HALE AP User manual

MANUAL P/N FSG–MNL–00184 REV A
COPYRIGHT © 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
[phone]
[phone] (FAX)
www.haleproducts.com

i
TABLE OF CONTENTS
Section Title Page
1. SAFETY.............................................................................................................................................1
1.1. PPE ............................................................................................................................................1
1.2. Environmental Protection ........................................................................................................1
1.3. Training .....................................................................................................................................2
1.4. Safety Summary .......................................................................................................................2
2. INTRODUCTION................................................................................................................................7
2.1. Overview....................................................................................................................................7
2.2. How To Use This Manual..........................................................................................................7
2.3. Pump Specifications And Numbering......................................................................................8
2.4. Principles Of Operation ............................................................................................................8
2.4.1 Explanation 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
2.4.1.7 PM Relief Valve Control............................................................................................ 11
2.4.1.8Volute ........................................................................................................................ 11
2.4.2 Standard Booster Pump Components............................................................................ 11
2.4.2.1 Volute ........................................................................................................................ 12
2.4.2.2 Impeller And Shaft Assembly................................................................................... 12
2.4.2.3 Mechanical Seal ....................................................................................................... 12
2.4.2.4 Gearbox..................................................................................................................... 13
2.5. Pump Drives........................................................................................................................... 13
2.6. Optional Pump Components................................................................................................. 14
2.6.1 Anodes............................................................................................................................. 14
2.6.2 TRVs ................................................................................................................................. 15

ii
TABLE OF CONTENTS – CONTINUED
Section Title Page
3. MAINTENANCE OPERATING PROCEDURES.................................................................................17
3.1. Repair Verification Operations ..............................................................................................18
3.2. Vacuum Test...........................................................................................................................20
3.3. Pressure Test .........................................................................................................................22
3.4. Pumping From Draft Verification Operations .......................................................................23
3.4.1 Draft Limiting Factors .......................................................................................................25
3.5. Cavitation (Details).................................................................................................................26
3.5.1 Process Of Cavitation ......................................................................................................26
3.5.2 Warning Signs Of Cavitation ...........................................................................................27
3.5.2.1 Discharge Pressure...................................................................................................27
3.5.2.2 Vacuum Compound Gauge.......................................................................................27
3.5.3 How To Prevent 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. Maintenance Log ...................................................................................................................33
4.3. Extreme Conditions Maintenance Guidelines......................................................................34
4.3.1 Freezing Weather ............................................................................................................34
4.3.2 Contaminated Water .......................................................................................................35
4.4. Booster Pump Preventive Maintenance Procedures...........................................................35
4.4.1 After Each Use (Flush Pump) ..........................................................................................35
4.4.2 Leakage Checks ..............................................................................................................35
4.4.3 Quarterly Maintenance....................................................................................................36
4.4.3.1 Check Gearbox Oil Level...........................................................................................36
4.4.3.2 Perform Vacuum Test ...............................................................................................37
4.4.4 Annual Pump Maintenance ............................................................................................38
4.4.4.1 Performance Testing.................................................................................................38
4.4.4.1.1 Testing Overview.................................................................................................38

iii
TABLE OF CONTENTS – CONTINUED
Section Title Page
4.4.4.1.2 Testing Equipment And Materials..................................................................... 38
4.4.4.1.3 Performance Testing Test Procedure ............................................................... 41
4.4.5 Annual Pump Maintenance............................................................................................ 41
4.4.6 Triennium Pump Maintenance....................................................................................... 42
4.4.6.1 Gearbox Fluid Change.............................................................................................. 42
5. CORRECTIVE MAINTENANCE (REPAIR) ....................................................................................... 43
5.1. Troubleshooting..................................................................................................................... 43
5.1.1 PTO Or Pump Engagement Problems ............................................................................ 43
5.1.2 Pump Priming Problems ................................................................................................. 44
5.1.3 Insufficient Pump Capacity............................................................................................. 45
5.1.4 Engine Speed Problems ................................................................................................. 45
5.1.5 Relief 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 Impeller Renew............................................................................................... 48
5.6. Miscellaneous Maintenance................................................................................................. 49
5.7. General Repair Guidelines.................................................................................................... 49
5.7.1 Match Mark Or Note Component Orientation ............................................................... 49
5.7.2 Recommended Lubricants ............................................................................................. 49
5.7.3 Cleaning And Lubrication Required For Mechanical Seal Installation ........................ 50
5.7.4 Replacement Fasteners ................................................................................................. 50
5.7.5 Circlip/Snap Ring Installation ........................................................................................ 51
5.7.6 Thread Lock Or Sealant Compound............................................................................... 51
5.7.7 Cleaning And Inspection Guidelines .............................................................................. 51
5.7.7.1 Recommended Cleaners ......................................................................................... 52
5.7.8 Repair Kits....................................................................................................................... 52

iv
TABLE OF CONTENTS – CONTINUED
Section Title Page
5.7.9 Impeller Renew Kits ........................................................................................................52
5.7.9.1 Worn Clearance Rings And Impeller Hubs...............................................................52
5.8. Removal And Replacement Instruction Guidelines .............................................................54
5.8.1 Tools Required/Suggested .............................................................................................54
5.8.2 General Pump Disassembly For Access Guidelines......................................................55
5.8.2.1 General Pump Removal From The Apparatus.........................................................56
5.8.3 General Pump Disassembly Methodology......................................................................58
5.8.4 Level 1 Procedures..........................................................................................................67
5.8.4.1 RSD Suction Head R&R............................................................................................67
5.8.4.2 RSD Volute R&R ........................................................................................................69
5.8.4.3 AP/MBP Volute R&R .................................................................................................72
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 Mechanical Seal R&R.......................................................................................93
5.8.4.11 AP/CBP/MBP Pump Head R&R ...............................................................................96
5.8.4.12 RSD Pump Head R&R...............................................................................................98
5.8.4.13 Pump Head R&R Bench Procedures .................................................................... 102
5.8.4.13.1 Pump Shaft Oil Seal Bench Procedure........................................................... 102
5.8.4.13.2 RSD Mechanical Seal Anti Rotation Pin Bench Procedure........................... 103
5.8.5 Level 2 Procedures....................................................................................................... 105
5.8.6 Level 3 Procedures....................................................................................................... 105
5.8.7 Miscellaneous Procedures........................................................................................... 106
5.8.7.1 Cooling System....................................................................................................... 106
5.8.7.1.1 Cooling Tube R&R............................................................................................ 108
5.8.7.2 Pump Clearance Ring R&R.................................................................................... 110
5.8.8 General Install On The Apparatus ............................................................................... 117

v
TABLE OF CONTENTS – CONTINUED
Section Title Page
5.9. Gearbox ................................................................................................................................ 118
5.9.1 Gearbox R&R................................................................................................................. 118
5.9.2 Gearbox Bench Procedures.......................................................................................... 120
5.9.2.1 Input Shaft .............................................................................................................. 121
5.9.2.1.1 Input Shaft Oil Seal (ONLY)..............................................................................126
5.9.2.1.2 Input Shaft Bearings (ONLY) ........................................................................... 127
5.9.2.1.3 Input Shaft Endcap (ONLY).............................................................................. 128
5.9.2.1.4 Drive Gear (Input Shaft)................................................................................... 129
5.9.2.2 Pump Shaft ............................................................................................................. 131
5.9.2.2.1 Pump Shaft Bearings (ONLY) .......................................................................... 139
5.9.2.2.2 Pump Shaft Endcap (ONLY)............................................................................. 139
5.9.2.2.3 Pump Gear (ONLY)........................................................................................... 141
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
C.1.1 Priming Pump................................................................................................................ C–1
C.1.2 Priming Valves............................................................................................................... C–2
C.2. TEMPERATURE CONTROL DEVICES.................................................................................... C–4
C.2.1 TRV................................................................................................................................. C–4
C.2.2 TRV–L Kit....................................................................................................................... C–4
C.3. ANCILLARY EQUIPMENT PREVENTIVE MAINTENANCE PROCEDURES ............................. C–5
C.3.1 Weekly Maintenance .................................................................................................... C–5
C.3.1.1 Pump Shift Warning Indicator Lights..................................................................... C–5
C.3.1.2 Check Valves........................................................................................................... C–5
C.3.1.3 Check And Clean Intake Strainers......................................................................... C–5
C.3.1.4 Check All Gauges.................................................................................................... C–5
C.3.1.5 Check Pump Controls............................................................................................. C–5
C.3.1.6 Inspect Water and Foam Tanks............................................................................. C–5

vi
TABLE OF CONTENTS – CONTINUED
Section Title Page
C.3.1.7 Check Roof and Bumper Turrets........................................................................... C–5
C.3.1.8 Check Auxiliary Fire Suppression Equipment....................................................... C–6
C.3.2 Monthly Maintenance .................................................................................................. C–6
C.3.2.1 Priming System Test (Dry Vacuum Test)............................................................... C–6
C.3.2.2 Drive Line 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 MAINTENANCE LOG .......................................................................... D–1
APPENDIX E. MANUFACTURER'S INFORMATION .......................................................................E–1
E.1. Manufacturer's Information ................................................................................................E–1
E.2. Warranty ...............................................................................................................................E–1
E.3. Returned Goods Procedure.................................................................................................E–1
FSG–MNL–00184 REVISION HISTORY
CHANGE
DATE
AFFECTED PAGES
Revision A 8 May 2019 All – Initial Release

vii
LIST OF FIGURES
Number Title Page
Figure 1. Centrifugal Force From A Rotating Disk ...........................................................................8
Figure 2. Single Stage Water Flow ...................................................................................................9
Figure 3. Clearance Ring Water Flow............................................................................................ 10
Figure 4. Parts Of The Hale Booster Pump................................................................................... 11
Figure 5. Mechanical Seal ............................................................................................................. 12
Figure 6. Direct Engine Mount....................................................................................................... 14
Figure 7.Hale Anode...................................................................................................................... 14
Figure 8. Driver Compartment Indicator Lights ............................................................................ 18
Figure 9. Pump Operator Panel..................................................................................................... 19
Figure 10. Results Of Cavitation.................................................................................................. 26
Figure 11. Low Pressure Regions................................................................................................ 27
Figure 12. Typical Gearbox Oil Fill/Level Component Locations ............................................... 36
Figure 13. Engine Or Opposite Engine Rotation ......................................................................... 47
Figure 14. Circlips (How To Recognize And Remove Them) ...................................................... 51
Figure 15. Measuring For Worn Clearance Rings And Impeller Hubs....................................... 53
Figure 16. Seal Removal Tool And Seal Driver Kit...................................................................... 55
Figure 17. 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 Pump Exploded View .......................................................................................... 62
Figure 23. MBP Pump Exploded View ......................................................................................... 63
Figure 24. RSD Pump Exploded View.......................................................................................... 64
Figure 25. Gearbox Exploded View (All Except 3.74:1 GR) ........................................................ 65
Figure 26. Gearbox Exploded View (3.74:1 GR) ......................................................................... 66
Figure 27. AP/MBP Volute R&R................................................................................................... 72
Figure 28. MBP Inducer R&R....................................................................................................... 77
Figure 29. RSD Inducer R&R ....................................................................................................... 77
Figure 30. MBP Impeller R&R...................................................................................................... 82
Figure 31. AP Impeller R&R ......................................................................................................... 84
Figure 32. CBP Impeller R&R....................................................................................................... 87
Figure 33. NORD-lock Washers Installation Details ................................................................... 89
Figure 34. Typical Mechanical Seal Detail.................................................................................. 91
Figure 35. RSD Mechanical Seal Notch ...................................................................................... 94
Figure 36. Align Slot On Seal With Pin In Pump Head................................................................ 95
Figure 37. Pump Head (Pump Side).......................................................................................... 100
Figure 38. Pump Head (Drive Side)........................................................................................... 101
Figure 39. Slots Cut In Clearance Ring–Volute......................................................................... 111
Figure 40. Clearance Ring Driven Out–Volute.......................................................................... 111

viii
LIST OF FIGURES – CONTINUED
Number Title Page
Figure 41. Wrap Around Clearance Rings – Pump Heads....................................................... 113
Figure 42. Clearance Ring Drilled Out (MPB Pump Head)....................................................... 113
Figure 43. Clearance Ring Bent Inward And Cut Thru ............................................................. 113
Figure 44. Slots Cut In Clearance Ring - Suction Head ........................................................... 115
Figure 45. Clearance Ring Driven Out – Suction Head............................................................ 115
Figure 46. RSD Wrap Around Clearance Rings ........................................................................ 116
Figure 47. RSD Wrap Around Clearance Ring R & R................................................................ 117
Figure 48. Pump Shaft Assembly.............................................................................................. 133
Figure 49. AP/CBP Pump Shaft................................................................................................. 135
Figure 50. MBP/RSD Pump Shaft............................................................................................. 136
Figure 51. Rotary Vane Positive Displacement Type Priming Pump....................................... C–1
Figure 52. Rotor And Vanes....................................................................................................... C–2
Figure 53. ESP Priming Pump ................................................................................................... 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 Bolt Marking .......................................................................................... C–7
Figure 61. ESP Exploded View................................................................................................... C–9
Figure 62. ESP-PVG Primer Repair Kit (P/N 546-1410-03-0)............................................... C–10
LIST OF TABLES
Number Title Page
Table 1. Vacuum Test Tools And Consumables List....................................................................20
Table 2. Pressure Test Tools And Consumables List ..................................................................22
Table 3. Additional Losses Beyond NFPA Rating Baseline .........................................................25
Table 4. Hose Sizes For Pump Rating Capacity...........................................................................28
Table 5. Lift Loss From Barometric Pressure ..............................................................................29
Table 6. Lift Loss From Elevation .................................................................................................29
Table 7. Recommended Preventive Maintenance – Pump ........................................................31
Table 8. Recommended Preventive Maintenance – Ancillary Equipment.................................32
Table 9. Example Performance Test ............................................................................................38
Table 10. Pressure And Flow For Various Size Nozzles.................................................................39

ix
LIST OF TABLES – CONTINUED
Number Title Page
Table 11. Engagement SCR Table.................................................................................................. 43
Table 12. Pump Priming SCR Table ............................................................................................... 44
Table 13. Insufficient Pump Capacity SCR Table .......................................................................... 45
Table 14. Engine Speed SCR Table................................................................................................ 45
Table 15. Relief Valve SCR Table ................................................................................................... 46
Table 16. Gearbox SCR Table......................................................................................................... 46
Table 17. Discharge Valve(s) SCR Table........................................................................................ 46
Table 18. Cavitation SCR Table ...................................................................................................... 47
Table 19. Rotation SCR Table......................................................................................................... 47
Table 20. Recommended O-ring Lubricant.................................................................................... 49
Table 21. Recommended Mechanical Seal Lubricant.................................................................. 50
Table 22. Maximum Torque Values ............................................................................................... 50
Table 23. Impeller And Clearance Ring Diameters And Clearance Values.................................. 53
Table 24. Pump R&R From The Apparatus Tools And Consumables List.................................... 56
Table 25. RDS Suction Head R&R Tools And Consumables List.................................................. 67
Table 26. RSD Volute R&R Tools And Consumables List.............................................................. 70
Table 27. AP Volute R&R Tools And Consumables List ................................................................ 72
Table 28. CBP Volute R&R Tools And Consumables List.............................................................. 74
Table 29. MBP/RSD Inducer R&R Tools And Consumables List.................................................. 78
Table 30. MBP/RSD Impeller R&R Tools And Consumables 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........ 90
Table 34. RSD Mechanical Seal Bench Procedure Tools And Consumables List....................... 93
Table 35. AP/CBP/MBP Pump Head R&R Tools And Consumables List..................................... 97
Table 36. RSD Pump Head R&R Tools And Consumables List .................................................... 99
Table 37. Pump Shaft Oil Seal Bench Procedure Tools And Consumables List........................ 102
Table 38. Mechanical Seal Pin Bench Procedure Tools And Consumables List....................... 104
Table 39. Gearbox Cooling Tube R&R Tools And Consumables List.......................................... 107
Table 40. Pump Clearance Ring R&R Tools And Consumables List .......................................... 110
Table 41. Input Shaft Bench Procedure Tools And Consumables List ...................................... 121
Table 42. Input Shaft Oil Seal Bench Procedure Tools And Consumables List......................... 126
Table 43. Input Shaft Endcap Bench Procedure Tools And Consumables List......................... 128
Table 44. Drive Gear Bench Procedure Tools And Consumables List ....................................... 130
Table 45. Pump Shaft Bench Procedure Tools And Consumables List ..................................... 131
Table 46. Pump Shaft Endcap R&R Tools And Consumables List ............................................. 139
Table 47. Pump Gear Bench Procedure Tools And Consumables List ...................................... 142

x
Abbreviations And Acronyms
The abbreviations used in this manual are limited to standard (commonly used and accepted)
scientific units of measure and therefore are NOT defined or listed. The acronyms used in this
manual are defined in this listing (in numerical-alphabetical order) and are NOT defined within
the text.
AKA Also Known As
AP Attack Pump
CBP Centrifugal Booster Pump
CCW Counter Clockwise
CW Clockwise
ESP
Environmentally Safe Priming
EVT Emergency Vehicle Technician
FAST Factory Authorized Service Team
gpm
Gallons Per Minute
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, Maintenance, Testing, And Retirement Of In-
Service Automotive Fire Apparatus
NLGI National Lubrication Grease Institute
NPT Normal Pipe Thread
OEM Original Equipment Manufacturer
OD Outside Diameter
PM Panel Mounted
PMD Panel Mounted Display
PPE Personal Protection Equipment
PTO Power Take Off
R&R Removal and Replacement (Installation)
RSD Removable Side Drive
SAE Society of Automotive Engineers
SCR Symptom, Cause, Remedy (Troubleshooting Table)
SPV Semi-automatic Priming Valve
SPVR Suction Pressure Relief Valve
TRV Thermal Relief Valve

1
1. SAFETY
This section provides definitions for DANGERS, WARNINGS, CAUTIONS, NOTICES, and NOTES
contained herein, precautions to be taken for pump repair as well as an alphabetical summary
listing of the DANGERS, WARNINGS, CAUTIONS, and NOTICES used in this manual.
DANGERS, WARNINGS, CAUTIONS, or NOTICES that immediately precede a step apply directly to
that step and all sub steps. DANGERS, WARNINGS, CAUTIONS, or NOTICES that precede an en-
tire procedure apply to the entire procedure. WARNINGS and CAUTIONS consist of two parts: a
heading (that identifies possible result if disregarded) and a statement of the hazard (that pro-
vides the minimum precautions). The headings used and their definitions are.
INDICATES A HAZARDOUS SITUATION, WHICH IF NOT AVOIDED WILL RESULT IN SERI-
OUS INJURY OR DEATH.
INDICATES A HAZARDOUS SITUATION, WHICH IF NOT AVOIDED COULD RESULT IN
SERIOUS INJURY OR DEATH.
INDICATES A POTENTIALLY 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 procedure, condition,
or statement and/or provides pertinent ancillary information.
NOTES may precede or follow the step or procedure, depending upon the information and how it
pertains to the procedure/step. The headings used and their definitions are.
1.1. PPE
The following is the minimum PPE required when performing maintenance.
•Safety Glasses •Work Shoes (Steel Toe)
• Safety Gloves • Ear Protection
•General Protection •Single Use
•Chemical Resistant •Ear Muffs
1.2. Environmental Protection
Used oil from the gearbox must be disposed of in accordance with your local regulations. It is
prohibited to pour oil and other contaminants onto the ground, down sewers, drains, or into wa-
ter courses. Dispose of lubricants through authorized waste disposal contractors, licensed waste
disposal sites, or to the waste reclamation trade. If in doubt, contact your Local Environmental
Agency for advice regarding disposal policies.

2
1.3. Training
AP, CBP, MBP, and RSD pumps must only be operated and maintained by trained personnel.
Training is available via the Hale Products Inc. website (www.haleproducts.com), Godiva √erified
Training (godiva.co.uk), or through your local dealer or vehicle manufacturer. The Hale website
provides a description of the course content and general information about the training, includ-
ing an invitation to register with the EVT Certification Commission (www.evtcc.org) to take one
EVT exam at the Hale facility.
NOTE
Be sure to record the contact phone number and contact person’s information before
completing the form.
Complete the SESSIONS, ORGANIZATION CONTACT INFORMATION, STUDENT CONTACT INFOR-
MATION portions of the form. Check the Captcha (provides the proof of human input) and then
click the SUBMIT button at the bottom of the page.
NOTE
Under the FAST buttons select No unless your facility is a FAST center. Do NOT click
Yes unless you know for sure you are a FAST member requiring certification or recer-
tification (a certification is valid for 4 years).
When the Thank you for Registering page appears record the halemarketing 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
Due to demand, classes fill far in advance of the scheduled dates. The ONLY way to
hold the selected dates is to pay at the time of enrollment submission.
1.4. Safety Summary
DO’S
•When installing or removing the pump, use ONLY appropriately rated lifting equipment that
has been inspected and is in good condition.
•Use/wear all required PPE when operating the pump (including for maintenance purposes).
See paragraph 1.1, PPE.
DON’TS
•Do NOT remove guards; rotating parts must be guarded against accidental contact.
•Do NOT insert items into the suction tube when pump is running.
•Do NOT disconnect discharge hoses while the unit is running.
•Do NOT loosen/unfasten/remove components while the unit is running.
The following warnings and cautions are used throughout this manual and are provided here as
a safety summary. WARNINGS or CAUTIONS within a procedure (preceding an individual step),
apply directly to that step, however WARNINGS or CAUTIONS that precede the entire procedure,
apply to the ENTIRE procedure.
A PRESS PRESENTS A POTENTIAL CRUSH HAZARD (FROM MOVING PARTS) AND/OR
STRIKE HAZARD (FROM EJECTED PARTS). WEAR APPROPRIATE PPE.

3
A PRESSURE HAZARD MAY EXIST EVEN WHEN THE PUMP 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.
ALWAYS FOLLOW LOCAL GUIDELINES FROM THE AHJ AND THE APPARATUS MANU-
FACTURER.
ALWAYS FOLLOW PROPER OPERATING PROCEDURES. THE PUMP OPERATOR MUST
BE FAMILIAR WITH THE PUMP OPERATING INSTRUCTIONS AS WELL AS OTHER OPER-
ATING GUIDELINES FOR THE APPARATUS AND ACCESSORIES.
DO NOT EXCEED OPERATING PRESSURE LIMITS OF PUMP, INSTALLED PLUMBING,
HOSE(S), OR EQUIPMENT IN USE.
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL OK TO PUMP LIGHTS IN
THE CAB ARE ILLUMINATED. 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 ENVIRON-
MENT. CATCH AND DISPOSE OF OIL PROPERLY. IMPROPER OIL HANDLING MAY RE-
SULT IN HEALTH RISKS AND/OR CRIMINAL PUNISHMENTS.
FAILING TO REDUCE SYSTEM PRESSURE BEFORE SYSTEM SHUTDOWN OR FLUSH-
ING COULD RESULT IN WATER HAMMERING.
THE AP PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 140 LBS
(64 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE PUMP
AND GEARBOX ASSEMBLY.
THE CBP PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 100 LBS
(45 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE PUMP
AND GEARBOX ASSEMBLY.
THE MBP PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 170 LBS
(77 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE PUMP
AND GEARBOX ASSEMBLY.

4
THE RSD PUMP AND GEARBOX ASSEMBLIES WEIGH APPROXIMATELY 225 LBS
(102 KG). USE PROPER LIFTING DEVICE WHEN REMOVING OR INSTALLING THE
PUMP AND GEARBOX ASSEMBLY.
USE PPE TO PROTECT HANDS AND FINGERS FROM SHARP EDGES. THE EDGES OF
THE BLADES ON THE INDUCER MAY BE SHARP.
A MECHANICAL SEAL IS A PRECISION ENGINEERED DEVICE. CARE MUST BE TAKEN
NOT TO DAMAGE THE MATING FACES (SEAL FORMING PORTION) OF THE SEAL. EN-
SURE THE FACES REMAIN ABSOLUTELY CLEAN THROUGHOUT THE ENTIRE INSTALLA-
TION. SEAL FACES MUST BE CLEANED WITH THE ALCOHOL WIPES PROVIDED WITH
THE REPAIR KIT.
ALWAYS INSTALL NEW BEARINGS WHEN INSTALLING THE PUMP GEAR OR PUMP
SHAFT (ESPECIALLY IF METAL WAS FOUND IN THE GEAR OIL). FAILURE TO INSTALL
NEW BEARINGS MAY RESULT IN PREMATURE PUMP FAILURE OR ADDITIONAL
EQUIPMENT 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 SEAL AND SEAT.
DO NOT ALLOW PUMP GEAR TO SLIDE THRU SUPPORTS. DO NOT ALLOW THE NEW
OIL SEAL TO BE CUT ON THE KEYWAY OR PINCHED BETWEEN THE ADJACENT PUMP
SHAFT COMPONENTS OR BE DAMAGED IN ANY OTHER WAY. DAMAGING THE OIL
SEAL WILL RESULT IN AN OIL LEAK AND POSSIBLE EQUIPMENT DAMAGE AND/OR
FAILURE.
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 DAMAGE TO OR FAIL-
URE OF THE WATER MAIN.
DO NOT APPLY LOCTITE TO A SELF-LOCKING NUT. DO NOT REUSE A SELF-LOCKING
NUT. REUSING A SELF-LOCKING NUT OR ADDING LOCTITE MAY RESULT IN THE ITEM
FAILING TO BE SECURED.
DO NOT CUT THRU THE CLEARANCE RING. CUTTING THRU THE CLEARANCE RING
WILL DAMAGE THE PUMP HEAD/SUCTION HEAD/VOLUTE AND MAY RESULT IN PUMP
FAILURE.

5
DO NOT DRIVE THE CLEARANCE RING INTO THE /SUCTION HEAD/VOLUTE AT AN AN-
GLE OR UNEVENLY (ALL THE WAY FROM ONE SIDE AT A TIME). BENDING, WARPING,
OR CHIPPING THE CLEARANCE RING MAY RESULT IN POOR PERFORMANCE OR PUMP
FAILURE.
DO NOT INSTALL A USED COTTER PIN. A USED PIN MAY FAIL RESULTING IN DEBRIS
GOING THRU THE PUMP AND/OR LOOSENING OF THE CASTLE NUT THAT SECURES
THE IMPELLER.
DO NOT LOOSEN THE CASTLE NUT TO INSTALL THE COTTER PIN. CONTINUE TO
TIGHTEN THE CASTLE NUT UNTIL THE COTTER PIN CAN BE PUSHED THRU THE HOLE
IN PUMP SHAFT.
DO NOT LUBRICATE VANES OR VANE SLOTS. USING LUBRICANT ON THE VANES OR
VANE SLOTS DURING DISASSEMBLY, CLEANING, OR ASSEMBLY EVENTUALLY CAUS-
ES A GUMMY RESIDUE TO DEVELOP, RENDERING THE SYSTEM INOPERATIVE.
DO NOT OPEN THE THROTTLE UNLESS THE OK TO PUMP (GREEN INDICATOR LIGHT)
IS ON. SEE FIGURE 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 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 HOSE). RUNNING THE PRIMER FOR LONGER
PERIODS WITHOUT ACHIEVING PRIME MAY RESULT IN PRIMER AND/OR PUMP DAM-
AGE OR FAILURE.
DO NOT STRIKE THE IMPELLER. STRIKING THE IMPELLER MAY RESULT IN IRREPA-
RABLE DAMAGE.
DO NOT STRIKE THE INDUCER OR IMPELLER. STRIKING THE INDUCER OR IMPELLER
MAY RESULT IN IRREPARABLE DAMAGE.
DO NOT USE GREASE DURING GEARBOX/PUMP SHAFT ASSEMBLY. IN ALL OTHER
CASES IT IS ACCEPTED PRACTICE TO HOLD COMPONENTS IN PLACE OR LUBRICATE
THEM FOR EASE OF ASSEMBLY USING GREASE, HOWEVER DURING GEARBOX/PUMP
SHAFT ASSEMBLY USE ONLY GEAR OIL. GREASE IS NOT COMPATIBLE WITH THE
SYNTHETIC GEAR OIL AND MAY CAUSE DRAIN HOLES TO CLOG PREVENTING CRITI-
CAL LUBRICATION.

6
IF A PUMP IS OPERATED WITHOUT WATER, OR WITHOUT DISCHARGING WATER, IT
MAY OVERHEAT. FAILURE TO FLOW WATER MAY DAMAGE THE MECHANICAL SEAL OR
THE DRIVE MECHANISM.
IF IN 30 TO 45 SECONDS ONE OF THE FOLLOWING (BULLETS) DOES NOT OCCUR
STOP THE PUMP AND CHECK FOR AIR LEAKS OR A POSSIBLE PUMP TROUBLE.
•THE DISCHARGE GAUGE READING INCREASES
•THE INTAKE GAUGE READING FALLS BELOW ZERO
•THE PRIMING PUMP DISCHARGES WATER TO THE GROUND
CONTINUING TO RUN THE PRIMING 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 PREVENT TOUCHING THE SEAL FACES WITH YOUR BARE HANDS.
(USE RUBBER, ACRYLIC, LATEX, ETC. – DO NOT USE CLOTH OR LEATHER.)
RUNNING THE ENGINE AT SPEEDS HIGHER THAN 1200 RPM DURING PRIMING IS
NOT RECOMMENDED SINCE IT WILL NOT IMPROVE PRIMING OPERATION AND MAY
CAUSE DAMAGE TO THE PUMP.
USE ONLY PAC-EASE RUBBER LUBRICANT EMULSION (OR EQUIVALENT) ON THE
RUBBER MECHANICAL SEAL PARTS TO EASE INSTALLATION. USING ANY OTHER LUB-
RICANT CAN DAMAGE THE SEAL AND SEAT.

7
2. INTRODUCTION
This section provides an overview of the Flex series pumps, drives, and their options. Additional-
ly, the section provides how to use this manual and principles of operation (including an explana-
tion of terms and standard components).
2.1. Overview
Hale Products currently produces four models of booster pumps:
•AP •MBP
• CBP • RSD
Unless otherwise indicated, these procedures will apply to all models of Hale booster pumps: Any
variations in operation or maintenance for the different models will be addressed within the con-
text of this manual. The AP, CBP, and MBP booster pump maintenance technics are similar and
are therefore grouped in this manual. The RSD booster pump maintenance technics differ signif-
icantly and are presented separate from the AP, CBP, and MBP booster pumps.
Hale booster pumps are the favorite of fire fighters throughout the world. Booster pumps can be
used as initial attack pumps or as auxiliary pumps in conjunction with the apparatus main pump.
Covering a range of capacities from 20 gpm (75 Lpm) to 1500 gpm (5,678 Lpm), Hale booster
pumps offer the versatility, dependability, reliability, small size, and ease of operation so neces-
sary for effective firefighting.
Hale booster pumps are of a compact size and lightweight design for easy mounting on the appa-
ratus chassis. The pump coupled with the new aluminum gearbox allows the apparatus builder to
only supply the PTO and connecting shaft or direct engine mount a Flex series single 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 pump maintenance and impeller
renewal. The manual also provides information to be used to troubleshoot and R&R failed com-
ponents based on the three levels of repair and impeller renew kits available from Hale Products
Inc. The repair/impeller renew kits support pump maintenance, repair, and rebuild.
This manual requires the use of the both the Hale Assembly drawings and the Parts Manual For
Hale Single Stage Booster Pumps (FSG–MNL–00185) for parts identification. Use the Parts
Manual to determine the drawing sheet (or sheets) required for reference. Then use the draw-
ing(s) to locate the part and the item number associated with that part. The item number also
appears listed (in numerical order) in the parts table along with the part number, description, and
quantity for that item number.
The Introduction section is of interest to management for pump familiarization, visual recogni-
tion, pump identification documentation, and risk assessment information.
The Safety section is of interest to both management and maintainers as it provides precautions
for maintenance (including operation for maintenance purposes) and definitions of warnings,
cautions, and notes. This section also provides a summary of both PPE and a DANGER/ WARN-
ING/CAUTION/NOTICE summary. The section provides a single point view of compiled hazards
and PPE in a condensed format. The appropriate DANGER, WARNING, CAUTION, or NOTICE and
PPE list also appears at each point of use throughout the manual.

8
The two Maintenance sections provide all aspects of maintaining the AP, CBP, MBP, and RSD
pumps, including sparing, preventive and corrective maintenance (which includes troubleshoot-
ing and remove and replace instructions). Notice that the use of this manual also requires
maintenance personnel to have received Hale training prior to using it. Use Hale Training Acad-
emy (Pumping And Maintenance) training (see paragraph 1.3, Training) and the two Maintenance
sections for all aspects of maintaining the pumps.
Within the two Maintenance sections, the troubleshooting provided utilizes SCR tables which
provide the list of known symptoms associated with a pump trouble/problem/failure. To use a
SCR table, locate the indicated SYMPTOM, verify the associated CAUSE (the maintainer must ver-
ify ALL the associated causes if multiple causes are listed) and then perform the associated
REMEDY (or remedies). The R&R procedures provide pump removal from the apparatus via two
separate methods: removing a pump as a complete assembly or removing only the pump portion
leaving the gearbox in the apparatus. Once removed the subsequent pump or gearbox repairs
are treated as bench procedures each covering a specific level (1, 2, 3, or renewal) of mainte-
nance. Each level of maintenance requires the associated repair kit be utilized. Utilizing the as-
sociated repair kit ensures all the required components are available for replacement. Utilizing
the repair kits as intended prolongs pump performance and supports the manufacturer’s warran-
ty.
Performing 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 occurred) is also key to maintaining each pump. A maintenance log
with meaningful entries will provide invaluable insight, time/money savings (in reduced down
time and shorted troubleshooting time), and cost savings over the life cycle of each pump.
2.3. Pump Specifications And Numbering
Hales policy is one of continuous development. Hale therefore reserves the right to amend speci-
fications without notice or obligation. Refer to Section 2.2, Pump Specifications And Numbering,
in the Hale OIM manual (FSG–MNL–00183) for serial number locations, model number defini-
tions, and major pump features. Refer to the Hale Products website (www.haleproducts.com) for
detailed booster pump specifications. NOTE: Using your pumps serial number and the Hale web-
site (or Customer Service) is the best way to ensure you receive/utilize the correct replacement
parts for your pump.
2.4. Principles Of Operation
Hale booster pumps are centrifugal pumps that operate on the principle that centrifugal force is
created by a rapidly spinning disk. Figure 1 shows an amount of water has been placed at the
center of a disk. The disk is rotated and the water is thrown outward from the center to the edge
of the disk. The velocity at which 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
volute), the velocity is converted to pressure; pressure is therefore, dependent on the speed of
rotation.
Figure 1. Centrifugal Force From A Rotating Disk