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D-1

APPENDIX D.

OPERATOR MAINTENANCE LOG

PUMP SERIAL NUMBER :

Use this Log to record all maintenance actions and problems (faults, part replacements, tear

downs, and major overhauls – as a minimum). Please contact Customer Services at Hale Prod-

ucts Inc. prior to any proposed return of either a single part, or a complete assembly.

Summary of Contents for AP

Page 1: ...GHT 2002 2018 BY HALE PRODUCTS INC ALL RIGHTS RESERVED TECHNICAL MANUAL FOR HALE SINGLE STAGE BOOSTER PUMPS BY HALE PRODUCTS INC A Unit of IDEX Corporation 607 NW 27th Ave Ocala FL 34475 800 533 3569...

Page 2: ......

Page 3: ...Of Terms 9 2 4 1 1 Atmospheric Pressure Static Air Pressure 9 2 4 1 2 Cavitation 10 2 4 1 3 Dead Heading 10 2 4 1 4 Impeller And Clearance Rings 10 2 4 1 5 Priming Pump 10 2 4 1 6 Relief Valve 10 2 4...

Page 4: ...event Cavitation 27 3 5 3 1 General Considerations 28 3 5 3 2 During Operations 29 3 6 Post Operation Procedure 30 4 PREVENTIVE MAINTENANCE 31 4 1 Preventive Maintenance Plan And Schedule 31 4 2 Maint...

Page 5: ...lief Valve Problems 46 5 1 6 Gearbox Problems 46 5 1 7 Discharge Valve Problems 46 5 1 8 Cavitation 47 5 2 Maintenance Level 1 48 5 3 Maintenance Level 2 48 5 4 Maintenance Level 3 48 5 5 Maintenance...

Page 6: ...5 8 4 4 CBP Volute R R 74 5 8 4 5 MBP RSD Inducer R R 76 5 8 4 6 MBP RSD Impeller R R 81 5 8 4 7 AP Impeller R R 83 5 8 4 8 CBP Impeller R R 87 5 8 4 9 AP CBP MBP Mechanical Seal R R 90 5 8 4 10 RSD...

Page 7: ...APPENDIX A TIGHTENING TORQUE INFORMATION A 1 APPENDIX B TEST EQUIPMENT AND SPECIAL TOOL INFORMATION B 1 B 1 SPECIAL TOOL INFORMATION B 1 APPENDIX C ANCILLARY PUMP EQUIPMENT C 1 C 1 PRIMING SYSTEMS C 1...

Page 8: ...ine And Flange Bolts C 7 C 3 3 Annual Maintenance C 8 C 3 3 1 Check Drain Lines to Multi Drain C 8 C 3 3 2 Tank To Pump Flow Rate Test C 8 C 3 3 3 ESP Primer Maintenance C 9 APPENDIX D OPERATOR MAINTE...

Page 9: ...7 Caliper Depth Rod Extended 55 Figure 18 Pump And Gearbox Assembly R R 57 Figure 19 One Piece Volute AP CBP MBP 59 Figure 20 Three Piece Volute RSD 59 Figure 21 AP Pump Exploded View 61 Figure 22 CBP...

Page 10: ...C 2 Figure 54 PVG Priming Valve C 3 Figure 55 SPVR Priming Valve C 3 Figure 56 TRV C 4 Figure 57 TRV L C 4 Figure 58 Engage Priming Pump C 6 Figure 59 Grade 8 Bolt Marking C 7 Figure 60 Class 10 9 Bo...

Page 11: ...List 82 Table 31 AP Impeller R R Tools And Consumables List 84 Table 32 CBP Impeller R R Tools And Consumables List 88 Table 33 AP CBP MBP Mechanical Seal Bench Procedure Tools And Consumables List 9...

Page 12: ...ute GR Gear Ratio ID Inside Diameter Lpm Liters Per Minute N A Not Applicable NFPA National Fire Protection Act NFPA 1901 Standard For Automotive Fire Apparatus NFPA 1911 Standard For The Inspection M...

Page 13: ...HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY ADDRESSES PRACTICES NOT RELATED TO PERSONAL INJURY NOTE Highlights an essential aspect of an operating or maintenance pr...

Page 14: ...eting email address Add this address to your email address book to prevent your response from being routed to the Junk folder and call the contact phone number recorded earlier to arrange payment NOTE...

Page 15: ...LLUMINATED SEE FIGURE 7 OPERATORS INSTALLERS AND MAINTENANCE PERSONNEL MUST BE TRAINED AND QUALIFIED FOR ALL THE ACTIVITIES THEY PERFORM ALWAYS USE PROPER PPE OIL MAY BE TOXIC TO PEOPLE AND OR THE ENV...

Page 16: ...NT DAMAGE ALWAYS USE AND ONLY USE PAC EASE RUBBER LUBRICANT EMULSION OR EQUIVA LENT WHEN INSTALLING THE MECHANICAL SEAL USING ANY OTHER LUBRICANT OR NOT USING THE LUBRICANT MAY DAMAGE THE MECHANICAL S...

Page 17: ...8 FAILURE TO WAIT FOR THE ILLUMINATED GREEN INDICATOR MAY RESULT IN EQUIPMENT DAMAGE OR FAILURE DO NOT OVER FILL THE GEARBOX EXCEEDING THE OIL LEVEL MAY RESULT IN EQUIPMENT DAMAGE DO NOT RUN THE PRIM...

Page 18: ...RIMING PUMP MAY RESULT IN PUMP FAILURE OR DAM AGE OIL AND GREASE INCLUDING SKIN OILS WILL DAMAGE THE MECHANICAL SEAL FACE NEVER TOUCH THE MATING FACES OF THE MECHANICAL SEAL WEAR PRO TECTIVE GLOVES TO...

Page 19: ...ngle stage booster pump 2 2 How To Use This Manual This manual was developed for the purposes of FAST team and OEM support This manual pro vides information and procedures to perform three levels of p...

Page 20: ...rforming a procedure is NOT the ONLY key action in maintaining a pump documentation of the pumps Preventive Maintenance R R and SYMPTOM REMEDY history including meaningful tracking of when each issue...

Page 21: ...is the centrifugal pump has basically only two moving parts the impeller and the shaft As shown on Figure 2 during operation water enters the suction eye of the impeller intake The rotating impeller v...

Page 22: ...he water An impeller consists of two discs surrounding curved vanes The vanes force water to rotate within the discs resulting in the water being thrown outward at high velocity The water from the imp...

Page 23: ...e water from the impeller and depending on its design can either increase pressure and decrease velocity or increase ve locity and decrease pressure 2 4 2 Standard Booster Pump Components All Hale Fle...

Page 24: ...ositions paragraphs for a reference to the appropriate drawing and sheet number s providing the views of the volute positions 2 4 2 2 Impeller And Shaft Assembly The impeller provides velocity to the...

Page 25: ...smission or four wheel drive transfer case which allows for pump and roll operation Direct engine mounting via SAE 3 or 4 flywheel housing Hale booster pumps are built to produce the volumes and press...

Page 26: ...m is a sacrificial metal which helps prevent corrosion A Hale makes an anode that will fit on any Hale truck mounted pump regardless of age or model The RSD uses Hale anodes designed to be easily inst...

Page 27: ...ort and a flange adaptor to house the TRV For all other Flex series booster pumps the TRV must be installed on a fabricated manifold and similar application and the installer is to provide 1 1 4 in NP...

Page 28: ......

Page 29: ...UMP IS NOT RUNNING PRIOR TO REMOVING HOSES OR CAPS FROM PUMP CONNECTIONS RELIEVE PRESSURE BY OPENING DRAINS BLEEDER VALVES SHOULD ALSO BE USED WHEN CONNECTING TO AN INTAKE FROM A PRESSURIZED SOURCE DO...

Page 30: ...ch could result from attempting to draft with an unverified pump NOTES Refer to department procedures for setting wheel chocks and laying out suction and discharge hoses All valves drain cocks and cap...

Page 31: ...rottle gradually until master discharge gauge indicates 5 desired pressure DO NOT ALLOW THE PRESSURE ON THE INTAKE GAUGE TO GO BELOW ZERO PLAC ING A VACUUM ON THE WATER MAIN MAY RESULT IN SERIOUS DAMA...

Page 32: ...um Test Refer to Table 1 for a list of tools and or consumables required for this procedure Table 1 Vacuum Test Tools And Consumables List Standard Tools Special Tools Consumables PPE Eye Hand and Ear...

Page 33: ...22 2 inHg 0 745 bar of vacuum with the blank ing caps in position a leak is present in the apparatus pump and a pressure test must be performed to trace the leak If the apparatus pump can NOT reach a...

Page 34: ...r leakage 3 Visually inspect all external areas surfaces of primer assembly for water 4 leakage a If leakage is found replace the primer seals and O rings Refer to para graph C 3 3 3 ESP Primer Mainte...

Page 35: ...arking brake 3 Shift truck transmission into NEUTRAL 4 Engage pump PTO 5 Shift road transmission into proper gear usually DRIVE 6 Check indicator lights to see if pump is in gear check speedometer and...

Page 36: ...ge pressure starts to increase Water may also be heard discharging to the ground If apparatus is equipped with a priming pump activate priming pump 3 Pull control handle located on pump panel Otherwis...

Page 37: ...n fire pump performance But when pumping from draft elevated water tempera ture does have a limiting effect Water temperatures above 90 F 32 C will cause a noticeable decrease in lift when drafting Se...

Page 38: ...ns occurring during cavitation break away or erode tiny piec es of metal from the internal parts and the pump casing When enough metal has been chipped away the impeller becomes unbalanced causing a s...

Page 39: ...ing in the pump 3 5 2 Warning Signs Of Cavitation As a pump approaches cavitation certain warning signs appear on the gauges that monitor the suction and discharge pressures These signs are discussed...

Page 40: ...Rating Capacity Hose Diameter In mm 3 76 4 102 4 5 114 5 127 6 152 Dual 6 Dual 152 Flow gpm Lpm Lift Loss In Head Ft Head M 250 946 5 2 19 7 350 1325 2 5 9 5 500 1893 5 0 19 0 3 6 51 5 750 2839 11 4 4...

Page 41: ...n NOTE When water reaches 90 F 32 C the operator is likely to notice a marked de crease in lift Monitor barometric pressure NFPA standards set a baseline of 29 9 inHg See Table 5 Table 5 Lift Loss Fro...

Page 42: ...e all valves C Place transmission into neutral or park D Drain pump especially important in freezing weather Open discharge valves remove suction tube caps and discharge valve 1 caps Open volute drain...

Page 43: ...ated Flush pump thoroughly with clean water See paragraph 4 4 1 Flush After Each Use Supply of clean water Leakage Checks Check for water or oil leaks wipe off road dirt and debris See paragraph 4 4 2...

Page 44: ...ump is powered by a hydraulic motor check the motor for function filters and fluid level Inspect drive for wear Check drive for proper operation Shop rags Check All Gauges Check that gauges that are r...

Page 45: ...he tank to pump line The minimum flow rate should be continuously dis charged until 80 of the tank is dis charged Supply of clean water Clean ESP Primer Disassemble ESP primer and clean mineral deposi...

Page 46: ...ies and components replaced but always include the little things hoses connectors fasteners seals thread lock etc The replacement of the little things can be just as critical or even more critical as...

Page 47: ...multiple procedures apply to the same periodicity 4 4 1 After Each Use Flush Pump A Connect apparatus to a fresh clean high quality water source NOTE Do NOT perform Step G on page 20 of the Repair Ver...

Page 48: ...filled with 1 to 1 1 2 qt 1 1 liter of the gear oil listed in 5 7 2 Recommended Lubricants The amount de pends on gearbox position Figure 11 shows the typical gearbox oil fill and level component lo c...

Page 49: ...o slowly drain oil from gearbox 3 Simultaneously examine magnetic drain plug for the following 4 a Metal fragments if metal fragments are present on drain plug continue otherwise go to Step 5 b Remove...

Page 50: ...le 9 Example Performance Test Example Performance Pump Rating gpm Lpm CAPACITY PRESSURE psi bar 250 946 350 1325 450 1703 500 1893 750 2839 1000 3785 FULL 150 10 250 946 350 1325 450 1703 500 1893 750...

Page 51: ...2 275 332 40 47 73 106 144 188 238 294 355 45 50 78 112 153 199 252 311 377 50 53 82 118 161 210 266 328 397 55 55 86 124 169 220 279 344 417 60 58 90 130 176 230 291 360 435 62 58 91 132 179 234 296...

Page 52: ...299 76 583 684 793 910 1036 1311 1618 2330 78 590 693 803 922 1049 1328 1639 2361 80 598 702 814 934 1063 1345 1660 2391 85 616 723 839 963 1095 1386 1711 2465 90 634 744 863 991 1127 1427 1761 2536 9...

Page 53: ...se sizes for pump rating capacity Table 5 for lift loss from barometric pressure Table 6 for lift loss from elevation and Table 10 pressure and flow for various size nozzles Select a properly sized no...

Page 54: ...indicate 4 4 6 1 Gearbox Fluid Change Use the lubricant listed in the paragraph 7 4 4 1 1 Recommended Gearbox Lubricants in the Flex Series Single Stage Booster Pump OIM FSG MNL 00183 when lubricatin...

Page 55: ...ALL if multiple are listed and perform the associated REMEDY or reme dies The SCR tables assume a single fault and the SYMPTOM CAUSE and REMEDY columns have been listed in a hierarchy order If multipl...

Page 56: ...e defects Primer NOT Operated Long Enough Proper priming procedures should be fol lowed Do not release the primer control be fore assuring a complete prime Air Leaks Attempt to locate and correct air...

Page 57: ...ontrol per the procedures in Section III Other bypass lines such as foam system or in line valves may reduce pump capacity or pressure 5 1 4 Engine Speed Problems Table 14 Engine Speed SCR Table SYMPT...

Page 58: ...Refer to the relief valve manual Relief Valve Does Not Re cover And Return To Origi nal Pressure Setting After Opening Valves Dirt In System Causing Sticky Or Slow Reaction Refer to the relief valve...

Page 59: ...pump closer to the water source Water Temperature Too High Reduce volume discharged by lowering RPM or gating the discharge valves Locate a source of cooler water Table 19 Rotation SCR Table SYMPTOM...

Page 60: ...aintenance performance test failures flow rate issues troubleshooting and restoration of pump performance resulting from typical wear items bearings seals gaskets O rings and select fasteners The Leve...

Page 61: ...pump testing may be prohibitive Miscellaneous maintenance procedures are included to replace all major components cooler parts shafts inducers impellers clearance rings gears etc however when Hale Cus...

Page 62: ...ICANT EMULSION OR EQUIVA LENT WHEN INSTALLING THE MECHANICAL SEAL USING ANY OTHER LUBRICANT OR NOT USING THE LUBRICANT MAY DAMAGE THE MECHANICAL SEAL AND SEAT 5 7 4 Replacement Fasteners Replacement s...

Page 63: ...aused by the punch press stamping the circlips out of a sheet of steel Additionally the shape of the circlip is critical and for this reason they should never be reused once removed The pumps utilize...

Page 64: ...ocker removal for hardware and clearance rings 5 7 8 Repair Kits Reference the applicable pump drawing REPAIR PART KITS IDENTIFICATION sheet typically sheet 3 of 6 for the available level 1 2 or 3 rep...

Page 65: ...022 152 959 5 987 152 070 0 0075 0 01 0 1905 0 254 RSD 1500 gpm 6 492 164 897 6 419 163 043 0 0075 0 01 0 1905 0 254 Often replacement of the clearance rings will reduce the bypass and restore the pu...

Page 66: ...nced technician who is NOT familiar with a Hale booster pump but is familiar with pumps in general a more detailed set of steps to R R the titled component Using all three levels of the steps provides...

Page 67: ...iver Kit Figure 17 Caliper Depth Rod Extended 5 8 2 General Pump Disassembly For Access Guidelines Before working on the pump disconnect the suction and discharge piping and drain the volute Disconnec...

Page 68: ...d Tools Special Tools Consumables PPE Eye and Hand Protection None Shop Rag s As Required PPE For Handling Oil Tags Wire Etc Catch Pan For Gear Oil Wheel Chocks Lifting Device And Rigging Or Jack 9 16...

Page 69: ...ms connections before removal 2 Remove ONLY items connections required to access pump and gearbox 3 Follow all OEM provided instructions to disassemble remove items when 4 required to access pump and...

Page 70: ...earbox assembly 11 D Remove pump and gearbox from apparatus See Figure 17 Using lifting device or jack lift or lower pump and gearbox free from 1 apparatus Place pump and gearbox assembly on stable wo...

Page 71: ...59 Figure 19 One Piece Volute AP CBP MBP Figure 20 Three Piece Volute RSD...

Page 72: ...om The Apparatus for generalized removal instructions No matter which method of removal is utilized Figure 20 provides an exploded view of the AP pump Figure 21 provides an exploded view of the CBP pu...

Page 73: ...61 Figure 21 AP Pump Exploded View...

Page 74: ...62 Figure 22 CBP Pump Exploded View...

Page 75: ...63 Figure 23 MBP Pump Exploded View...

Page 76: ...64 Figure 24 RSD Pump Exploded View...

Page 77: ...65 Figure 25 Gearbox Exploded View All Except 3 74 1 GR...

Page 78: ...66 Figure 26 Gearbox Exploded View 3 74 1 GR...

Page 79: ...val to examine or access in ternal pump components suction side clearance ring inducer or impeller Typically the suction head would not require replacement unless it has been damaged by allowing the p...

Page 80: ...ing suction head removal F Remove four 4 7 16 14 X 2 63 in studs that hold suction head to volute G Remove suction head from volute NOTE Gentile tapping with a non marring hammer may be required to lo...

Page 81: ...ping as noted match marked I Perform paragraph 4 4 4 1 3 Performance Testing Test Procedure to verify repair complete and pump in working condition Repair any leaks or prob lems See page 41 J Update m...

Page 82: ...ent Loctite 243 Or Equivalent Perform the following to remove and replace the volute NOTES Remove any suction tube and or piping blocking access to the pump per OEM equipment manufacturer instructions...

Page 83: ...rings or impeller install volute onto pump head NOTE Gentile tapping with a non marring hammer may be required to seat the volute onto the pump head Using the bolts to pull the volute especially if t...

Page 84: ...P MBP Volute R R Refer to Table 27 for a list of tools and or consumables required for this procedure Table 27 AP Volute R R Tools And Consumables List Standard Tools Special Tools Consumables PPE Eye...

Page 85: ...12 7 16 14 X 1 25 in bolts Remove twelve 12 7 16 14 X 1 25 in bolts 2 NOTE Do NOT damage brass clearance rings or impeller during volute removal F Remove volute from pump head G Remove O ring from pu...

Page 86: ...ntenance log entries I Place apparatus in service in accordance with departmental procedures 5 8 4 4 CBP Volute R R The primary difference between the CBP and the AP MBP volute removal is the number o...

Page 87: ...sure proper alignment during reas sembly D If pump is still in apparatus disconnect ONLY mounting bracket s required for volute removal E Remove eight 8 3 8 16 X 7 8 in bolts that hold volute to pump...

Page 88: ...require replacement unless it has been damaged by allowing a large piece of debris into the pump by not using or maintaining strainers Long term wear can damage an inducer to the point it must be repl...

Page 89: ...RSD prior to performing this procedure remove the suction head as described in paragraph 5 8 4 1 RSD Suction Head R R on page 67 Figure 28 shows the RSD pump with the suction head removed and depicts...

Page 90: ...RSD Cold Cut Chisel Cotter pin Inducer Nut To Pump Shaft See FSG PL 01486 Sheet 4 Item 5 MBP See FSG PL 01487 Sheet 4 Item 9 RSD Flat Blade Screwdriver Gasket MBP Volute to Pump Head See FSG PL 01486...

Page 91: ...1 3 4 in or adjustable wrench and strap wrench i Hold impeller with a strap wrench ii Using 1 3 4 in or adjustable wrench loosen turn CCW castle nut Remove castle nut 3 DO NOT STRIKE THE INDUCER OR IM...

Page 92: ...se to hold key in place B Carefully slide inducer over pump shaft aligning inducer keyway with key C Install inducer nut If pump is a RSD 1 a If using a 2 1 2 in socket torque limiting extension and i...

Page 93: ...install the volute as described in para graph 5 8 4 3 AP MBP Volute R R 5 8 4 6 MBP RSD Impeller R R Prior to performing this procedure remove the volute as described in paragraph 5 8 4 3 Volute R R f...

Page 94: ...e APPENDIX B Shop Rag s As Required Brush For Grease Grease See paragraph 5 7 2 page 49 IMPELLER See FSG PL 01486 Sheet 4 Item 7 MBP See FSG PL 01487 Sheet 4 Item 21 RSD Key Impeller To Pump Shaft See...

Page 95: ...slide impeller over pump shaft aligning key with impeller keyway After performing this procedure install the inducer by performing the Inducer Installation portion of Inducer R R procedure see paragra...

Page 96: ...1 3 4 in Torque Limiting Socket 110 ft lb 149 Nm Shop Rag s As Required 1 3 4 in Socket and Ratchet Puller Set See APPENDIX B Impeller FSG PL 01483 Sheet 4 Item 4 Cold Cut Chisel Impeller Nut ZS 274 F...

Page 97: ...RIKING THE IMPELLER MAY RESULT IN IRREPA RABLE DAMAGE C Remove impeller Pull impeller off pump shaft by hand if possible 1 If impeller can NOT be removed by hand use wedges and puller to pull 2 impell...

Page 98: ...t CW tighten castle nut If using a 1 3 4 in torque wrench and strap wrench 2 a Hold impeller with a strap wrench b Using 1 3 4 in torque wrench torque turn CW castle nut to 110 ft lb 149 Nm DO NOT LOO...

Page 99: ...ler to the point it and the clearance rings must be replaced to maintain pump performance specifications Re fer to Table 23 page 53 for the impeller and clearance rings wear specifications If the impe...

Page 100: ...CBP pump impeller Impeller Removal A Remove impeller nut If using a 1 1 16 in socket and impact driver set CCW 1 a Hold impeller by hand Use proper PPE b Using 1 1 16 in socket and impact driver set...

Page 101: ...eal R R on page 90 If inspection indicates the pump shaft oil seal requires replacement see 3 paragraph 5 8 4 13 1 Pump Shaft Oil Seal And O ring on page 102 Impeller Installation A Remove mechanical...

Page 102: ...he inducer and then refer to paragraph 5 8 4 6 page 81 AP or MBP 5 8 4 7 page 83 or paragraph 5 8 4 8 CBP on page 87 for instructions to R R the impeller Refer to Table 33 for a list of tools and or c...

Page 103: ...key Allen wrench between back side of pump head and pump shaft c Using steady gentle pressure pry on hex key with a screwdriver twist the screw driver to push stationary seat out of the pump head NOT...

Page 104: ...he mechanical seal installation tool as a push tube to seat the sta tionary portion of mechanical seal in the bore of the pump head Use PAC EASE to lu bricate the sides of the seat for easier installa...

Page 105: ...5 on page 76 to remove the inducer and the impeller as de scribed in paragraph 5 8 4 6 on page 81 RSD Impeller R R Refer to Table 34 for a list of tools and or consumables required for this procedure...

Page 106: ...Seal Notch b Slide short end of a 3 32 in or 7 64 in or 2 5 3 0 mm hex key Allen wrench between back side of pump head and pump shaft c Using steady gentle pressure pry on hex key with a screwdriver t...

Page 107: ...UCHING THE SEAL FACES WITH YOUR BARE HANDS USE RUBBER ACRYLIC LATEX ETC DO NOT USE CLOTH OR LEATHER USE ONLY PAC EASE RUBBER LUBRICANT EMULSION OR EQUIVALENT ON THE RUBBER MECHANICAL SEAL PARTS TO EAS...

Page 108: ...arring hammer may be used to tap on the mechanical seal installation tool to fully and evenly seat the diaphragm on the pump shaft D Install spring NOTE It is easier to install the impeller key before...

Page 109: ...AP CBP MBP Pump Head R R Tools And Consumables List Standard Tools Special Tools Consumables PPE Eye and Hand Protection None Shop Rag s As Required 3 4 in 19 mm Wrench Or Ratchet Wrench Or Pass Thru...

Page 110: ...Using a 3 4 in 19 mm wrench tighten CW four 4 M12 x 1 75 full nuts 3 D Using a cross pattern torque nuts Refer to Table 22 for recommended torque values for fastener size and material With only the p...

Page 111: ...Item 17 Clearance Ring See FSG PL 01487 Sheet 4 Item 18 ONLY One Required Select From If ONLY the pump head remains attached to the gearbox perform the following to remove and replace the pump head R...

Page 112: ...tion portion of RSD Mechanical Seal Pin R R see paragraph 5 8 4 13 2 b Install pump head clearance ring see Figure 36 Refer to paragraph 5 8 7 2 on page 110 for instructions c Lubricate new Teflon O r...

Page 113: ...ner threads or replace with correct new fasteners Then apply Loctite 243 or equivalent to threads D Secure pump head to gearbox Install four washers 1 Install four 4 M12 x 1 75 full nuts 2 Using a 3 4...

Page 114: ...portion of the following procedures to isolate the pump head as a separate item Volute R R for an AP MBP pump use paragraph 5 8 4 3 for a CBP pump use para graph 5 8 4 4 and a RSD pump for use paragr...

Page 115: ...ion Pin Bench Procedure The RSD mechanical seal anti rotation pin prevents the mechanical seal seat from sinning inside the pump head bore ONLY replace the pin if it is damaged to the point it may all...

Page 116: ...pin The combination of the two allows the grease to be forced under the pin pushing it out of the blind hole When the punch nears the end of the pin bottom of the blind hole remove the punch and refi...

Page 117: ...ge and suction port hoses plumbing will require removal before the pump removal procedure can be performed Follow OEM instruc tions procedures to remove and install discharge and or suction port hoses...

Page 118: ...oling system circulates pump water to transfer heat from the gearbox oil to the pump discharge thus maintaining lower gearbox operating temperatures The gearbox cooling system has no internal joints t...

Page 119: ...FSG PL 01486 Sheet 4 Item 27 MBP See FSG PL 01487 Sheet 4 Item 6 RSD 5 8 in Wrench Elbow 3 8 Comp X 3 8 Comp See FSG PL 01483 Sheet 4 Item 19 AP See FSG PL 01482 Sheet 4 Item 17 CBP See FSG PL 01486 S...

Page 120: ...Using 5 8 in wrench or adjustable wrench loosen turn CCW return 2 side compression nut on adapter 1 2 male NPT X 3 8 tube Slide both nuts out of the way 3 NOTE Use care when cutting the cooling tube N...

Page 121: ...ide and hand start adapter into gearbox threads d Using 1 1 16 in wrench or adjustable wrench tighten turn CW adapter e Repeat Step b thru Step d except for return side Install compression fittings 2...

Page 122: ...ize a wraparound style ring located in the pump head If pump is an AP CBP or MBP refer to paragraph 5 8 4 3 see page 72 or paragraph 5 8 4 4 see page 74 for volute removal If the pump is a RSD refer t...

Page 123: ...OT CUT THRU THE CLEARANCE RING CUTTING THRU THE CLEARANCE RING WILL DAMAGE THE VOLUTE AND MAY RESULT IN PUMP FAILURE B Using cutting wheel cut two slots 180 apart opposite each other into failed clear...

Page 124: ...d cavity while the MBP wrap around clearance ring presses on to the outside shoulder The CBP is similar to the MBP configuration however the CBP utilizes both a different pump head and a different siz...

Page 125: ...NOT into pump head See Figure 41 Figure 42 Clearance Ring Drilled Out MPB Pump Head D Using a chisel and hammer bend clearance ring slightly inward at holes Then cut clearance ring thru with chisel Se...

Page 126: ...r D Align new wrap around clearance ring to pump head DO NOT DRIVE THE CLEARANCE RING INTO THE PUMP HEAD AT AN ANGLE OR UNE VENLY ALL THE WAY FROM ONE SIDE AT A TIME BENDING WARPING OR CHIPPING THE CL...

Page 127: ...e ring out of suction head See Figure 44 Figure 45 Clearance Ring Driven Out Suction Head RSD Suction Head Clearance Ring Installation A Clean suction head to remove old Loctite Use Loctite Clean Up S...

Page 128: ...earance ring during the initial pump priming to prevent the ring from contacting the impeller RSD Pump Head Clearance Ring Removal A Place pump head on stable work surface with drive side down NOTE As...

Page 129: ...ULT IN POOR PERFORMANCE OR PUMP FAILURE NOTE A circular piece of plate steel the size of the outside diameter of the clearance ring may be used to prevent the ring from tipping or jamming inside the s...

Page 130: ...CLOG PREVENTING CRITICAL LUBRICATION The Flex series gearbox provides the latest in gearbox technology a wider range of gear ratios and decreased preventive maintenance The gearbox new technology util...

Page 131: ...ortion of AP Impeller R R see para 2 graph 5 8 4 7 on page 83 If pump is a CBP perform Removal portion of CBP Impeller R R see par 3 agraph 5 8 4 8 on page 87 E Remove mechanical seal as described bel...

Page 132: ...2 If pump is a CBP perform Installation portion of CBP Volute R R see 3 paragraph 5 8 4 4 on page 74 F Install drive flange snap ring Expand and install retaining ring 1 a Using snap ring pliers inser...

Page 133: ...rocedure requires gearbox removal prior to performance to provide input shaft access See the previous paragraph for references to remove the unit from the apparatus and then the pump assemblies from t...

Page 134: ...OTE If required using 10 mm hex socket and ratchet set for CW tighten adjacent drain plug NOTE Plug should be approximately flush with the housing when tighten Using seal removal tool remove input sha...

Page 135: ...ove drive gear key 2 NOTE ONLY remove the drive side bearing if the shaft is being repaired and reused other wise discard entire assembly If required remove drive side bearing from input shaft 3 a Pre...

Page 136: ...ss is NOT available use a 3 inch long piece of 2 in DOM steel tube Use ONLY 0 188 wall tube and a dead blow hammer to assemble the bearing and shaft Grease the shaft and bearing inner bore to aide in...

Page 137: ...g Using gear oil lubricate bore of pump side bearing entire pump side of 2 input shaft outside of pump side bearing and pump side bearing bore in gearbox Place new pump side input shaft bearing on inp...

Page 138: ...ted in place this prevents seal movement which would cause an oil leak and there is no way to remove the oil seal without damaging it Therefore the oil seal is typically replaced as part of any input...

Page 139: ...b Pry input shaft oil seal out of gearbox B Install new input shaft oil seal Apply Loctite 680 or equivalent to mating surface of seal 1 Using gear oil lubricate mating surfaces of oil seal and input...

Page 140: ...to the required Removal From The Apparatus procedures If gearbox removal is required prior to bench procedure performance see paragraph 5 9 1 on page 118 for reference to the required Removal portion...

Page 141: ...th smooth part of cap facing out 2 ward Using seal driver drive endcap into gearbox until flush 3 B Perform Gearbox Oil Level Check Refer to paragraph 4 3 2 This procedure may require gearbox installa...

Page 142: ...ive gear for wear or damage and to remove and replace the gear if required Drive Gear Removal A Remove gearbox cooling tube IAW paragraph 5 8 7 1 1 on page 108 B Remove pump shaft IAW paragraph 5 9 2...

Page 143: ...pump removal from an apparatus and para graph 5 9 1 on page 118 for reference to the required Gearbox R R procedure Performing the removal portion of this procedure places a lot of stress on the pump...

Page 144: ...G PL 01486 Sheet 5 Item 1 MBP Pump Shaft ONLY 3 74 1 GR See FSG PL 01486 Sheet 5 Item 15 MBP Non marring Hammer Shop Rag s As Required 13 mm Socket Gearbox Lubricant See paragraph 5 7 2 on page 49 Rat...

Page 145: ...rting the gearbox If using cribbing to support suspend the gearbox above the bolster plate the gearbox is required to be held securely safely and stable enough to press the shaft out of the drive side...

Page 146: ...requires removal from the pump shaft All other ratio pump gears will NOT pass thru the bore and must be removed from the gearbox after the cover is removed ONLY remove gearbox cover if pump gear remai...

Page 147: ...acement pump shaft prior to installation With the exception of the RSD which is NOT available with the 3 74 1 GR Flex series booster pumps require a different pump shaft when configured with the 3 74...

Page 148: ...o NOT ex ceed 8 hrs Using dry ice in an alcohol bath cool shaft to 65 54 C Do NOT exceed 1 hr Use appropriate PPE to handle assemble bearing and shaft a Lubricate pump shaft and bearing center bore wi...

Page 149: ...ated in groove NOTES The 3 74 1 GR configuration does NOT use a pump side spacer The notch in the spacer faces the pump gear For all except 3 74 1 GR pumps install pump side pump gear spacer 3 Install...

Page 150: ...lubricate pump side bearing outer race and gearbox housing bore b Align bearing outer race squarely in gearbox housing bore c Push pump side bearing already installed on pump shaft into gearbox housin...

Page 151: ...side and the other located on the pump side of the pump shaft Both of these bearings are one piece bearings pressed onto the pump shaft and installed in the gearbox housing Using good practices whenev...

Page 152: ...e catch container under drain plug b Remove magnetic and or adjacent drain plug i Using 9 16 in wrench or 8 pt socket and ratchet set for CCW loosen mag netic drain plug NOTE If required using 10 mm h...

Page 153: ...mp gear turns the pump shaft The pump shaft turns faster than the in put shaft how much faster depends on the gear ratio selected when the pump was designed manufactured The Flex series gearbox design...

Page 154: ...on page 108 B Remove pump shaft IAW paragraph 5 9 2 2 on page 131 Perform the following to remove and replace ONLY the pump gear Pump Gear Removal A If GR is 1 14 1 31 1 64 or 1 90 1 remove loose pump...

Page 155: ...ore of inner race of bearing with gear oil 2 Place bearing on plate opening or cribbing so bearing is stable and se 3 cure and pump shaft will pass thru bearing Align pump shaft drive side toward bear...

Page 156: ...lign pump gear with drive gear teeth and gearbox pump shaft bores B Install pump shaft assembly For all EXCEPT 3 74 1 gear ratio pumps install drive side bearing retain 1 ing ring in gearbox a Using s...

Page 157: ...g on pump shaft and into gearbox 3 bore ONLY far enough to verify alignment of shaft in bearing and bearing in gearbox Align bearing squarely with pump shaft and in gearbox hous ing bore Using hydraul...

Page 158: ...146 THIS PAGE INTENTIONALLY BLANK...

Page 159: ...M12 1 75 Stud 25 mm Long Gearbox To Pump Head 54 40 478 3 8 16 Screw Grade 8 0 88 in Long Volute Screw Iron 68 50 600 3 8 16 Screw SS 0 88 in Long Volute Screw Bronze Pump 39 28 349 7 16 14 Stud 2 63...

Page 160: ...en until flush or below flush to provide flat mounting surface for OEM Use grease and impact gun to drive these plugs Nuts FASTENER USED ON Nm FT LB IN LB 1 12 Castle Nut Brass Inducer Nut RSD MBP 110...

Page 161: ...e specified in the procedure can be used The required torque is listed for Nm and then shown converted into ft lb and then in lb providing a variety of torque scales The torque required for use on the...

Page 162: ...Thermometer Precise Non Contact IR Hydraulic Press A 20 ton or greater hydraulic press is primarily used to press gearbox components typically bearings on or off the pump or input shafts NOTE A large...

Page 163: ...ming Pump C 1 1 Priming Pump A priming pump draws air out of the pump body and suction piping allowing water to enter The priming pump has a rotor mounted off center eccentric to the housing The eccen...

Page 164: ...environmentally friendly primer that does not require a separate lubricant reservoir The vanes and volute are self lubricating for maintenance free op eration Figure 52 shows an ESP priming pump Figu...

Page 165: ...pump allowing for faster priming and longer primer life The SPVR is a remotely mounted valve the SPV and a sep arate panel mounted switch the PRIME button The SPV is a diaphragm operated valve that op...

Page 166: ...hed to the discharge piping either by flange mounting or 1 in NPT threaded connection 38 mm for the TRVM The valve monitors the temperature of the water in the pump When the temperature exceeds 120 F...

Page 167: ...egral to the proper operation of the pump Refer to the valve manual for proper valve maintenance procedures A Lubricate all suction and discharge valves using an approved lubricant B Verify each valve...

Page 168: ...to intake test gauge connection DO NOT RUN THE PRIMER FOR MORE THAN 45 SECONDS IF PRIME IS NOT ACHIEVED IF PRIME IS NOT ACHIEVED IN 45 SECONDS STOP AND LOOK FOR CAUS ES AIR LEAKS OR BLOCKED SUCTION H...

Page 169: ...in 5 minutes at least one air leak is indicated If leaks cannot be located by following this procedure hydrostatically test the pump A Open all valves B Place caps on all valves DO NOT EXCEED LOWEST...

Page 170: ...mation only It does NOT supersede any lo cal procedure A Fill water tank until it overflows B Close tank fill line bypass cooling line and all pumpintakes C Attach sufficient hose s and nozzle s to fl...

Page 171: ...gure 61 ESP Exploded View Perform the following to maintain the primer NOTE Before beginning disassembly note match mark tag the position and locations of components to ensure correct assembly Disasse...

Page 172: ...3 tor F Match mark note each primer vane location G Disassemble pump Remove shaft and rotor assembly 1 Remove vanes from pump body 2 Remove seal from pump head 3 Inspect all components for corrosion d...

Page 173: ...pump head onto pump body Align pins with holes in pump body and slide pump head over rotor shaft 1 Once head is seated against pump body make sure rotor turns freely in 2 pump C Install motor on pump...

Page 174: ...C 12 THIS PAGE INTENTIONALLY BLANK...

Page 175: ...RIAL NUMBER Use this Log to record all maintenance actions and problems faults part replacements tear downs and major overhauls as a minimum Please contact Customer Services at Hale Prod ucts Inc prio...

Page 176: ...D 2 DATE HOURS RUN MAINTENANCE PROBLEM PART S USED REASON REPLACED INITIALS...

Page 177: ...ck on the Documents tab and then click on the Hale Warranty Statement link E 3 Returned Goods Procedure lf you identify a component or assembly that is worn defective supplied in incorrect quantity or...

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HALE AP, Technical Manual

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