach the suction hose to the pump. b.
Preventive Maintenance 2. All bolts are tight. Use a torque wrench to torque bolts to the drive train manufacturer's recommended specifications. 3. Bolts used are “Grade 8” strength. Be sure to use Hale genuine replacement parts before you attempt any repair maintenance. Figure 4-5: Grade 8 Bolt Head Indicator Light Test Operate the respective component having indicator lights and observe the indicator light operation. If the light fails to tunr ON, check and/or replace the bulb and test again.
Preventive Maintenance For the pedestal, see heading “Replace Pedestal Oil - SMR Series” for additional information. Note: Assembly orientation determines which plugs are used for oil fill, drain and level detection. Also see Installation Drawings at the back of this manual. 3. Examine the oil for contamination (e.g., water – turns the oil a milky color or settles to the bottom). Properly dispose of the used oil. 4. Inspect the magnetic drain plug.
Preventive Maintenance 5. Drain the oil from the pedestal into a suitable container (1.5 pints/ 0.7 liters). 6. Remove the oil fill/dipstick and replace the drain plug. (See Figure 4-7: “Pedestal Oil Change” on page 4-9.) 7. Fill the pedestal with an approved oil per preceding Step 2 and run the pump for a short period, then re-check the oil level.
Preventive Maintenance 7. Reopen the discharge valve, and check the flow through the nozzle using a Pitot tube or flowmeter. Adjust the engine throttle to bring the pressure to the amount previously determined. 8. Compare the flow rate measured to the NFPA minimum or the designed rate of the pump. If the flow rate is lower, a problem exists in the tank to pump line. The minimum flow rate should be continuously discharged until 80% of the tank is discharged.
Preventive Maintenance Use smooth bore test nozzles of accurate size with the Pitot Gauge. The volume pumped is then determined by referring to the discharge tables for smooth nozzles. Preferably, nozzles will be used on a Siamese deluge gun for greatest accuracy. A stream straightener, just upstream of the nozzle, is advisable. Refer to local procedures for pump testing procedures and practices. For Pitot Gauge accuracy, the nozzle pressures should be between 30 and 85 PSIG (2.1 and 6.0 BAR).
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) 30 (2.1) 366 (1,386) 430 (1,628) 498 (1,885) 572 (2,065) 35 (2.4) 395 (1,495) 464 (1,756) 538 (2,037) 618 (2,339) 40 (2.7) 423 (1,601) 496 (1,878) 575 (2,177) 660 (2,498) 751 (2,843) 45 (3.1) 448 (1,696) 525 (1,987) 610 (2,309) 700 (2,650) 50 (3.
2” (38 mm) Hose with 1-1/2” (38 mm) Coupling GPM (LPM) FLOWING 3-1/2” (89 mm) Hose 4” (102 mm) 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) 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.
Preventive Maintenance Because deluge guns are not always available, other hose layouts may be used, such as one 2-1/2” (0.8 mm) line to a 1-3/8” (0.42 mm) nozzle for 500 GPM (1892 LPM). ❑ Generally, the nozzle used on one, 2-1/2” line should not be larger than 1-1/2 inches (0.46 mm) for accuracy in measuring GPM (LPM). Another alternative when a deluge gun is not available consists of a 1-1/4” (0.38 mm) nozzle on one and a 1-1/2” (0.46 mm) nozzle on the other to pass 1,000 GPM (3,785 LPM).
Preventive Maintenance 5. If the apparatus does not reach performance levels, refer to Section 5, “Troubleshooting” in this manual. 6. Compare the results of this test to those from when the apparatus was delivered. The apparatus may not have shown the 10% reserve at delivery. 7. If the apparatus performance has dropped appreciably compared to its original performance, it needs to be serviced. Note: Apparatus test results should be on file with the delivery documents.
Preventive Maintenance It should not be necessary to replace clearance rings and impellers until the average radial clearance exceeds 0.015” to 0.020” (0.381 to 0.508 mm) or more per side as measured with calipers. See Figure 4-11: “Clearance Ring and Impeller Measurement” on page 4-16. If the clearance rings on the SM pump show significant wear but the impeller itself is within the size tolerance, "undersized " clearance rings can be installed to delay a complete rebuild.
Preventive Maintenance Contaminated Water After pumping salt water, contaminated water or foam solution, or if water containing sand or other foreign matter has been used, connect the pump to a fresh water hydrant or other source of fresh clean water and flush the contaminants out of the pump.
Troubleshooting SECTION 5: TROUBLESHOOTING Table 5-1 lists the Conditions, Possible Causes and Suggested Corrective Action measures. Before calling Hale Products or a Hale authorized parts service center for assistance, eliminate problem causes using the following table.
Troubleshooting CONDITION Standard transmission, with POWER shift system continued POSSIBLE CAUSE Insufficient air supply or air leaks in shift system Automatic transmission, with POWER shift system Insufficient air supply or air leaks in shift system SUGGESTED CORRECTIVE ACTION ! Attempt to locate and repair leak(s). Leakage, if external, may be detected audibly. Leakage could be internal and not as easily detected. ! Repeat recommended shift procedures with the transmission in NEUTRAL.
Troubleshooting POSSIBLE CAUSE CONDITION PUM P LOSES PRIM E OR IT WILL NOT PRIM E - continue d Priming not operated long enough SUGGESTED CORRECTIVE ACTION ! Proper priming procedures should be followed. Do not release the primer control before assuring a complete prime. Open the discharge valve slowly during completion of prime to ensure complete prime. NOTICE! DO NOT RUN THE PRIMER OVER 45 SECONDS.
Troubleshooting CONDITION INSUFFICIENT PUM P CAPACITY continue d POSSIBLE CAUSE Engine governor set incorrectly - if so equipped Truck transmission is in wrong gear, or clutch is slipping Suction hose diameter is too small for the volume being discharged Restriction in the suction line at the strainer Air leaks ! If the engine governor is set too low when on automatic, the engine speed decelerates before the desired pressure is reached.
Troubleshooting POSSIBLE CAUSE CONDITION ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE continue d Faulty suction hose Blockage at suction hose entry Worn pump impeller(s) or clearance rings Impeller blockage Pump is approaching “Cavitation” CAVITATION (Pump beginning to cavitate.
Troubleshooting CONDITION RELIEF VALVE DOES NOT RELIEVE PRESSURE WHEN VALVES ARE CLOSED POSSIBLE CAUSE Incorrect setting of control (PMD) valve Relief Valve inoperative RELIEF VALVE DOES NOT RECOVER AND RETURN TO ORIGINAL PRESSURE SETTING AFTER OPENING VALVES Dirt in system causing sticky or slow reaction Relief Valve inoperative RELIEF VALVE OPENS WHEN CONTROL VALVE IS LOCKED OUT Drain hole in housing, piston or sensing valve blocked UNABLE TO OBTAIN PROPER SETTING ON RELIEF VALVE Using the wrong
Troubleshooting POSSIBLE CAUSE CONDITION DISCHARGE VALVES DIFFICULT TO OPERATE Lack of lubrication Valve in need of more clearance SUGGESTED CORRECTIVE ACTION ! Recommended weekly lubrication of discharge and suction valve. Use a good grade of petroleum base silicone grease. ! For Hale Products SVS Valves, use Never-Seize® White Food Grade with PTFE. ! Refer to valve manual for additional information. ! Multi-gasket design allows additional gaskets for more clearance and free operation.
Troubleshooting Opposite Engine Rotation Engine Rotation Figure 5-3: Engine Rotation NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _______________________________________________
Maintenance and Repair SECTION 6: MAINTENANCE AND REPAIR OVERVIEW This section describes the removal, inspection, and reinstallation (as required for maintenance and repair) of the Stainless Max (SM) series pump components. To completely dismantle the pump, gearbox, and/ or pedestal, follow the disassembly instructions in the order which they appear in this text. At any point in the disassembly process, the unit may be reassembled by following the instructions in the reverse.
Maintenance and Repair Gearbox (Model) Recommended Oil X SAE EP-90, 80W-90, or Synthetic 75W-80 HG S A E 50 SMR 10W-40 to 15W-40 Multigrade Engine Oil (Pedestal) Capacity qts. (liters) 4 (3.8) 1.5 pints (0.75) All Gear Oils Must Meet Service Rating of API GL-5 Requirements Table 6-1: Recommended Lubricants Bolt Size Material Minimum Torque ft-lb (N-m) 5/16-18 Zinc-Plated Steel 17 (23) 5/16-18 Zinc-Plated Steel 19 (26) 5/16-18 Sillicon Bronze 10.
Maintenance and Repair 3. Match mark, tag and/or note the orientation of all mechanical and electrical components and connections to the pump, gearbox and/or pedestal before disconnecting or removing them. This aids in proper reassembly. CAUTION ! BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP BODY. 4. Drain the inlet (suction) side of the pump body per your required procedures. 5. Remove the 14” NPT pipe plug from the pump body to drain any remaining fluid.
Maintenance and Repair WARNING ! THE SM SERIES PUMP AND GEARBOX ARE HEAVY AND BULKY (WEIGHING UP TO 750 TO 850 LBS. / 340 TO 386KGS. (APPROXIMATE). BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING SM SERIES PUMP AND GEARBOX ASSEMBLIES. 11. For lifting, tapped holes for eyebolts are provided to secure the assembly to your lifting apparatus. Where applicable, include a lifting strap to balance the load.
Maintenance and Repair ❑ Imperial #777 ❑ Mobil Grease Special ❑ Sunoco Moly #2EP Also see Table 6-1: “Recommended Lubricants” on page 6-2. 15. When replacing fasteners, use the proper nuts, bolts, and other hardware. Many are specifically rated; that is, SAE Grade 5 or higher and must be replaced with the identical type. Apply a coating of Loctite 242 or 246 High Temperature Removable Thread Locker (or equal) before installing.
Maintenance and Repair IMPORTANT! WHEN REASSEMBLING, ALL COMPONENTS MUST BE CLEAN AND FREE OF DEFECTS. ❑ Wherever there is a requirement for new parts, it is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators. ❑ Wherever gaskets are removed, the gasket must be replaced. Clean all gasket material from mating surfaces before installing a new gasket. Be careful not to score the finished surfaces.
Maintenance and Repair ❑ Ball peen hammer ❑ Center punch ❑ Drift punch ❑ Allen wrenches ❑ Strap wrench ❑ Snap ring pliers ❑ Pry bars (2) ❑ Ratchets and wrenches for disassembly ❑ Torque wrench, capable of 40, 65, and 135 ft.-lb.
Maintenance and Repair 4. Place and support the pump assembly on a stable work stand / bench of suitable capacity (see WARNING ! on page 6-7). Have the air vent and covers exposed to provide easy and safe access to the internal parts. Installing Pump Assembly to Apparatus After completing repairs and /or maintenance, install the pump assembly to the apparatus before filling with oil. 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2.
Maintenance and Repair Pump Body (Volute) O-ring Seal Sealing Screw Seal Retaining Washer Mechanical Seal Pump Head Rear Wear Ring Key O-ring Seal O-ring Seal Pump Body (Volute) O-ring Seal Pump Shaft Water Drain Port O-ring Seal Suction Cover Plate Clearance Ring O-ring Seals Impeller ( 1 each ) Adapter Ring Options: Rams Horn Suction Victaulic Suction Suction Inlet 6” (152 mm) Impeller Pump Shaft O-ring Seal Lock Washer (pair) Impeller Nut Figure 6-4: Stainless Max Pump Assembly SERVI
Maintenance and Repair Note: The front clearance ring includes two identical O-rings. One face-mounted towards the suction tube and the other mounted in a groove behind the flange. Inspection See Figure 6-3: “Critical Dimensions” on page 6-2. Also see Figure 6-5: “Clearance Ring Measurement.” Inspect clearance ring ID for signs of wear. Using a digital caliper, measure the inside diameter of the clearance ring in several places. (See A in Figure 65.
Maintenance and Repair 3. Remove the twelve M12 bolts and hardware securing the suction cover plate (with O-ring) to the volute (pump body). 4. Insert three jacking screws (M12) into the tapped holes adjacent to the bolt-down holes. Evenly tighten the jacking screws until the suction cover plate is free (removable by hand). 5. Remove the tachometer sender, if equipped. 6. While holding the impeller with a strap wrench, remove the impeller nut, then the lock washer (pair).
Maintenance and Repair Front (A) Rear (B) new/limit new/limit 7.346" - 7.3 4 8 " (1 8 6 .6 -1 8 6 .6 5 mm) 7.236" - 7.2 4 0 " (1 8 3 .8 -1 8 3 .9 mm) 7.31" (185.7 m m ) 7.25" (184.2 m m ) Table 6-7: Impeller Specifications Installation Notes To install, follow the preceding instructions in the reverse order, paying attention to the following: ❑ Review preceding section “Before You Begin...,” beginning on page 6-1.
Maintenance and Repair Inspect wear ring OD for signs of wear. Measure the outside diameter) of the clearance ring in several places, using a digital caliper. (See X in Figure 6-8.) ❑ New clearance ring diameter: Figure 6-8: Wear Ring Measurements 7.220" to 7.222" (183.4-183.5mm) ❑ Wear Limit: 7.200" (182.8mm) If the measured dimensions do not fall within the acceptable ranges specified, the wear ring must be replaced.
Maintenance and Repair 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2. Remove the front clearance ring, the impeller and the rear wear ring as described in the previous sections, beginning on page 6-9. The mechanical seal assembly is then exposed. CAUTION! MECHANICAL SEALS ARE PRECISION ENGINEERED DEVICES. EXTREME CARE MUST BE TAKEN TO ENSURE THAT NO DAMAGE OCCURS TO THE MATING FACES. ENSURE THAT THE FACES ARE ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLATION.
Maintenance and Repair 4. Remove the silicon carbide mating ring, fitted in the rear side of the impeller. A small screwdriver should be inserted between the ring and its rubber cap. The ring can then be carefully pried free. See Figure 6-9: “Mechanical Seal Assembly” on page 6-14. 5. Examine the carbon face and mating ring matching face. If either is scored you must replace the mechanical seal assembly. Order Hale p/n: 60022/01. Installation See Figure 6-9: “Mechanical Seal Assembly” on page 6-14. 1.
Maintenance and Repair 7. With the impeller bores and all surfaces of the mating ring assembly clean, carefully push the mating ring assembly into the impeller bore. A special “fitting tool” may be needed, order Hale p/n: 60275/08. Make sure that the face of the mating ring assembly is squared to the impeller housing within 0.00393” (0.1 mm). 8.
Maintenance and Repair 5. Remove the twelve nuts and hardware to dismantle the volute from the rear cover plate. Pull the volute body from the assembly being careful not to damage the impeller or scratch the sealing surfaces of the volute. Note: A dead blow hammer may be needed. Tap, in a crisscross pattern, around the volute until it is separated from the cover plate.
Maintenance and Repair 4. Using a soft faced (dead blow) hammer, carefully tap around the pump body until it is separated from the bearing housing. Note: If the pump head is assembled to a pedestal mount, there are two guide pins affixed to the bottom portion of the rear pump cover. These pins slide free of the pedestal as the two parts are separated.
Maintenance and Repair O-ring Seal Seal Housing (Seal Housing) O-ring Seal O-ring Seal Seal Wear Ring Bearings Oil Seal Pump Shaft Seal Flinger Seal Flinger O-ring Seal Bearing Housing Oil Seal Oil Seal Seal Housing Pump Head Seal Housing Figure 6-10: Front Oil Seal Breakdown, Pedestal 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2. Drain oil into an appropriate container from the gearbox or pedestal.
Maintenance and Repair 4. Remove the six nuts and hardware securing the oil seal housing to the bearing housing. Slide the housing from the pump shaft. See Figure 6-10: “Front Oil Seal Breakdown, Pedestal” on page 6-19. 5. Press the oil seal from the housing and discard. 6. Remove and examine the pedestal O-ring seal and the seal wear ring, mounted on the pump shaft. If either is defective, it must be replaced. For O-ring, order Hale p/n: 55837; for seal wear ring, order Hale p/n: 60012.
Maintenance and Repair Rear Oil Seal See Figure 6-11: “Rear Oil Seal Breakdown, Pedestal.
Maintenance and Repair Also see Section 4: “Preventive Maintenance,” headings: ❑ Replace Gearbox Oil, on page 4-8 ❑ Replace Pedestal Oil - SMR Series, on page 4-9 3. Disconnect tachometer sender option, if equipped. 4. With the tail end of the pump (impeller) shaft exposed, remove the hex nut and lock washer pair. See Figure 6-11: “Rear Oil Seal Breakdown, Pedestal” on page 6-21. A strap wrench may be needed to hold the shaft while removing the nut. 5.
Maintenance and Repair ❑ Torque the six nuts to 21 ft.-lb. (28 N-m) using 5 ft.-lb. (6.8 N-m) increments. ❑ Add fresh oil. See Figure 6-1: “Recommended Lubricants” on page 6-2, for oil capacities. Also see Section 4: “Preventive Maintenance,” headings: ❑ ● Replace Gearbox Oil, on page 4-8 ● Replace Pedestal Oil - SMR Series, on page 4-9 Reassemble the pump. See section “Pump Head,” heading “Installation Notes” on page 6-17. Bearing Housing See Figure 6-12: “Pedestal Breakdown” on page 6-24.
Maintenance and Repair Bearing Location Plates Bearing, Front Roller Bearing Nut Roller Bearing Needle Bearing Eccentric Lock Washer (Pair) Balance Weight Pump (Impeller) Shaft Rear Seal Housing and Oil Seal Assembly Spacer Washer Front Seal Housing and Oil Seal Assembly Bearing, Rear Bearing Housing Spacer Washer Bearing Location Plate Shaft Keys Eccentric Bearing, Front Needle Bearing Bearing Location Plate Balance Weight Pump Shaft Roller Bearing O-ring Seal Shaft O-ring Figure 6-12
Maintenance and Repair Installation Notes See Figure 6-12: “Pedestal Bearing Housing” on page 6-24. To install, follow the preceding step in the reverse order, paying attention to the following: ❑ Review preceding section “Before You Begin...,” beginning on page 6-1. ❑ Pay attention to section “Cleaning and Inspection Guidelines,” beginning on page 6-6 to ensure a thorough installation. ❑ The matched angular contact bearing pair must be assembled with the large faces of the inner race furthest apart.
Maintenance and Repair Front Oil Seal See Figure 6-13: “Oil Seal Breakdown, HG Series.” O-ring Seal Seal Housing (Seal Housing) O-ring Seal O-ring Seal Seal Wear Ring Bearings Oil Seal Pump Shaft Seal Flinger Seal Flinger O-ring Seal Bearing Housing Oil Seal Oil Seal Seal Housing Pump Head Seal Housing Figure 6-13: Oil Seal Breakdown, HG Series Removal 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2.
Maintenance and Repair ❑ O-ring seal ❑ Seal housing ❑ Oil seal ❑ O-ring seal, under side of seal housing 4. Remove the six nuts and hardware securing the oil seal housing to the bearing housing. Slide the housing from the pump shaft. See Figure 6-12: “Oil Seal Breakdown, HG Series” on page 6-26. 5. Press the oil seal out from the housing and discard. 6. Remove and examine the pedestal O-ring seal and the seal wear ring, mounted on the pump shaft. If either is defective, it must be replaced.
Maintenance and Repair Also see Section 4: “Preventive Maintenance,” headings: ❑ ● Replace Gearbox Oil, on page 4-8 ● Replace Pedestal Oil - SMR Series, on page 4-9 Reassemble the pump. See section “Pump Head,” heading “Installation Notes” on page 6-17. Dismantle the HG Gearbox See Figure 6-14: HG Series Gearbox Breakdown on page 6-29. Review preceding section “Pump and Gearbox Assembly,” beginning on page 6-7 to remove the assembly from the apparatus.
Maintenance and Repair Oil Fill / Drain Port Pinion Gear, Pump Shaft Bearing Housing, to Pump Roller Bearing, Pump Shaft Drive Gear Bearing Cap and Gasket Key, Shaft Washer Knockout Plug Screw Drive Shaft Oil Seal Retaining Ring Bearing (Snap Ring) Gearbox Housing Bearing Cooling Port Cover and Gasket Magnetic Plug (1) (Water Manifold Option Location) (Oil Drain) Figures 6-14: HG Series Gearbox Breakdown Exercise care to protect the drive gear from damage during disassembly. 8.
Maintenance and Repair ❑ Review preceding section “Before You Begin...,” beginning on page 6-1. ❑ Pay attention to section “Cleaning and Inspection Guidelines,” beginning on page 6-6 to ensure a thorough installation. ❑ Replace all O-ring seals, and gaskets with new parts. It is recommended to use only Hale authorized replacement parts for optimum safety of the equipment and its operators. ❑ Evenly press-in a new oil seal in the housing until flush with the housing lip.
Maintenance and Repair Oil Seal See Figure 6-15: “Oil Seal Breakdown, “X” Series.” Air Vent Housing Cap Assembly Seal Housing Angular Contact Bearing Oil Seal Washer (A) Pump (Impeller) Shaft Screw (C) Housing Gasket Angular Contact Bearing Key Shims Seal Housing (as Required) Pump Gear O-ring Seal (B) Intermediate Gear Bearing Spacer Figure 6-15: Oil Seal Breakdown, “X” Series 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2.
Maintenance and Repair At this point, the pump shaft and attached components (bearings, pinion gear and shaft key, etc.) are removable (slide free) from the housing as a complete unit. See Figure 6-15: “Oil Seal Breakdown, “X” Series” on page 6-31. 6. Remove (drive out) the oil seal from the seal housing. Removing the seal renders it defective - Order Hale p/n: 60012. 7. Remove and examine the O-ring seal in the housing. If defective, it must be replaced - Order Hale p/n: 142-1230-00-0.
Maintenance and Repair Dismantle the “X” Series Gearbox Review preceding section “Pump and Gearbox Assembly,” beginning on page 6-7 to remove the assembly from the apparatus. Also review the following sections and dismantle other equipment from the “X” Gearbox: ❑ Pump Head, beginning on page 6-17 ❑ Pedestal Mount, beginning on page 6-18 1. First, review preceding section “Before You Begin...,” beginning on page 6-1. 2.
Maintenance and Repair Installation Notes See Figure 6-14: “Oil Seal Breakdown, “X” Series” on page 6-32. To install, follow the preceding steps in the reverse order, paying attention to the following: ❑ Review preceding section “Installation Notes, “beginning on page 6-32. ❑ The matched angular contact bearing pair must be assembled with the large faces of the inner race apart from each other. ❑ The pinion gear, shaft key and bearing may be assembled by hand but may prove to be a tight fit.
Maintenance and Repair Upper Seal Housing Assembly O-ring Seal Pinion Gear O-ring Seal Gearbox Housing Intermediate Shaft Assembly Screw (A) Tapper Bearing Bearing Spacer Washer Intermediate Gear Sliding Gear Figure 6-16: Intermediate Shaft Assembly, “X” Series 6. Press the gear bearing and spacer from the intermediate gear. 7. Remove both intermediate shaft seal rings from the gear shaft and discard. Installation Notes See Figure 6-15: “Intermediate Shaft Assembly.
Maintenance and Repair ❑ Refer to previous sections to rebuild the top portion (upper housing assembly) of the gearbox. Tail Shaft Assembly See Figure 6-17: “Lower Housing Assembly” on page 6-37. Notes: If only the tail shaft assembly is removed, set the gearshift mechanism to engage the sliding gear (PUMP position). The sliding gear assembly and the shift cylinder assembly need not be removed.
Maintenance and Repair Screw, Hold-Down Intermediate Gear Assembly (Intermediate Shaft) Retaining Ring Bearings Gasket Sliding Gear Assembly (Inner and Outer) Speed Counter Option, with Bushing Tail Shaft (or Plug & Seal) Oil Seal Front Bearing Cap Retaining Rings (4) Slinger Needle Bearing Slide Gear Shaft Oil Seal Rear Bearing Cap Retaining Ring Bearing Switch Seal Ring Rod End Gearshift Cap Lock Nut Ball Rod Extension Spring Shifting Rod Nylon Set Screw, Gearshift Oil Drain
Maintenance and Repair If the tail shaft or the sliding gear shaft require service, it is not necessary to remove the gearbox from the apparatus. Removal See Figure 6-17: “Lower Housing Assembly” on page 6-37. 1. Disconnect the electrical connector to the tachometer/speed counter switch, if equipped. 2. Remove the four screws securing the front bearing cap to the gearbox housing. 3. Slide (pull back) the sliding shaft assembly from the gearbox housing.
Maintenance and Repair ❑ Pay attention to section “Cleaning and Inspection Guidelines,” beginning on page 6-6 to ensure a thorough installation. ❑ Make sure the needle bearing is in place before sliding the tail shaft assembly into position. ❑ Rotate the sliding gear shaft and manually shift the gearshift shaft to check for proper operation - spins and slides freely. ❑ Refer to previous sections to rebuild the top portion (upper housing assembly) of the gearbox.
Maintenance and Repair Shift Cylinder Assembly See Figure 6-18: “Shift Cylinder Assembly.” Seal Rings (3) Screws (B) Spacer Seal Ring Extension Shaft Lock Nut Rod End Cylinder Cap Bushing Piston Gasket Screws (A) Shift Cylinder Air Inlet Port 1/8” NPT Figure 6-18: Shift Cylinder Assembly Removal 1. Pull the shift rod into PUMP position (out). Loosen the lock nut and remove rod end and nut from end of shift shaft. 2. Dismantle the cylinder cap - four screws marked (A). 3.
Maintenance and Repair Installation Notes See Figure 6-18: “Shift Cylinder Assembly” on page 6-40. To install, follow the preceding steps in the reverse order, paying attention to the following: ❑ Review preceding section “Before You Begin...,” beginning on page 6-1. ❑ Pay attention to section “Cleaning and Inspection Guidelines,” beginning on page 6-6 to ensure a thorough installation. ❑ Using a light coating of general-purpose grease to hold it in place, install gasket on gearbox.
Maintenance and Repair Installation Notes See Figure 6-17: “Lower Housing Assembly” on page 6-37. To install, follow the preceding steps in the reverse order, paying attention to the following: ❑ Review preceding section “Before You Begin...,” beginning on page 6-1. ❑ Pay attention to section “Cleaning and Inspection Guidelines,” beginning on page 6-6 to ensure a thorough installation. ❑ Inspect the Cooling Tube for damage and leaks.
Maintenance and Repair SM SERIES OVERVIEW Pump Discharge Port O-ring Seal Volute (Pump Body) Pump Body Pump Body Wear Ring O-ring Seal Rear Wear Ring O-ring Seals (3) Seal Retaining Washer Key, Impeller Shaft Impeller Nut Pump / Impeller Shaft Impeller Lock Washer See Figures 5-20: HG Gearbox 5-21: X Gearbox 5-22: Pedestal (Pair) Impeller O-ring Seal Mechanical Seal Assembly Impeller (See Figure 1-6: “Mechanical Seal” on page 1-6, for an overview of the seal.
Maintenance and Repair Spacer Oil Fill /Drain Port Bearing Housing Shaft Key (Stainless Steel) Seal Housing Gasket (Rear Bearing Cap) Oil Seal Washer Nut Seal Flinger (Pump Shaft) Oil Seal Rear Bearing Cap Pump Shaft (Standard) See Figure - 5-19: Stainless Max Pump Bearing (Shipped Loose) Bearing Pinion Gear (Angular Contact) (Shipped Loose) Seal Ring Drive Shaft Bearing Housing Knock Out Plug Key Oil Seal Retaining Ring Bearing Bearing Washer Drive Gear (Shipped Loose) Screw (
Maintenance and Repair Air Vent Seal Housing Housing Cap Assembly Angular Contact Bearing Oil Seal Washer Screw, Impeller Shaft Pump (Impeller) Shaft Screw Angular Contact Bearings Housing Gasket Key Upper Seal Housing Shims (as Required) O-ring Seal Pinion Gear Screw Intermediate Gear O-ring Seal Bearing Spacer Intermediate Shaft Assembly O-ring Seal Washer (Hold-down) Tapper Bearing Screw (Hold-down) Sliding Gear Retaining Ring Bearings Gasket (Inner and Outer) Speed Counter Opti
Maintenance and Repair GEARBOX SIDE PUMP SIDE Bearing Location Plates Bearing, Front Roller Bearing Nut Roller Bearing Needle Bearing Eccentric Lock Washer (Pair) Balance Weight Pump (Impeller) Shaft Rear Seal Housing and Oil Seal Assembly Spacer Washer Front Seal Housing and Oil Seal Assembly Figure 6-22: Pedestal Overview 6-46 Stainless Max Series Pumps
Installation SECTION 7: INSTALLATION OVERVIEW This section provides guidelines and recommendations for installing a Stainless Max Pump Assembly into your truck chassis. FRAME MOUNTING Also see “Installation and Parts Drawings,” located at the back of this manual for more detail.
Installation These problems include: drive shaft failure, loosened drive ends on pump gearboxes, broken mounting brackets, driveline joint or slider wear, bearing wear on pumps or rear axles, and vibrations at specific road speeds. While the incidence of these problems is low, they are expensive to fix yet easy to avoid. It is critical to use computer driveline analysis software, such as Dana’s “The Expert,” during driveline layout. Dana’s software is available free on the World Wide Web at: http://www2.
Installation Figure 7-1: "Maximum Recommended Drive Lengths” lists the maximum driveline length using a safety factor of 42% of critical speed. This table is based on a 0.134” (3.4mm) wall thickness. Although wall thickness does not have a significant effect on drive shaft length for this calculation, it does have some effect. Extremely short drive lengths between the pump and the rear axle can also cause problems from excessive operating angles when the suspension articulates.
Installation PLUMBING CONNECTIONS Also see “Installation and Parts Drawings,” located at the back of this manual for more detail. ❑ Plate # 994A – Sheet 1: Pedestal, with HG Gearbox Sheet 2: Pedestal only ❑ Plate # 1043A – SMD -A Series Pump, with HG Gearbox ❑ Plate # 1041A – SMD-X Series Pump, with X Gearbox ❑ Plate # 1045A – Inlet Configurations The Stainless Max pump offers the following suction and discharge arrangements: 7-4 ❑ Standard Suction – 6” (152.
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 Buyer takes delivery of the products from the manufacturer. LIMITATIONS: HALE’s obligation is expressly conditioned on the Product being: ● ● ● ● ● Subjected to normal use and service.
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.
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