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Booster

iii

SECTION VI: PARTS LISTS ...................................................................... 6-1

AP Pump ............................................................................................................................................. 6-2
CBP Pump ........................................................................................................................................... 6-5
2CBP Pump ......................................................................................................................................... 6-8
Hydraulic Adapter ........................................................................................................................................... 6-12
Tachometer Option .......................................................................................................................................... 6-13

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Summary of Contents for AP

Page 1: ...subject to change without notice HALE PRODUCTS INC A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken PA 19428 TEL 610 825 6300 FAX 610 825 6440 MANUAL P N 029 0020 69 0 REV B 2002 HALE PR...

Page 2: ...eral Operation 2 1 Draft limiting factors 2 2 Pumping from Draft 2 2 Pump and Roll Operation 2 4 Relief Valve Procedures 2 4 TPM P35 Relief Valve Procedures 2 4 Process of Cavitation 2 5 Warning Signs...

Page 3: ...l Seal 5 6 Reinstall AP Mechanical Seal 5 6 Reinstall the AP Impeller 5 6 REMOVE AP PUMP HEAD 5 6 REINSTALLAP PUMP HEAD 5 7 AP Gearbox 5 8 DisassembleAP Gearbox 5 8 Reassemble and Reinstall AP Gearbox...

Page 4: ...Booster iii SECTION VI PARTS LISTS 6 1 AP Pump 6 2 CBP Pump 6 5 2CBP Pump 6 8 HydraulicAdapter 6 12 Tachometer Option 6 13...

Page 5: ...es a description of the pump components Centrifugal Force Hale booster pumps are centrifugal pumps that operate on the principle that centrifugal force is created by a rapidly spinning disk Figure 1 1...

Page 6: ...peller 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 There are three...

Page 7: ...ter pump These parts are briefly described in the following section Pump Body The Hale single stage booster pump body is a single piece casting Service of the impeller clearance rings and mechanical s...

Page 8: ...O Pump Drives There are four common types of booster pump drives used on fire fighting apparatus 1 The most common drive is the PTO mounted on the truck transmission or four wheel drive transfer case...

Page 9: ...h 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 A priming pump draws air out of the pump body...

Page 10: ...nation valve and switch When the handle on the PVG is pulled out the valve opens and the switch energizes the primer motor Pushing the handle de energizes the motor and closes the valve Pressure Contr...

Page 11: ...level the valve closes The TRV will flow up to 1 2 GPM 3 7 LPM TRV L Kit The TRV L kit includes a chrome panel placard with a warning lamp lamp test button and a preassembled wiring harness The light...

Page 12: ...lly an impeller consists of two discs separated by curved vanes The vanes force the water to rotate between the discs and is thrown outward at high velocity The water from the impeller discharges into...

Page 13: ...DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS AND LAYING OUT SUCTION AND DISCHARGE HOSES ALL VALVES DRAIN COCKS AND CAPS SHOULD BE CLOSED 2 Bring the truck to a complete stop before attempting to sh...

Page 14: ...pen the valve to access the bypass line if it is furnished or open the valve to the booster tank both suction and discharge sides to circulate water 14 After completion of pumping operations gradually...

Page 15: ...engine speed to idle and close the discharge valves To resume pumping open the throttle and discharge valves 14 Set the automatic relief valve according to department policy Refer to the Relief Valve...

Page 16: ...on 5 Observe pump discharge pressure and verify the pump pressure increases 6 Prime the pump if necessary 7 Open the discharge valves and commence operations RELIEF VALVE PROCEDURES TPM P35 Relief Val...

Page 17: ...in the pump by decreasing engine speed Cavitation Cavitation occurs when a centrifugal pump is attempting to discharge more water than it is receiving It is often referred to as the pump running away...

Page 18: ...ng conditions knowing the capabilities of the equipment and regular inspection are the best protection against cavitation During Operations o Do not increase the pump speed beyond the speed at which t...

Page 19: ...p The pump may be primed however air leaks can cause rough operation and an increase of engine speed without an in crease in pressure or flow If an air leak is suspected discontinue pumping and refer...

Page 20: ...s or Hale multiple drain valve If a multiple drain valve is used all pump drain lines should be connected to this valve c After the pump is completely drained replace all caps and close all valves o I...

Page 21: ...ump shift warning indicator lights o Valve Maintenance o Checking and cleaning the intake strainers o Checking any auxiliary engine o Verifying all gauges are in working order o Operating pump control...

Page 22: ...e relief valve operator should be lubri cated every 5 months Check and Clean the Intake Strainers Remove the strainers Clean any debris out of the intake Flush the pump if required by department proce...

Page 23: ...t gauge connection on the pump panel 3 Engage the priming pump until the gauge indicates at least 22 IN ng vacuum 4 Compare the readings of the test gauge and the apparatus gauge Note any difference 5...

Page 24: ...erplate to visually inspect and clean the internal components Repair or replace as necessary 4 Replace the cooler or cover if necessary Remove the oil fill plug and replace the drain plug 5 Fill the g...

Page 25: ...performance test consists of checking the pump according to the rating at three capacities and comparing the results to when the pump first placed in service This provides some measure of any performa...

Page 26: ...f Valve Testing procedure under Weekly Maintenance 2 Perform steps 2 and 3 of the Post Operation Maintenance procedures in this section 3 Run the standard pump test in accordance with NFPA standards t...

Page 27: ...319 403 498 602 120 81 127 183 249 325 412 509 615 GPM AT VARIOUS NOZZLE SIZES NOZZLE Nozzle Size PRESS 1 1 5 8 1 1 7 8 2 2 1 4 2 3 30 366 430 498 572 651 824 1017 1464 35 395 464 538 618 703 890 1098...

Page 28: ...0 020 inch or more per side as measured with calipers Refer to Table 3 2 If the clearance rings on the CBP pump show significant wear but the impeller itself is within the size tolerance undersized cl...

Page 29: ...able 4 1 lists the symptoms of some common problems and possible corrective measures Before calling Hale or a Hale authorized parts service center for assistance eliminate problem causes using this gu...

Page 30: ...ng a complete prime Suction Connections PUMP LOSES PRIME OR WILL NOT PRIME cont d Air Leaks Attempt to locate and correct air leaks using the following procedure 1 Perform dry vacuum test on pump per...

Page 31: ...e discharge of another pumper to pressurize the pump with water and look for visible leakage and correct A pressure of 100 PSI 6 9 BAR should be sufficient Do not exceed pressure limitations of pump a...

Page 32: ...ont d ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE Truck transmission in wrong range or gear Verify the transmission is in the correct gear Lift too high suction hose too small Higher than...

Page 33: ...Refer to the relief valve manual CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION Worn pump impeller s and or clearance rings Installation of new parts required Impeller blockage Blockage in the impeller...

Page 34: ...or gating the discharge valves Locate a source of cooler water Pump is beginning to cavitate Discharging more water than the pump is taking in Gate the discharge valves to reduce flow and maintain pr...

Page 35: ...ed pressure 60 100 psi and reduced flow Wrong impeller installed Verify the new impeller vanes are oriented the same as the old impeller before installing See figure 4 3 Impellers installed backwards...

Page 36: ...Sec IV 8 Troubleshooting...

Page 37: ...ore installing the mechanical seal use the alcohol swabs provided by Hale Products Inc to clean all grease or oil from the pump shaft and bearing housing 5 Use only PAC EASE Rubber Lubricant Emulsion...

Page 38: ...ilicon bronze 29 39 Table 5 2 Torque Values Pump Model Clearance Ring Inner Diameter pressed into pump body or pump head In mm Impeller Hub Outer Diameter Permissible Clearance CBP 3 6312 3 6326 92 23...

Page 39: ...small section of PVC tubing to fit over the shaft PUMP COMPONENTS Pump and Gearbox Assembly Read all the instructions before beginning any repair THE PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 25...

Page 40: ...pump and gearbox assembly into position on the equipment Connect the mounting brackets using the proper fasteners Torque the fasteners to values provided in Table 5 3 3 Connect the drive shaft to the...

Page 41: ...the mating surfaces of the pump body and pump head Install the Pump body 1 Use a press to install the clearance ring in the pump body 2 Apply a small amount of grease to the gasket and align on the p...

Page 42: ...ide the stationary seat over the pump shaft and fit the stationary seat of the mechanical seal into the pump head 5 Carefully push the stationary seat into the pump head bore using a soft clean pusher...

Page 43: ...the gearbox side 6 Use a press to remove the oil seal and mechanical seal seat from the pump side of the pump head 7 Inspect and clean all components according to the Cleaning and Inspection Guideline...

Page 44: ...ing towards the pump side Be careful not to lose the pump gear key in the gearbox 7 Remove the 306W bearing pump gear pump gear key and 208M bearing from the pump shaft or gearbox housing 8 Remove the...

Page 45: ...the pump gear with the shaft key 12 Align the pump gear to the drive gear and install into the gearbox Press the shaft into the 306W bearing 13 Install the 208M bearing over pump shaft 14 Stand the g...

Page 46: ...Sec V 10 Maintenance and Repair Booster Pumps Figure 5 7 CBP for Parts Identification...

Page 47: ...all components according to the Cleaning and Inspection Guidelines above Reinstall CBP Pump Body After checking the impeller and clearance rings reinstall the pump body 1 Apply a light coating of grea...

Page 48: ...lcohol swabs and install the stationary seat NOTE Oil and grease will damage the mechanical seal face Be careful not to touch the seal face of the mechanical seal 3 Apply a generous coating of PAC EAS...

Page 49: ...d CBP GEARBOX Remove and Disassemble CBP Gearbox 1 Remove the pump and gear box assembly from apparatus as described above 2 Place the pump and gearbox on a work stand 3 Remove the pump body impeller...

Page 50: ...t into the gearbox housing bore 6 Install the retaining ring to hold the bearing and drive shaft in place 7 Install a new oil seal 8 Lift the gearbox onto its base Apply Loctite 242 and install the 1...

Page 51: ...Maintenance and Repair Booster Pumps Sec V 15 Figure 5 11 2CBP for Parts Identification...

Page 52: ...e position NEVER STRIKE THE IMPELLER SEVERE IMPACT WILL CAUSE DAMAGE THAT REQUIRES REPLACEMENT 7 Hold the impeller with a strap wrench Use a 1 3 4 socket or wrench to remove the impeller nut and washe...

Page 53: ...gm and retainer onto the shaft with the pusher tube o Keep the shaft well lubricated and verify the carbon seal ring seats against the stationary seat If binding occurs apply additional lubricant Slid...

Page 54: ...screws and remove the water manifold and gasket from the gearbox If the pump is not equipped with a water manifold remove the capscrews lockwashers gearbox cover and gasket 5 Remove the bearing cover...

Page 55: ...ing 9 Set the gearbox flat with the drive shaft facing down 10 Insert the 306W bearing in the bore on the pump end of the gearbox housing 11 Insert the pump gear key into the pump shaft and install th...

Page 56: ...embly of the pump Level 2 kits provide bearings and any other wear item A level 2 kit is recommended as the minimum spare part kit for five years Level 3 kits are purposed for complete overhaul of the...

Page 57: ...rts Lists Booster Sec VI 1 SECTION VI PARTS LISTS This section contains part lists and exploded views for the following Booster Pump models o AP o CBP o 2CBP o Hydraulic Drive Option o Tachometer Opti...

Page 58: ...Sec VI 2 Parts Lists Booster Figure 6 1 AP Pump...

Page 59: ...0 APM 25 DRIVE UNIT 2 55 RATIO 3 1 004 0520 00 0 AP 28 DRIVE UNIT 2 85 RATIO 4 1 008 0601 00 0 AP BEARING COVER 016 0940 00 0 AP IMPELLER O E ROT CCW 5 1 016 0950 00 0 AP IMPELLER ENG ROT CW ROT 6 1 0...

Page 60: ...82 0203 02 0 3 8X1 4 COMP FIT SLF ALGN L170 29 2 082 0513 00 0 BUSHING 3 4 X 1 4 NPT 30 12 097 0810 01 0 WASHER 5 16 STL ZINC PL FLAT 31 1 101 0082 00 0 GEARBOX SERIAL NUMBER PLATE 35 1 110 7040 00 0...

Page 61: ...Parts Lists Booster Sec VI 5 Figure 6 2 CBP Pump...

Page 62: ...9 018 1422 02 0 6 SCREW 5 16 18 X 2 1 4 HX HD 10 018 1406 02 0 8 SCREW 5 16 18X3 4 PLD SEE L170 11 018 1412 02 0 2 SCREW 5 16 18 X 1 1 4 ZINC PL 12 018 1607 07 0 8 SCREW 3 8 16X7 8 HX HD ZINC NY 13 01...

Page 63: ...PLATE 29 110 2701 11 0 1 NUT 3 4 16 NYL LOCK STNLS JAM 30 217 0201 00 0 5 1 4 NPT SQUARE HEAD STEEL PLUG 31 217 0301 00 0 4 PLUG 3 8 NPT SQUARE HEAD 32 217 0401 00 0 2 PLUG 1 2 NPT M I 33 217 0401 08...

Page 64: ...Sec VI 8 Parts Lists Booster Figure 6 3 2CBP Pump...

Page 65: ...E 8 008 0150 00 0 1 CBP 61D BEARING CAP 9 016 0270 00 0 1 2CBP 16F 6 1 2 IMPELLER FRONT 10 016 0280 00 0 1 2CBP 16R 6 1 2 IMPELLER REAR 11 017 0270 00 0 1 2CBP 17 KEY 12 017 0300 00 0 1 SSA 95XD KEY 1...

Page 66: ...BP GASKET 37 062 0190 00 0 1 2CBP 251 BEARING CENTER 38 064 0608 02 0 1 03 64 04S SPRING PIN 39 064 6010 00 0 2 AB 68 3 4 DOWEL PIN 40 077 0870 05 0 1 78S87 RETAINING RING 41 077 0980 25 0 1 78SS98 RE...

Page 67: ...56 250 0207 00 0 2 207K BEARING 57 250 0403 00 0 1 403S BEARING 58 250 9130 00 0 1 2CBP 250 FRONT SLEEVE BEARING 59 296 2140 00 0 1 2CBP 296 OIL SEAL 60 296 2210 00 0 1 60R 296 OIL SEAL 296 5050 00 0...

Page 68: ...standard pump gearbox Use the part list below for reference when contacting Hale Products for service Figure 6 4 Hydraulic Adapter Hydraulic Adapter Part List Item Part Number Description 1 007 1930 0...

Page 69: ...the actual rotation of the shaft The drawing and parts list below illustrate the standard installation of the assembly Tachometer Drive Part List Item Part Number Description 1 008 0150 02 0 Bearing...

Page 70: ...ALING USAGE OF TRADE OR PATENT INFRINGEMENT FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER S DESIGN AND SPECIFICATIONS EXCLUSIVE REMEDIES If Buyer promptly notifies HALE upon discovery of any such defec...

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