OPERATING AND MAINTENANCE MANUAL

1 MUSCLE PUMPS OPERATING AND MAINTENANCE MANUAL SINGLE STAGE TWO STAGE Qpak Qtwo Qflo Qmax Failure to follow the OPERATING , lubrication, and MAINTENANCE requirements set forth in this OPERATING and MAINTENANCE 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. In order to maintain the high quality of your pump and to keep it in a ready condition, it is important to follow the instructions on care and operation. Proper use and good preventative MAINTENANCE will lengthen the life of your pump.

2 ALWAYS INCLUDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE. 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 material are 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 029-0020-63-0, REV B, 2000 HALE PRODUCTS, INC., PRINTED IN Muscle Pumps - i - TABLE OF CONTENTS SECTION PAGE 1 A.

3 B. Principles of Centrifugal Pump Single-Stage Single-Stage Pump Two-Stage Two-Stage Pump Volume (Parallel) Pressure (Series) Volume Versus Pressure Transfer Choosing Between Volume and Pressure Transferring Between Volume and Pressure C. Parts of Basic Parts of Hale Midship Centrifugal Pump Qmax and Qtwo Qpak and Qflo Clearance Pump Mechanical Auto Lube ..1-11 D. Pump Pump Mounting G-Series Principle of LP and XP J Series E. Priming Priming Pressure control Relief Valve Hale Total Pressure Master (TPM) Relief Valve Cooling Model K Auxiliary Heat Thermal Relief Valve (TRV).

4 1-23 Suction Muscle Pumps - ii - TABLE OF CONTENTS (CONTINUED) SECTION PAGE 1 INTRODUCTION (Continued) Discharge Tank Suction In-line Drain Booster 2 OPERATING A. B. OPERATING Pumping From a Hydrant, General TPM Operation from a Pumping From Draft, General Pumping From the Onboard Water Pumping In Tandem Pumping Operation From a Pump to Road Shift Standard Relief Valve TPM Relief Valve TPM system with Engine Emergency Pump Shift Post Operation 3 PREVENTATIVE A. B. Post Operation Extreme Conditions MAINTENANCE During Freezing After Pumping from Salt Water, Contaminated Water, or with Foam Weekly Relief Valve and TPM Governor Transfer Valve Priming system Pump Shift Warning Indicator Valve Monthly Suction Check Valve Packing Gland Drive Line and Flange Muscle Pumps - iii - TABLE OF CONTENTS (CONTINUED) SECTION PAGE 3 PREVENTATIVE MAINTENANCE (Continued) Pump Mounting Priming system Test (Dry Vacuum Test).

5 3-4 Relief Valve system Indicator Light Annual Performance Testing Performance Testing Equipment and Performance Annual MIV and 40BD Relief Valve Test and Worn Clearance Rings and Impeller Anode TRV 4 5 CORRECTIVE A. Midship B. C. Packing D. Mechanical Seal Qmax and Qtwo Pump Mechanical Qflo and Qpak Pump Mechanical Seal and Clearance E. AutoLube Service (Qmax/Qtwo)..5-13 F. Impeller Impeller and Clearance Rings Disassembly (Single-Stage Pump)..5-16 Assembly (Single-Stage Pump)..5-16 Disassembly (Two-Stage Pump).

6 5-17 Assembly (Two-Stage Pump)..5-18 Installation (Impeller and Clearance Rings)..5-18 G. Relief Valve Muscle Pumps - iv - TABLE OF CONTENTS (CONTINUED) SECTION PAGE 5 CORRECTIVE MAINTENANCE (Continued) PM/PMD control QD Relief QG Relief PG30 Relief Sensing H. TRV I. Anode J. Qtwo Transfer K. Qtwo Check Valves (Two-Stage Only)..5-28 L. Tank To Pump Check M. Suction Extension and Suction N. Gearbox Disassembly and Removal and Assembly and Removal and Assembly and O. ESP Priming SPV Priming PVG Priming P. 40BD Series Valve 40BD Valve Seat Replacement.

7 5-41 Valve Stem Seal Drain Valve Repair 6 PARTS APPENDICES Data for Practical Use A Parts and Service Centers B Warranty C Muscle Pumps 1-1 1. INTRODUCTION A. Description 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) (2,838 Liters Per Minute, LPM) to 2,250 GPM (8,516 LPM), Hale pumps offer the versatility, dependability, reliability, and ease of operations necessary for effective fire fighting. This section reviews the principles of operation of Hale s single-stage and two-stage midship pumps.

8 B. Principles of Operation Centrifugal Force A centrifugal pump operates on the principle that centrifugal force is created by a rapidly spinning disk. Figure 1-1 shows that an amount of water has been placed at the center of a disk. The disk is rotated at some speed, and the water is thrown from the center toward the outer circumference of the disk. The distance that the water travels from the center directly relates to the diameter of the disk and the speed of rotation. When water is confined in a closed container (such as the pump body), its pressure rises to a level that depends on the speed of rotation.

9 There are three interrelated factors that regulate the performance of a centrifugal pump: q SPEED (RPM). If the speed of rotation increases with flow held constant, the water pressure increases. q PRESSURE. Pressure is usually measured in Pounds Per Square Inch (PSI) (BAR). If pressure changes with speed held constant, the flow (measured in GPM) (LPM) will change inversely, that is, if pressure increases, flow decreases. q FLOW. Flow is usually measured in the number of gallons of water per minute (GPM) (LPM) that a pump can deliver when supplied from draft.

10 If the pressure is held constant, the flow will increase with an increase in the speed of rotation. The centrifugal pump is preferred by the fire protection service due to its ability to fully utilize any positive suction inlet pressure, reducing the amount of work done by the pump. For example, if the required discharge pressure is 120 PSI (8 BAR), and the inlet pressure is 45 PSI (3 BAR), the pump must only produce the difference in pressures of 75 PSI (5 BAR). This contributes to low engine and pump speeds with reduced MAINTENANCE .