OPERATING AND MAINTENANCE MANUAL MODEL: DSD SERIAL NO._______________ Failure to follow the operating, lubrication, and maintenance requirements set forth in the operating and instruction manual may result in serious personal injury and/or damage to equipment. A Hale pump is a quality product; ruggedly designed, accurately machined, carefully assembled and thoroughly tested.
Limited Warranty EXPRESS WARRANTY: Hale Products Inc. (Hale) hereby warrants to the original buyer that products manufactured by it are free of defects in material and workmanship for two (2) years or 2000 hours usage whichever shall first occur. The Warranty Period commences on the date the original buyer takes delivery, of the product from the manufacturer. LIMITATIONS: HALES obligation is expressly conditioned on the Product being: Subjected to nominal use and service.
CSP4 Rev: 03/01/2000 Material Return Procedure • A Material Return Authorization (RGA) number must be requested from Hale Products Inc., prior to returning any merchandise. • Replacement parts, complete items or accessories must be in new condition or are able to be resold, properly identified with Hale part numbers. • Any material that is returned that does not reflect the original purchase will be accepted upon Hale’s discretion and evaluation fee.
1. INTRODUCTION OVERVIEW Hale single-stage and two-stage midship pumps are favorites of firefighters throughout the world. Covering a range of capacities from 750 Gallons Per Minute (GPM) to 2000 GPM, Hale pumps offer the versatility, dependability, reliability, and ease of operation so necessary to effective fire fighting. This section reviews the principles of operation of Hales single-stage and two-stage midship pumps.
BASIC PARTS OF A HALE Midship CENTRIFUGAL PUMP Figure. 1-2 shows the basic parts of a Hale midship centrifugal pump. These parts are briefly described in the following text IMPELLERS (TWO STAGE) BALL BEARINGS SLEEVE BEARING AUTO-LUBE SLINGER RING PACKING CLEARANCE RINGS Impeller The impeller provides velocity to the water. This part is mounted on a shaft that is rotated by the drive.
Bearings Bearings support and align the impeller shaft for smooth operation. See Figure 1-2. Pump Body The standard pump body (Figure 1-2) and related parts are constructed from fine grain alloy cast iron, with a minimum tensile strength of 30,000 PSI. All moving parts subject to water contact are of high quality bronze with stainless steel shafts. The body is split horizontally on a single plane in two sections for easy removal of the entire impeller assembly, including clearance rings and bearings.
Mechanical Seal The mechanical seal is an option to pump packing. As shown m Figure 1-5, a stationary seal seat is in constant contact with a rotating carbon face to prevent high pressure leakage. The sealing boot is made of a rubber elastomer that is specifically designed for high temperature operation. MECHANICAL SEAL Auto-Lube A miniature centrifugal pump (A) is built into the shaft of Hale midship pumps (see Figure 1-6).
CENTRIFUGAL PUMP DRIVE There are four common types of centrifugal pump drives used with fire fighting apparatus: Operation from the truck chassis drive shaft (split-shaft PTO). Operation from a separate engine. Operation from the front of the truck chassis engine (front engine PTO) crankshaft Operation from a PTO from the truck transmission. A PTO before the engine transmission or a PTO from the (four wheel-drive) transfer case.
GEARBOX Hale offers a variety of pump gear ratios to accommodate a wide range of apparatus manufacturer requirements. The gearbox (Figure 1-8) consists of a gearbox, gear set, and input and output drive shafts that are both made of heat treated nickel steel. This unit can withstand the full torque of the engine in road operating conditions up to 16,000 pounds-feet. If the gearbox is equipped with a power shift system, an in-cab control valve is provided for mode selection.
DESCRIPTION OF HALE MIDSHIP PUMPS SINGLE-STAGE There are two series of single-stage pumps: 750 GPM to 1250 GPM 1000 GPM to 2000 GPM Hale single-stage pumps are of a size and design to attach to the chassis rails of commercial and custom chassis. The pump is driven from the truck main drive line.
TWO-STAGE PUMPS There are two series of two-stage pumps: 750 GPM to 1250 GPM 1000 to 2000 GPM Hale two-stage pumps are of a size and design to mount on the chassis rails of commercial and custom trucks The pump is driven from the truck main drive line.
Pressure (Series) Operation Pressure operation, Figure 1-11, finds the impellers connected in series. That is, the output of the impeller supplied from the pump intake is supplied to the input of the next impeller. The pressure at the pump discharge is the sum of the pressures of the two impellers plus the pressure at the intake. The amount of water delivered to the discharge is the same amount that entered the first impeller. Using the example above when in series operation.
When shifting the transfer valve from volume to pressure operation, the pressure will be doubled. You may hear a metallic click or two clicks, which will be the check valves closing. If the clicks sound too harshly, you are changing the transfer valve while the pressure is too high. This happens when the truck engine is running at high speed. Refer to your fire department policy for when to use volume operation and when to use pressure operation.
BOOSTER PUMPS Hale booster pumps offer the added dimension of low volume and high pressure for use with the midship pumps. The booster is ideal for high pressure, hose reel operation. As shown in Figure 1-12, the booster pump is designed for direct mounting at the accessory port of the Hale gearbox. The booster pump is driven by the gearbox intermediate gear to provide a positive drive. Water is directed to the booster pump through a pre-piped supply hose.
PRIMING PUMP\ Priming pumps are used to create a vacuum; they are designed to evacuate air through the suction hose and into the pump. The vacuum created allows atmospheric pressure to push water from the open body of water through the suction hose and into the pump. Hale centrifugal midship pumps use Rotary Vane Positive Displacement pumps for priming. A positive displacement pump moves a specified amount of air or fluid with each revolution.
PRESSURE CONTROL DEVICES Three basic types of pressure control devices are used with Hale Midship pumps: Engine speed governor system (optional). Relief valve system (standard). Hale Total Pressure Master Relief Valve System (optional). Relief Valve System As shown in Figure 1-14, the Relief Valve System is a single bronze, variable press= setting relief valve of sufficient capacity to prevent an undue pressure rise (NFPA Pamphlet No. 1901).
Hale Total Pressure Master (TPM) Relief Valve System This system, Figure 1-15, includes a sensing device connected to the inlet side of the pump that works in conjunction with a Pressure Master control on the pump panel to give complete control over the entire system. The operating point is set by the Pressure Master control. Small changes in pump pressure are normally handled internally by the recirculating relief valve.
CAVITATION Often referred to as running away from the water supply. Cavitation simply means that the operator is trying to pump more water out of the pump than is going into the pump. AUXILIARY COOLING Model K Auxiliary Heat Exchanger/Cooler NFPA 1901 requires a supplementary heat exchanger cooling system for the pump drive engine during pumping operations. Hale model K heat exchangers meet the NFPA 1901 requirements.
2. OPERATING PROCEDURES 2. Bring the truck to a complete stop before you attempt to shift from road to pump. A. Overview 3. Apply the truck parking brake. This section supplies information and procedures for the operation of Hale single -stage and twostage pumps. Included in this section are procedures for pumping from a hydrant, pumping from draft, pumping from a booster tank, pumping in relay, tandem pumping from a hydrant, and post-operation procedures. B.
8. Verify that the pump panel shift indicator green "OK TO PUMP" light is on. 9. Open the hydrant. 10. If necessary, open the suction valve. 11. If applicable, set the transfer valve to either volume or pressure, as required. 12. If necessary to eliminate air pockets open valve to let air out or prime the pump: see “Pumping From Draft” for instructions. 13. Note the intake and discharge pressures then open the engine throttle gradually until the master discharge gauge indicates the desired pressure. 14.
2. Bring the truck to a complete stop before you attempt to connect suction hoses or shift from road to pump. 3. Apply the truck parking brake. 4. Shift the truck transmission to the NEUTRAL position. 5. Move the in-cab pump shift control valve from the ROAD to the PUMP position. The shift warning light should come on in a second or two, indicating a completed shift. If the truck manufacturer has used another in-cab valve to achieve pump shift, follow the instructions supplied with that valve 6.
DO NOT PUMP ENOUGH WATER TO CAUSE A WHIRLPOOL AT THE STRAINER. THIS ALLOWS AIR INTO THE PUMP, RESULTING IN ROUGH OPERATION AND PULSATION. REPOSITION THE STRAINER OR REDUCE FLOW TO CORRECT THE SITUATION. As the throttle is opened, the pressure gauge reading increases with the engine speed. If the engine speed increases without an increase in pressure, the pump may be cavitating. If the pump is cavitating, warn personnel that the pressure is being dropped.
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN THE CAB AND PANEL ARE ON. 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. 7.
TPM (if available) very low in order to limit the incoming pump pressure by dumping water on the ground before you have discharge hose lines connected and are flowing water. Then, as you are able to use the ni coming water, the relief valve control can be moved up to the desired operating pressure and set as instructed. This technique will also help you to purge the air from the incoming hose and the pump before it can get to a dangerously high pressure.
Pump To Road Shift Procedures TPM Relief Valve Procedures 1. Verify that the operator’s hand throttle or governor control has returned to idle speed. These procedures cover the Hale TPM Relief Valve System. Be sure to select the correct procedure, according to relief valve. 2. Shift the truck transmission into the NEUTRAL position, and wait four seconds. Check to make sure the speedometer reads 0. 3. Moving pump shift control valve lever to the ROAD position.
5. Turn the hand wheel slowly clockwise, until the amber light just goes out. Then turn the hand wheel one additional full turn clockwise for proper operation. THE TPM PRESSURE CONTROL VALVE MUST BE SET SLIGHTLY HIGHER THAN THE GOVERNOR CONTROL FOR PROPER OPERATION. Decreasing Pressure a. Put the governor control in the RPM mode, and reduce the speed to the new pressure. b. Move the TPM handwheel counterclockwise until the relief valve opens and the amber pilot light comes on. c.
DO NOT ATTEMPT EMERGENCY SHIFT PROCEDURES WHILE THE ENGINE IS RUNNING. 6. Employ manual override procedure at the shift cylinder on the pump gearbox as follows: An eyebolt is provided in the shift shaft to accept a drift punch or screwdriver. By inserting this tool into the hole provided, it will enable you to pull or push the shaft manually. Pull the shift shaft Out for Pump Position (after in-cab control valve selection), or push shift shaft for Road Position (after in-cab control valve sele ction).
3. PREVENTATIVE MAINTENANCE A. Overview Hale Midship Pumps require very little care and maintenance. However, the little required is extremely important. Preventive maintenance tasks require very little time to accomplish and consist mainly of testing for leaks, lubrication, and cleaning. The procedures supplied in this section are for normal use and conditions. Extreme conditions may indicate a need for increased maintenance.
Relief Valve and TPM Test When the relief valve is not in operation, maintain a setting above the normal operating pressure. 1. Set up to pump from the onboard water tank with the discharge valve back to the water tank open less than 1/2 way. See the procedures in Section 2 for assistance. d. Verify that the discharge pressure gauge readings have approximately doubled. 2. For power transfer valves: a.
2. Verify that the warning indicators in the cab and the pump control panel are on. 3. Switch to non-pumping operations, and verify the warning indicators are off. Valve Lubrication 1. Spray all moving parts of the suction, discharge, hose drain, and multi drain valves with a good grade of lithium base grease. 2. Lubricate all of the valve linkages.
Drive Line and Flange Bolts a. Attach the suction hose to the pump. Check all drive line and flange bolts to ensure: b. Place the suction tube cap on the end of the hose in place of a strainer. c. Close all valves and drains. Cap all suction openings and the outlet of the suction side relief valve (if so equipped). d. Connect a test vacuum gauge or manometer to the intake test gauge connection on the pump panel. e. Engage the priming pump until the gauge indicates at least 22 inches mercury. f.
f. Test apparatus and check for leaks around strainer fittings 3. Place apparatus back in service. testing criteria refer to the latest version of NFPA 1911 pamphlet. Pumpers are rated at capacities of 500, 750, 1000, 1250, 1500, 1750, 2000, or 2250 GPM (1892, 2839, 3785, 4731, 5678, 6624, 7570, or 8516 LPM). See Table 3-1. Indicator Light Test 1. Operate component with indicator lights and observe the respective indicator lights. If the indicator light fails to light replace the bulb and test again.
TABLE 3-1.
TABLE 3-2.
TABLE 3-2.
TABLE 3-3. 5" Hose 4" Hose 3 1/2" Hose GPM Flowing 3" Hose 3" Hose with 2 1/2" Couplings 2 1/2” Hose 2” Hose with 1 1/2” couplings 1 ¾” Hose with 1 1/2” Couplings GPM Flowing 1 1/2” Hose 1” Booster ¾” Booster GPM Flowing HOSE FRICTION LOSS (PSI PER 100 FEET) 10 13.5 3.5 95 14 8 500 9.
TABLE 3-4. PUMP RATING 750 1000 1250 1500 1750 2000 2250 FULL CAPACITY 1-3/4 2 (2) 1-1/2 or 2-1/4 (2) 1-3/4 or 2-1/4 (2) 2 (2) 2 (2) 2-1/4 SUGGESTED NOZZLE SIZE (INCHES) 70% CAPACITY 50% CAPACITY 1-3/8 1-1/4 1-5/8 1-3/8 1-7/8 1-1/2 2 1-3/4 (2) 1-1/2 or 2-1/4 1-7/8 (2) 1-3/4 or 2-1/4 2 (2) 1-3/4 or 2-1/4 2 The following general guidelines should be used when testing the apparatus. For 750 GPM (2839 LPM) test, two 2-1/2-inch lines should be laid from the pumper to the nozzle.
performance has dropped appreciably compared to its original performance, it needs to be serviced. (Apparatus test results should be on file with the delivery documents. If not, they may be obtained from the apparatus manufacturer or from the original certifying authority). Repacking Refer to figure 1-9 for a cross-section showing the packing arrangement and number of packing rings. The three rings adjacent to the packing gland can be replaced without disassembling the pump.
BAR). Test and set relief valve as necessary using the following procedures and figure 3-1. 1. Open operator panel and gain access to the relief valve adjustment cap screw. 2. Make sure the valve is closed and install a pressure test cap on the suction tube or discharge fitting. 3. Connect a pressurized water source or hydrostatic test pump and water supply to the pressure test cap fitting. 4. Open water supply valve and air bleed valve.
In clear water, the clearance rings continue to effectively seal for hundreds of hours of pumping. In dirty or sandy water, the impeller hub and clearance rings will wear faster than in clear water. The more the wear, the greater the bypass and the lower pump performance. Also, the greater the pressure at which each stage is operated, the larger will be the bypass and the more the performance will be lowered. 1.
Midship Pump Maintenance Check List Truck Manufacturer ________________________ Pump Model & Serial Number ________________ Year __________ Unit# _____________________ RECOMMENDED WEEKLY PROCEDURES q q q q q Test relief valve system or governor at 150, 200, 250 PSIG. Test transfer valve (if applicable). Test the priming system (check lubrication level in priming tank were installed). Lubricate all valves, discharge, suction, hose, drain, and multi-drain. Check pump shift warning indicator lights.
4. TROUBLESHOOTING Table 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 Table 4-1. If you cannot correct a problem, please have the following information ready prior to calling the Hale Customer Service Technician Department for assistance. Customer Service Number: 610-825-6300.
CONDITION Automatic Transmission With Power Shift System (continued) POSSIBLE CAUSE Insufficient air in shift system SUGGESTED CORRECTION Repeat recommended shift procedures. Air leaks in shift system Check system for loss of air. Check of leak in system. Employ manual override procedures if necessary. See Standard Transmission with Power Shift System. Attempt to locate and repair leak(s). Leakage, if external, may be detected audibly. Leakage could be internal and not as easily detected.
CONDITION POSSIBLE CAUSE PUMP LOSES PRIME Air Trap in Suction Line OR IT WILL NOT PRIME (CONTINUED) SUGGESTED CORRECTION Avoid placing any part of the suction hose higher than the suction intake. Suction hose should be laid with continuous decline to water supply. If trap in hose is unavoidable, repeated priming may be necessary to eliminate air pocket in suction hose. Pump Pressure too low when nozzle is opened Prime the pump again and maintain higher pump pressure while opening discharge valve slowly.
CONDITION INSUFFICIENT PUMP CAPACITY POSSIBLE CAUSE Insufficient engine power SUGGESTED CORRECTION Engine power check or tune up may be required for peak engine and pump performance. Transfer Valve not in proper “Volume” position TWO STAGE PUMPS ONLY. Place transfer valve in “Volume” position (parallel) when pumping more than 1/2 rated capacity. For pressure above 200 PSI (13.8 BAR), pump should be placed in “Pressure” (series) position.
CONDITION LEAK AT PUMP PACKING REMOTE CONTROL DIFFICULT TO OPERATE ENGINE SPEEDS TOO HIGH FOR REQUIRED CAPACTICTY OR PRESSURE POSSIBLE CAUSE Packing out of adjustment or worn. Lack of lubrication SUGGESTED CORRECTION Adjust the packing per the procedure in Section 3 of this manual (8 to 10 drops per minute leakage at 150 PSI (10 BAR) preferred). Replace pump packing per Section 3 of this manual. Packing replacement is recommended every 2 or 3 years depending on usage.
CONDITION RELIEF VALVE DOES NOT RECOVER AND RETURN TO ORGINAL PRESSURE SETTING AFTER OPENING VALVES RELIEF VALVE OPENS WHEN CONTROL VALVE IS LOCKED OUT UNABLE TO OBTAIN PROPER SETTING ON RELIEF VALVE WATER IN PUMP GEARBOX POSSIBLE CAUSE Dirt in system causing sticky or slow reaction Drain hole in housing, piston, or sensing valve blocked Wrong procedure SUGGESTED CORRECTION Relief valve dirty or sticky. Follow instructions for disassembling, cleaning, and lubricating. Blocked relief valve.
Glossary Atmospheric Pressure Pressure caused by the elevation of air above the earth. Auxiliary Permits water from a pump to cool the radiator water through a heat exchange. Cooling Valve Capacity Pump flow rating. Cavitation Caused by the pump attempting to deliver more water than is being supplied. This causes the formation of water vapor, and liquid water, under pressure, rushes in to fill the empty space. This damages the pump.
Glossary Gauge Pressure Pressure read from a gauge (PSIG). Governor Minimizes pressure changes by controlling engine speed. Horsepower A measure of mechanical work. Impeller The working part of a centrifugal pump that, when rotating, imparts energy to water. Essentially, an impeller consists of two disks separated by curved vanes. The vanes force the water to move outward between the disks so that it is thrown outward at high velocity by centrifugal force.
Glossary Pump Shift A midship pump is usually mounted with a split gearbox installed in the drive shaft. The pump shift moves a sliding gear in the gearbox that transmits power either to the pump or the rear axle. In road position, power is transmitted to the rear axle for driving; in pump position, the rear axle is disconnected, and power is transmitted to the pump shaft. Relay Movement of water from apparatus at a water source to additional apparatus until water Reaches the fire ground.
Let Us Put Out A Few Fires For You.
Fighting Fires Is Your Business. Looking Out For Your Pump Is Ours. Few things in life are more reliable than your new Hale midship pump. We do our best to keep it that way, too, with our standard two-year/2,000-hour warranty. Now we’re going ourselves one better, with an extended warranty that can keep your Hale midship pump covered for up to five whole years. We call it the Pro•Tech Maximum Warranty. It’s an exceptional value in long-term protection and peace of mind. Buy More, Pay Less.
extended warranty period commences two (2) years after the date the Product is first placed in service — that is, upon the date on which the standard warranty expires. The length of the extended warranty period (one year/1,000 hours, two years/2,000 hours, or three years/3,000 hours) shall be as selected and purchased by the original buyer of the product. Keep This Portion For Your Records.
(Continued from other side.) THIS EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS WARRANTIES ARE MADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY; FITNESS FOR A PARTICULAR PURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; OR PATENT INFRINGEMENT FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER’S DESIGN AND SPECIFICATIONS.
