4DK Series Pumps Installation, Operation and Maintenance 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.
4D Series Pumps Contents SECTION 1 INTRODUCTION ....................................................................................................... 7 OVERVIEW ..................................................................................................................................... 7 PRINCIPLES OF OPERATION ...................................................................................................... 7 Centrifugal Force .................................................................
D Series Pumps SECTION 4 TROUBLESHOOTING - continued Engine Speeds Too High for Required Capacity or Pressure ................................................................ 18 Discharge Valves Difficult to Operate .................................................................................................... 19 Section 5 Maintenance and Repair ..................................................................................................... 21 SECTION 5 MAINTENANCE AND REPAIR ..................
4D Series Pumps SECTION 5 MAINTENANCE AND REPAIR - continued PUMP BODY/IMPELLER ............................................................................................................. 32 Pump Body Disassembly ...................................................................................................................... 32 Figure 15: Pump Body and Impeller Assembly .............................................................................. 32 Figure 16: Impeller / Mechanical Seal Assembly ..
4D Series Pumps NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _____________________________________________
4DK Series Pumps SECTION 1 INTRODUCTION OVERVIEW Centrifugal Force Hale 4DK Series pumps are designed for handling fuel or demineralized water in the aircraft service industry. Hale 4DK series pumps are self-priming and driven primarily by a split-shaft 4DK series gearbox. Hale 4DK series pumps are self-priming centrifugal pumps that operate on the principle of centrifugal force created by a rapidly spinning disk. Figure 1 below shows that an amount of fluid has been placed at the center of a disk.
4DK Series Pumps If pressure changes with speed held constant, the flow, measured in gallons per minute (GPM) or liters per minute (LPM), changes inversely; that is, if pressure increases, flow decreases. ❑ FLOW Flow is usually measured in the number of gallons of fluid per minute (GPM or LPM) that a pump can deliver when supplied from draft. If the pressure is held constant, the flow increases with an increase in the speed of rotation.
4DK Series Pumps The impeller develops discharge pressure and directs the fluid to a single cut water and then to the discharge opening. The cut water is wedge-shaped and divides the fluid between the volute and the pump discharge. Figure 2: "Impeller Operation" on page 8 shows the flow of fluid through the Hale 4DK series pump. Cavitation Cavitation occurs when a centrifugal pump is attempting to discharge more fluid than it is receiving.
4DK Series Pumps The pump has a suction inlet on the front. The incoming fluid is directed to the impeller through the suction piping. Wear is due to foreign material found in most fluids. Clearance rings are designed for replacement as the clearance increases from usage and wear. Impeller If a pump is operated without fluid for extended periods or without discharging fluid, it may overheat. This may damage the pump and the drive mechanism. Fluid should be circulated to prevent overheating.
4DK Series Pumps The split shaft gearbox has a sliding collar that selectively directs the engine power to the pump or the apparatus drive axle. The gearbox is capable of handling the required engine horsepower, enabling the pump to meet optimum performance levels as well as torque requirements for over-the-road applications. The gearbox consists of the housing, helical gear set, and input and output shafts that are made of heat-treated nickel steel.
4DK Series Pumps Indicator Light Road Position Note that some vehicles drive the speedometer from the front wheel of the chassis. In this case, the speedometer will not read 5 to 15 MPH after shifting to the PUMP position. See the truck’s chassis manual for details. Control Handle Neutral Position Panel Placard Neutral Position Pump Position Figure 4: In-Cab Pump Shift Control 2. Bring the truck to a complete stop before attempting to shift from ROAD to PUMP. 3. Apply the truck parking brake. 4.
4DK Series Pumps To increase the pressure when this occurs, reduce the pump flow. 2. Apply the truck parking brake and chock the wheels. 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. In this case, close the throttle slowly until the pressure begins to stabilize and track with engine speed.
4DK Series Pumps Post Operation Procedures 1. Fill out the pump run log, indicating total pumping time, per your company guidelines. 2. Report all pump, vehicle equipment malfunctions, and irregularities to the proper authority.
4DK Series Pumps SECTION 3 PREVENTIVE MAINTENANCE AFTER EACH USE 4DK AMBIENT TEMPERATURE OIL SELECTION ❑ Check seals for leaks. ❑ Check piping for leaks. ❑ Close all valves and caps. DEXRON III SYNTHETIC COGNIS 2803 EMGARD SAE 50 SYNTHETIC COGNIS 294 / 2833 WEEKLY -40 -30 -20 -10 ❑ Verify operation of pump shift indicator. ❑ Check drive lines. -5 0 10 5 20 30 40 60 80 100 120 °F Note: Use above specified lubricants or equal. Consult factory for additional recommendations.
4DK Series Pumps Speed Counter – Lubrication See Figure 6: "Sight Level Gauge/Lubrication" on page 15. Lubricate the speed counter grease fitting annually using Mobil Grease 28 or equal – Hale p/n: 029-0670-00-0. 1. Follow the operating procedures in Section 2, beginning on page 11, to engage the pump. 2. Verify that the warning indicators in the cab and on the pump control panel are ON. 3. Switch to non-pumping operation and verify the warning indicators are OFF.
4DK Series Pumps SECTION 4 TROUBLESHOOTING Table 4-1 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.
4DK Series Pumps CONDITION PUMP LOSES PRIME OR WILL NOT PRIME continued POSSIBLE CAUSE Air trapped in suction line continued Pump pressure too low when nozzle is opened Air leaks INSUFFICIENT PUMP CAPACITY SUGGESTED CORRECTIVE ACTION ● ● ● ● Insufficient engine power ● Relief valve improperly set - if so equipped ● Engine governor set incorrectly - if so equipped ● ● ● Truck transmission is in wrong gear, or clutch is slipping Air leaks INSUFFICIENT PRESSURE ENGINE SPEEDS TOO HIGH FOR REQU
4DK Series Pumps CONDITION POSSIBLE CAUSE ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACITY OR PRESSURE continued Lift too high, suction hose too small SUGGESTED CORRECTIVE ACTION ● ● Faulty suction hose ● ● Blockage at suction hose entry ● ● Worn pump impeller(s) or clearance rings Impeller blockage ● ● ● DISCHARGE VALVES DIFFICULT TO OPERATE Lack of lubrication ● ● Valve in need of more clearance ● ● Higher than normal lift (10' / 3.
4DK Series Pumps NOTES ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ __________________________________________________
4DK Series Pumps SECTION 5 MAINTENANCE AND REPAIR OVERVIEW This section describes the removal, inspection, and reinstallation of the 4DK series pump and components as required for maintenance and repair. Service should be performed by a trained and qualified service technician, or your authorized Hale Products service representative. Be sure you have sufficient knowledge, experience, the proper tools and Hale genuine replacement parts before you attempt any repair maintenance.
4DK Series Pumps OIL SEALS (Input/Tail Shafts) GEAR BOX and PUMP See Figure 7 "Oil Seal Replacement." Removal 1. Park the vehicle on a level surface with ample clearance around all sides for maintenance availability. Screw & Washer 3/4-10 x 1-3/4" 2. Shut down the engine. Shaft Oil Seal (Input or Tail) 3. Set the parking brake and chock the front and rear tires. Obtain access to the pump and gearbox using safe practices in accordance with your regulations. 4.
4DK Series Pumps Installation Installation 1. Place pump and gearbox assembly on a stable platform. Attach proper lifting device to the pump and gearbox assembly. 1. Apply a light coating of general-purpose grease to the gasket and gearbox mating surfaces. 2. Lift pump and gearbox assembly into position on the apparatus. Connect mounting brackets and secure using proper fasteners. 2. Align gasket and cover on gearbox. 3. Correctly align driveline angle for proper operation.
4DK Series Pumps O-Ring Bearing Carrier Oil Seal Retaining Ring Bearing Cone Yoke Roller Bearing Inner Race Screw 1/2-13 x 1-3/4" Tail Shaft Washer Shims and Spacer Bearing Cup Bearing Cup Figure 8: Tail Shaft Assembly 9. Remove the bearing cone from the bearing carrier. Gently tap out the bearing cups and remove the bearing spacers. Reassembly and Installation See Figure 8: "Tail Shaft Assembly." 10. Using retaining ring pliers, remove the retaining ring from the bearing carrier. 1.
4DK Series Pumps Bearing Carrier Shim Placement Adjust gap between shafts to 0.060" ± 0.010" 1.52mm ± 0.25mm Figure 9: Shaft End Gap 5. Insert tail shaft into gearbox housing, aligning inner race of roller bearing with outer race on the mating input shaft. Also see Figure 9: "Shaft End Gap." 6. Carefully slide bearing carrier over the tail shaft. 7. Temporarily secure bearing cover using eight 7/16-14 x 1-1/2" screws. Torque screws to 50ft.-lb. (68N-m). 8.
4DK Series Pumps Rotate the yoke to ensure free spin. If too tight, back-off slightly on the 3/4-10 bolt. 15. Secure the bearing carrier using eight 7/16-14 x 1-1/2" screws. Apply Loctite 246 (or equal) to the threads prior to installation. Torque screws to 50 ft.-lb (68 N-m). 16. Replace the fluid and install the gearbox cover. Slide the yoke off the input shaft. 3. Carefully drive the input shaft into the gearbox using a dead blow hammer, or similar, to avoid marring the shaft. 4.
4DK Series Pumps 7. Remove the remaining bearing cone out of the housing. (See Figure 10: "Input Shaft Assembly" on page 26.) 8. Tap out bearing cups and remove outer spacer. 9. Using retaining ring pliers, remove the retaining ring from the gearbox housing. Inspection 1. Clean bearings and other components using parts cleaner. 2. Carefully inspect bearings and seals for signs of excessive wear. The tapered roller bearings, shims and spacers are a matched set and must be replaced as a unit.
4DK Series Pumps Screws (2), 7/16-14 x 1" Seal Rings (3) Seal Ring Spacer Extension Shaft Lock Nut Bushing Rod End Piston Gasket Cylinder Cap Screws (4) 5/16-18 x 1" Shift Cylinder Air Inlet Port 1/8" NPT Figure 11: KPS Shift Cylinder Assembly 8. Remove seal ring from shift cylinder. 9. Remove and check bushing for wear. Replace accordingly with Hale p/n: 2509550-00-0. Installation See Figure 11: "KPS Shift Cylinder Assembly." 1. Install new seal ring in cylinder groove. 2.
4DK Series Pumps Setscrew 1/2-20 x 1/2" Detent Spring Detent Ball Shifter Shaft Cap Ball Gasket Bushing Bracket Screws (2 - not shown) #10-32 x 1/2" Shift Switch (See Figure 12 below for details) Figure 12: KPS Shift Cap Assembly KPS SHIFT CAP and SWITCH See Figure 12: "KPS Shift Cap Assembly." Removal Installation See Figure 13: "KPS Shift Cap Assembly." 1. Apply a light coating of general-purpose grease to hold gasket in place, then place gasket on gearbox. 1. Disconnect control connection. 2.
4DK Series Pumps 2. Align the gearshift shaft cap. Apply Loctite 246 (or equal) and install two 7/16-14 x 1" screws. 2. While holding the shift fork in place, insert shift shaft into gearbox housing by sliding shaft through the shift fork. 3. Install the detent ball and spring. Secure using 1/2-20 x 1/2" setscrew. 3. Install shift fork screw. This is a specialty screw that cannot be substituted with standard hardware. Contact Hale for replacement part, p/n: 018-8350-00-0. 4.
4DK Series Pumps Inspection 2. Next press the bearing cups into the idler gear. See Figure 14: "Idler Shaft Assembly." 1. Clean bearings and other components using parts cleaner. 2. Carefully inspect bearings and seals for signs of excessive wear. The bearings, shims, and spacers are a matched set and must be replaced as a unit. Order a new set using Hale p/n: 2508270-50-0. 3. Obtain new components from Hale Products as appropriate. Installation See Figure 14: "Idler Shaft Assembly." 3.
4DK Series Pumps PUMP BODY/IMPELLER To service the internal parts of the gearbox or pump head (pump shaft, bearings, seals, impeller, etc.) the pump body must first be removed. See Figure 15: "Pump Body and Impeller Assembly." Note: The pump body can be removed while the pump and gearbox assembly are mounted on the apparatus. CAUTION ! BEFORE WORKING ON THE PUMP, DISCONNECT SUCTION AND DISCHARGE PIPING AND DRAIN THE PUMP BODY. Pump Body Disassembly See Figure 15: "Pump Body and Impeller Assembly." 1.
4DK Series Pumps Pump Shaft Mechanical Seal Mechanical Seal Pump Head Clearance Ring Seal Spring Impeller Clearance Ring Shaft Key Impeller Nut Spring Pin Figure 16: Impeller / Mechanical Seal Assembly Impeller Disassembly Impeller Hub See Figure 16: "Impeller/Mechanical Seal Assembly." Inspect the impeller hub(s) for signs of wear per dimensions listed below. Replace impeller if hub is worn or damaged beyond repair. 1. Remove the pump body per preceding section.
4DK Series Pumps ❑ Wear Limits: 4.770" to 4.787" (121.2-121.6mm) Mechanical Seal Assembly See Figure 15: "Pump Body and Impeller Assembly" on page 32. 1. Inspect the mechanical seal. 2. If replacing mechanical seal, remove the seal spring and seal bellows from pump shaft. 3. Remove seal stationary seat from pump head. Installation See Figure 16: "Impeller/Mechanical Seal Assembly" on page 33. 1.
4DK Series Pumps 1. Install the impeller shaft key into the slot on the pump shaft. Tighten cap screws to 40 ft.-lb. (54.2 N-m). 7. Install impeller and pump body. 2. Carefully slide impeller over pump shaft aligning keyway with impeller key. 3. While holding the impeller with a strap wrench, tighten impeller nut. Pump Body Installation See Figure 15: "Pump Body and Impeller Assembly" on page 32. 4. Install spring pin to lock the impeller nut to the pump shaft.
4DK Series Pumps Shims Bearing Cover Screw (4) 7/16-14 x 1-1/2" Adapter Spacer Bearing Cup Pump Shaft Cap Spring Pin Bearing Cone Roller Bearing Speed Counter Pump Gear Shims Shaft Key Figure 18: Pump Shaft Assembly 3. Unscrew the four 7/16-14 x 1-1/2" screws allowing removal of the bearing cover and shims. Clean the mating surfaces of all shim material. 4. Using the proper pushing tool, remove the pump shaft and attached components out of the gearbox from the bearing cover side to the pump. 5.
4DK Series Pumps 8. Measure the gap under the cover using feeler gauges. Install shims as necessary to obtain 0.002" to 0.004" (0.051-0.101mm) of axial shaft float. Shaft should rotate smoothly and freely. ❑ two pieces – 0.005" (0.13mm) BLUE ❑ two pieces – 0.0075" (0.19mm) CLEAR ❑ two pieces – 0.020" (0.51mm) YELLOW 9. Install impeller and pump body. See heading "Impeller/Pump Body Installation" on page 34.
4DK Series Pumps 4DK SERIES OVERVIEW Shift Fork Gearbox Housing (Shown in PUMP Position) Input Gear Air / Electric Switch KPS Shift Cylinder Assembly Shift Shaft and Extension Gear Shift Switch Assembly Rod End Detent Spring and Ball Yoke Yoke (Input) (Tail / Output) Input Shaft Assembly Tail / Output Shaft Assembly (Also see Figure 20) (See Figure 20) Idler Gear Impeller Shaft Assembly (Also see Figure 21) Idler Shaft Assembly O-Ring Seal (Also see Figure 21) Speed Counter Assembly 4"
4DK Series Pumps Shift Rod End Screw and Washer Air Inlet Port (Input Shaft Assembly) (Shift Cylinder) Seal Ring Yoke Shift Rod Extension (Input Shaft Assembly) Seal Ring Rod Scraper Gasket (Shift Cylinder) Seal Ring Input Shaft Cylinder Cap Oil Seal Seal Ring Piston Bearing Cup Shift Cylinder Assembly Spacer and Shims Air Inlet Port Retaining Ring Bearing Cone (Shift Cylinder) Shifter Bushing Input Gear Shift Rod Shift Collar Needle Bearings Roller Bearing Outer Race Gearbox Housin
4DK Series Pumps Speed Counter Pump Shaft Cover (10:1) Idler / Idler Shaft Cap (Remove to connect Speedometer cable) Adapter O-Ring Seal Pin Bearing Cone Pump Bearing Shim Bearing Cup Bearing Cup Bearing Cone Retaining Ring Pump Spacer Pump Gear Idler Gear Pump Key Idler Spacer Bearing Cone Pump Shaft 4" (102mm) Victaulic Discharge Bearing Cup Oil Seal Seal Ring Pump Head Gasket Impeller Mechanical Seal Assembly Clearance Rings Impeller Nut Impeller Key Impeller Nut Pin Plug Volute (Pu
4DK Series Pumps SECTION 6 PUMP INSTALLATION OVERVIEW 4" (102mm) Victaulic Discharge 3.25" (83 mm) This section provides guidelines and recommendations for installing a Hale 4DK pump and gearbox into a truck chassis. 3.72" (95mm) 4" (102 mm) Victaulic Suction FRAME MOUNTING The 4DK gearbox is mounted using four 5/8-11 bolts on either side of the gearbox. See Figure 22: "4DK Series Pump Installation" in the next column. All eight bolt holes are tapped 1" (25mm) deep.
4DK Series Pumps ❑ Suspension travel and torque wrap-up can change a marginal driveline into one that is unacceptable. Always consider the full movement of the driveline. ❑ Center your driveline sliders and ensure they have sufficient travel to allow for the entire movement of the suspension. ❑ Do not measure driveline angles using a bubble protractor. Instead, use a digital inclinometer. Remember to zero the inclinometer on the truck frame, not the ground.
4DK Series Pumps 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...............
4DK Series Pumps 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 .......
4DK Series Pumps Positive................ Pressure above atmospheric. Pressure Power Valve ........ A valve that uses hydraulic pressure to transfer two-stage pump operation from volume mode to pressure mode, and vice versa Pressure .............. Force per unit area. Pressure .............. The pressure gauge is usually graduated in pounds per square inch (PSI) only. It is Gauge connected to the pump discharge manifold, thus indicating pump discharge pressure. Priming ................
4DK Series Pumps Stages ................. The number of impellers in a pump that are used in series; that is, one following another in terms of flow. Each impeller develops part of the total pump pressure. Tachometer ......... Indicates the speed of the engine crankshaft in revolutions per minute. Torque ................. The force that acts to produce rotation. Transfer Valve .....
4DK Series Pumps 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 ........................................
4DK Series Pumps NOTES ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ __________________________________________________
4DK Series Pumps 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.
4DK Series Pumps 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.
