Document Outline

• APS/MBP Booster Pump Operation & Maintenance Manual, 029-0020-83-0
  • NOTICE !
  • Contents
    • 1 Safety Precautions
    • 2 Introduction
    • 3 Operation
    • 4 Preventive Maintenance
    • 5 Troubleshooting
    • 6 Repair
    • 7 Installation
    • 8 Maintenance Kits
    • Appendix A: Glossary
    • Appendix A-1: Measurements
    • Appendix C: Alternate Lubricant Manufacturers
    • Appendix D: Hose Friction Loss
    • Express Warranty
    • Drawings
  • 1 Safety Precautions
    • 1.1 Guidelines
  • 2 Introduction
    • 2.1 Overview
      • Table 2-1: Booster Pump Capacity
    • 2.2 Principles Of Operation
      • Centrifugal Force
        • Figure 2-2: Centrifugal Force, from Rotating Disk
        • Figure 2-3: Pump Water Flow, Cutwater
    • 2.3 Booster Pump Components
      • Impeller and Shaft Assembly
      • Pump Body
        • Figure 2-4: Overview of Hale Booster Pump and Gearbox
      • Mechanical Seal
        • Figure 2-5: Mechanical Seal Overview
      • Gearbox
    • 2.4 Pump Drives
      • Figure 2-6: Pump/Engine Rotation
      • HALE Power Takeoff (PTO) Driven Pumps
      • Hale Engine Mounted Pumps
      • Hale Hydraulic-Drive Pumps
    • 2.5 Accessories
      • Priming Systems
        • Figure 2-7: Rotary Vane and ESP Priming Pumps
      • Priming Valves
        • Figure 2-8: SPVR Priming Valves
        • Figure 2-9: PVG Priming Valves
      • Pressure Control
        • The P Relief Valve System
          • Figure 2-10: P Series Relief Valve System Arrangement
        • How the Relief System Works
        • Thermal Relief Valve (TRV)
          • Figure 2-11: Thermal Relief Valve, TRV
        • TRV-L Kit
        • Anodes
          • Figure 2-12: Hale Anode
        • Manifolds
          • Figure 2-13: Typical Manifold Assembly Option
  • 3 Operation
    • 3.1 Stationary Pumping Operations
      • Pumping from a Hydrant (General Operation)
        • Figure 3-1: Driver’s Compartment Indicator Lights
        • Figure 3-2: Pump Operator’s Panel
      • Draft Limiting Factors
        • Table 3-3: Base Line NFPA Ratings
      • Pumping from Draft
      • Pumping from Onboard Water Tank
    • 3.2 Pump and Roll Operation
    • 3.3 Relief Valve Procedures
      • Figure 3-4: TPM Relief Valve Control
    • 3.4 Cavitation
      • Figure 3-5: Sample, Cavitation Regions
      • Process of Cavitation
      • Warning Signs of Cavitation (Discharge and Gauges)
        • Discharge Pressure
        • Vacuum Compound Gauge
      • To Eliminate Cavitation
      • During Operations
        • Table 3-6: Lift Loss from Elevation
        • Table 3-7: Lift Loss from Elevation
      • Preventive Measures
        • Table 3-8: Hose Size vs. Pump Rating Capacity
    • 3.5 Post Operation procedure
  • 4 Preventive Maintenance
    • 4.1 Overview
    • 4.2 Post-Operation
      • Drain Pump
    • 4.3 Extreme Conditions
      • During Freezing Weather
    • 4.4 Weekly
      • Relief Valve Test
        • Figure 4-1: TPM Relief Valve Control
      • Priming System
      • Pump Shift Warning Indicator Lights
      • Valve Maintenance
      • Intake Strainers
      • Auxiliary Engine
      • Verify All Gauges are in Working Order
      • Operate Pump Controls
      • Inspect Water and Foam Tanks
      • Check Roof and Bumper Turrets
    • 4.5 Monthly
      • Gearbox Lubrication
        • Figure 4-2: Gearbox Capacity / Recommended Lubricants
        • Figure 4-3: Typical Drain, Fill and Level Plugs
      • Drive Line and Flange Bolts
      • Priming System Test (Dry Vacuum Test)
        • Figure 4-4: PVG Priming Valve Handle
    • 4.6 Annually
      • Replace Gearbox Oil
      • Check Drain Lines to Multi-Drain
      • Tank-to-Pump Flow Rate Test
      • Performance Testing Overview
        • Figure 4-5: Pump Ratings (GMP/LPM)
        • Performance Testing Equipment and Materials
        • Performance Testing
          • Table 4-6: Nozzle Flow and Pressure Ratings, Part 1
          • Table 4-7: Nozzle Flow and Pressure Ratings, Part 2
      • Worn Clearance Rings and Impeller Hubs
      • Anode Check
        • Figure 4-8: Hale Anode
  • 5 Troubleshooting
    • Figure 5-1: Sample, Serial Nameplate
    • Figure 5-2: Troubleshooting Charts
      • PTO Will Not Engage
      • Pump Loses Prime...
      • Insufficient Pump Capacity
      • Insufficient Pressure
      • Valve Remote Contorl...
      • Engine Speeds Too HIGH...
      • Cavitation
      • Relief Valve Does Not Relieve...
      • Relief Valve Does Not Recover...
      • Relief Valve Opens...
      • Unable to Optain Proper Setting...
      • Discharge Valves Difficult...
      • Water in Pump Gearbox
      • Rotation Symptoms
  • 6 Repair
    • Figure 6-1: Silencer Series Booster Pump
    • Figure 6-2: Gearbox Capacity / Recommended Lubricants
    • Table 6-3: Torque Values Chart
    • 6.1 Overview
    • 6.2 General Repair Guidelines
      • Before You Begin...
      • Cleaning and Inspection Guidelines
      • Hale Recommended Cleaners
      • Tools Required
    • 6.3 Pump and Gearbox Assembly
      • Installing the Assembly to Apparatus
    • 6.4 Servicing the Booster Pump
      • Volute (Pump Body)
        • Figure 6-4: Booster Pump Parts Breakdown
        • Figure 6-5: Typical Water Cooling Lines
        • Installation Notes - Volute
      • Impeller
        • Inspection - Clearance Rings
          • Figure 6-6: Clearance Ring ID Measurement
        • Installation Notes - Clearance Rings
        • Inspection - Impeller
          • Figure 6-7: Impeller OD Measurement
        • Installation Notes - Impeller
    • 6.5 Mechanical Seal Assembly
      • Figure 6-8: Mechanical Seal Overview / Replacement
      • Removing the Seal
      • Installing Seal
    • 6.6 Pump head
      • Figure 6-9: Oil Seal Replacement / Pump Head Parts
      • Removing the Pump Head and Oil Seal
        • Installation Notes - Pump Head and Oil seal
    • 6.7 “B” Series Gearbox
      • Oil Seal - Input Shaft
        • Figure 6-10: Oil Seal, Input Shaft
        • Installation Notes
          • Figure 6-11: Typical Bearing and Seal Insertion Tools
    • 6.8 Dismantle the B Series Gearbox
      • Figure 6-12: B Gearbox Parts Identification
      • Figure 6-13: Typical Angular Bearing Insertion Tool
      • Installation
        • Figure 6-14: Angular Contact Bearing Orientation
    • 6.9 Available options
      • Hydraulic Drive Option
        • Figure 6-15: Hydraulic Drive Option
        • Installation Notes
      • Tachometer Drive Option
        • Figure 6-16: Tachometer Drive Option
        • Installation Notes
  • 7 Installation
    • 7.1 Overview
    • 7.2 Frame Mounting
      • Mounting Holes
    • 7.3 DriveLine Issues
      • Drive Line and Flange Bolts
      • Issues
        • Table 7-1: Maximum Recommended Driveline Lengths
    • 7.4 Plumbing Connections
  • 8 Maintenance Kits
    • 8.1 Recommended spare parts kits
      • Level 1
        • Figure 8-1: Typical Level 1 Basic Repair Kit
      • Level 2
        • Figure 8-2: Typical Level 2 Intermediate Repair Kit
        • Table 8-3: Level 2 Kit Part Numbers
      • Complete Overhaul
        • Figure 8-4: Additional Booster Pump Maintenance Kits, Level 3
  • Appendix A: Glossary
  • Appendix A-1: Measurements
    • Conversion
  • Appendix C: Alternate Lubricant Manufacturers
    • Table C-1: Alternate Lubricant Manufacturers
    • Table C-2: Alternate Lubricant Manufacturers, continued
  • Appendix D: Hose Friction Loss
    • Table D-1: Hose Friction Loss (PSI/BAR 100 Feet)
  • Express Warranty
    • Hale Products, Inc.
  • Drawings - Plate #
    • APS Installation & Identification, Plate # 1027A
    • MBP Installation & Identification, Plate # 1026A
    • Anit-Corrosion Anode, Plate # 869A
    • ESP Priming Pump, Plate # 821A
    • P Series Relief Valve, Plate # 547C
    • PVG Priming Valve, Plate # 480G
    • PTO Shift Indicator Lights, Plate # 825A
    • SPV Priming Valve, Plate # 828A
    • TRV/TRVM Relief Valve, Plate # 729A
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