Idex HALE SmartCAFS User manual

UV SmartCAFS
Installation and Operation Manual
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
607 NW 27th Ave
Ocala, FL 34475
United States
800-533-3569
800-520-3473
www.haleproducts.com
[e-mail]




FSG-MNL-00157
REV D, July 2020

Page 2 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
REVISION RECORD
REV
Date
BY
Page
Description
A
28DEC2015
JDF
All
New Issue
B
24JAN2017
JJS
Drawings
Revised Drawing Update
C
21AUG2018
RAA
21, 22
86
Add pictures of gear pump w/ new motor driver
Changed separator element replacement kit QTY from 1 to 2
D
13JUL2020
JS2
10
16
22
40-44
49
60
95-105
108-111
Added Dual Foam data
Updated manifolds
Updated dimensional diagrams
Updated FSG-PL-01308 and FSG-PL-01422
Added multi-display setup/operation instructions
Added Auto-Fill info, layout and components
Updated wiring diagram, PL729, FSG-PL-01306, FSG-PL-
01307
Added Air pressure limiter, dual bypass solenoids, coolant valve

Page 3 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
T.O.C.
Table of Contents
REVISION RECORD ...................................................................................................................... 2
T.O.C. ............................................................................................................................................. 3
INTRODUCTION ............................................................................................................................ 7
ENVIRONMENTAL PROTECTION ................................................................................................ 7
SAFETY - RELEVANT DATA ........................................................................................................ 8
MAINTENANCE ..................................................................................................................................... 8
TRAINING ............................................................................................................................................ 8
NOISE ................................................................................................................................................. 9
GAUGES ............................................................................................................................................. 9
CLUTCH ENGAGEMENT ......................................................................................................................... 9
GENERAL DATA ......................................................................................................................... 10
COMPRESSOR ................................................................................................................................... 10
PUMP ............................................................................................................................................... 10
COOLING SYSTEM .............................................................................................................................. 10
FOAM PROPORTIONING SYSTEM 3.3 - CLASS A AND B FOAM COMPATIBLE ............................................. 10
FOAM PROPORTIONING SYSTEM 5.0 - CLASS A AND B FOAM COMPATIBLE ............................................. 10
FOAM PROPORTIONING SYSTEM 6.5 - CLASS A AND B FOAM COMPATIBLE ............................................. 10
FOAM PROPORTIONING SYSTEM DUAL 6.5 - CLASS A AND B FOAM COMPATIBLE .................................... 10
LUBRICANTS .............................................................................................................................. 11
COMPRESSOR SYSTEM ...................................................................................................................... 11
PUMP GEARBOX ................................................................................................................................ 11
CLUTCH HOUSING .............................................................................................................................. 11
MAXIMUM INPUT RPM ............................................................................................................... 11
MODEL IDENTIFICATION SYSTEM ........................................................................................... 12
RECOMMENDED FOAM AGENTS ............................................................................................. 13
MAJOR COMPONENTS AND CONTROLS ................................................................................ 14
GENERAL ARRANGEMENT ................................................................................................................... 14
SMARTCAFS MIXING MANIFOLD ......................................................................................................... 15
(A)VOLUTE STYLE PUMP ............................................................................................................................................. 15
(B)HIGH PRESSURE .................................................................................................................................................... 16
(C)STANDARD PRESSURE ........................................................................................................................................... 16
FOAM UNIT 3.3, 5.0, 6.5 FOAM PUMP COMPONENT GROUP ................................................................... 17
CONTROL PANEL - SMARTCAFS ......................................................................................................... 18
COMPONENT PANEL CUT-OUT DIMENSIONS ......................................................................................... 18
SYSTEM OVERVIEW ................................................................................................................... 19
SAFETY INTERLOCKS ARE PROVIDED TO ENSURE THAT: ......................................................................... 19
COMPRESSOR ................................................................................................................................... 19
OIL COOLER ...................................................................................................................................... 19
SEPARATOR TANK ............................................................................................................................. 19
MANIFOLD ......................................................................................................................................... 20
FOAM UNIT - FOAM PROPORTIONING SYSTEM ....................................................................................... 20

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
FOAM UNIT 3.3, 5.0, 6.5 SYSTEM – REMOTE MOUNTED ........................................................................ 21
FOAM UNIT DIMENSIONS ..................................................................................................................... 22
INSTALLATION AND INITIAL SET-UP ....................................................................................... 24
LIFTING POINTS ................................................................................................................................. 24
STRAP LIFT POINTS ............................................................................................................................ 24
DRIVE LINE ................................................................................................................................. 25
PUMP CLEARANCE ............................................................................................................................. 27
PANEL STRAINER ............................................................................................................................... 28
COMPRESSOR CONNECTIONS ............................................................................................................. 29
COMPRESSOR OIL SERVICE ACCESS ................................................................................................... 30
FLUID DRAIN POINTS .......................................................................................................................... 31
WATER DRAIN – VOLUTE STYLE.......................................................................................................... 32
WATER DRAIN – Q-SERIES ................................................................................................................. 33
SYSTEM OIL FILL ....................................................................................................................... 34
OIL FILLING POINTS ........................................................................................................................... 34
ADDING OIL ....................................................................................................................................... 34
GEARBOX .......................................................................................................................................... 34
GEARBOX OIL FILLING AND CHECKING.................................................................................................................. 34
OIL SEPARATOR TANK........................................................................................................................ 35
SEPARATOR TANK FOR COMPRESSOR OIL ....................................................................................................................... 36
HOT-SHIFT CLUTCH HOUSING ............................................................................................................ 37
CLUTCH FLUID FILLING & CHECKING ..................................................................................................................... 37
SCHEMATICS .............................................................................................................................. 38
PLUMBING CONNECTIONS – DSD ........................................................................................................ 38
PLUMBING CONNECTIONS – Q-SERIES .................................................................................................. 40
SMARTCAFS200 INTERCONNECTION DIAGRAM – DSD ........................................................................ 42
SMARTCAFS200 INTERCONNECTION DIAGRAM – Q-SERIES ................................................................. 43
SMARTCAFS200 INTERCONNECTION DIAGRAM – ALL UNITS ................................................................. 44
FOAM TANK LOW LEVEL SENSOR .......................................................................................... 45
ADDITIONAL INSTALLATION POINTS ...................................................................................... 45
FOAM TANK TO FOAM PUMP ............................................................................................................... 45
VEHICLE DESIGN CONSIDERATIONS ...................................................................................... 46
COMMISSIONING / START-UP PROCEDURE ........................................................................... 47
OPTIONAL TANK SELECTION FOR FOAM UNIT 3.3/5.0/6.5 ...................................................................... 48
OPTIONAL MULTI-DISPLAY SETUP/OPERATION ....................................................................................... 49
(A)SETUP ................................................................................................................................................................... 49
(B)OPERATION ........................................................................................................................................................... 50
GENERAL OPERATION .............................................................................................................. 51
PRESET SCREEN (START SCREEN) ....................................................................................................... 51
(C)PRESET BUTTONS .................................................................................................................................................. 51
(D)WATER FLOW DISPLAY ............................................................................................................................................ 52
(E)HOME BUTTON ....................................................................................................................................................... 52
(F)MENU BUTTON ....................................................................................................................................................... 52
OPERATING SCREEN .......................................................................................................................... 52
(G)WATER FLOW DISPLAY ....................................................................................................................................... 52
(H)FOAM FLOW CAPACITY ............................................................................................................................................ 52
(I)FOAM PERCENTAGE INDICATOR ............................................................................................................................... 53

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
(J)FOAM POWER BUTTON ............................................................................................................................................ 53
(K)FOAM INCREASE AND DECREASE BUTTONS .............................................................................................................. 53
(L)AIR/WATER PRESSURE DUPLEX GAUGE .................................................................................................................... 53
(M)HOME BUTTON ................................................................................................................................................... 53
(N)CURRENT PRESET .................................................................................................................................................. 53
(O)AIR DISPLAY ...................................................................................................................................................... 54
(P)CAFS AIR/WATER FLOW RATIO ............................................................................................................................... 54
(Q)CAFS ARC VALVE POSITION .............................................................................................................................. 54
(R)CAFS POWER BUTTON ........................................................................................................................................... 54
(S)CAFS WET AND DRY BUTTONS .............................................................................................................................. 54
(T)TANK-TO-PUMP VALVE BUTTON ............................................................................................................................... 54
(U)AUTO-FILL MANUAL BUTTON .................................................................................................................................... 55
(V)AUTO-FILL ON/OFF BUTTON .................................................................................................................................. 55
(W)MENU BUTTON ................................................................................................................................................... 55
(X)ADDITIONAL INFORMATION DISPLAY ......................................................................................................................... 55
FOAM/CAFS OPERATION .......................................................................................................... 56
ENGAGE THE PUMP ............................................................................................................................ 56
START FOAM/CAFS OPERATION BY SELECTING A PRESET (OR MANUAL) ................................................. 56
INCREASE ENGINE SPEED FOR DESIRED WATER PRESSURE .................................................................... 57
SELECTING A NEW PRESET ................................................................................................................. 57
MODIFY THE CURRENT OPERATING PARAMETERS .................................................................................. 57
DISENGAGING THE COMPRESSOR CLUTCH ............................................................................................ 58
OVERHEAT SHUT DOWN ..................................................................................................................... 59
FLUSHING ......................................................................................................................................... 59
OPTIONAL WATER AUTO-FILL OPERATION ........................................................................... 60
SYSTEM LAYOUT................................................................................................................................ 60
COMPONENTS ................................................................................................................................... 60
ENABLING AUTO-FILL .......................................................................................................................... 61
START/STOP AUTOMATIC AUTO-FILL .................................................................................................... 61
MANUALLY OPEN THE AUTO-FILL VALVE ................................................................................................ 62
SETTING THE DESIRED TANK LEVEL FOR AUTO-FILL ............................................................................... 62
MENUS ......................................................................................................................................... 63
SYSTEM MENU ................................................................................................................................... 63
SETTING THE SYSTEM TIME ................................................................................................................. 63
USER MENU ....................................................................................................................................... 64
(Y)UP/DOWN ARROW BUTTONS ................................................................................................................................. 64
(Z)“+” AND “-“ BUTTONS ............................................................................................................................................... 65
(AA)EXIT BUTTON ..................................................................................................................................................... 65
(BB)SAVE BUTTON .................................................................................................................................................... 65
OEM MENU ....................................................................................................................................... 65
(CC)UP/DOWN ARROW BUTTONS ............................................................................................................................. 66
(DD)“+” AND “-“ BUTTONS .......................................................................................................................................... 66
(EE)EXIT BUTTON ..................................................................................................................................................... 66
(FF)SAVE BUTTON .................................................................................................................................................... 66
CALIBRATIONS .......................................................................................................................... 67
WATER FLOW CALIBRATION (STANDARD) .............................................................................................. 67
WATER FLOW CALIBRATION (DIRECT) ................................................................................................... 70
FOAM FLOW CALIBRATION ................................................................................................................... 70
CONFIGURATION ....................................................................................................................... 73
PRESET CONFIGURATION (STANDARD) ................................................................................................. 73
PRESET CONFIGURATION (LIVE) ........................................................................................................... 74

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
ON-SCREEN WARNINGS AND INFORMATION ........................................................................ 75
MAINTENANCE MINDER ............................................................................................................ 76
ROUTINE MAINTENANCE .......................................................................................................... 78
AIR COMPRESSOR MOISTURE DRAIN ................................................................................................. 79
OIL AND OIL FILTER ........................................................................................................................... 80
COOLING WATER STRAINER ............................................................................................................... 81
AIR CLEANER ELEMENT ...................................................................................................................... 81
COMPRESSOR BELT MAINTENANCE ...................................................................................... 82
REMOVE BELT GUARD ....................................................................................................................... 82
CHECKING BELT TENSION ................................................................................................................... 83
ADJUSTING BELT TENSION ................................................................................................................. 84
HOT SHIFT CLUTCH MAINTENANCE ........................................................................................ 85
CHANGING CLUTCH OIL ...................................................................................................................... 85
MAINTENANCE SCHEDULE FOR SMARTCAFS....................................................................... 86
MAINTENANCE OPERATIONS PUMP – SMARTCAFS ............................................................. 87
CAFS MIXING MANIFOLD – GREASING BALL VALVE ............................................................................. 87
LUBRICANTS: ................................................................................................................................. 87
VACUUM TEST PUMP MANIFOLD ......................................................................................................... 88
PRESSURE TEST – PERFORMED WITHOUT PUMP RUNNING .................................................................... 88
CAFS - SETTING THE AIR BALANCE CONTROL VALVES ......................................................................... 89
1. SYMPTOMS OF IMPROPER ADJUSTMENT .................................................................................................................. 89
2. FUNCTIONALLY TEST SMART CAFS AIR PRESSURE /WATER PRESSURE & ADJUST MATCH ....................................... 89
CAFS – HOT SHIFT CLUTCH ENGAGEMENT ......................................................................................... 91
1. THE HOT SHIFT CLUTCH IS ENGAGED WHEN THE CAFS SWITCH IS ACTIVATED. ........................................................... 91
3. SETTING THE HOT SHIFT CLUTCH ENGAGEMENT: ...................................................................................................... 91
RECOMMENDED SPARES KIT FOR SERVICE ......................................................................... 92
HALE PUMP ILLUSTRATED PARTS LIST ................................................................................. 92
COMPRESSOR ILLUSTRATED PARTS LIST ............................................................................ 92
FOAM UNIT ILLUSTRATED PARTS LIST .................................................................................. 92
PARTS LIST ................................................................................................................................. 93
MAJOR ASSEMBLIES .......................................................................................................................... 93
SMARTCAFS200 WIRING HARNESS ................................................................................................... 95
THERMAL RELIEF VALVE ..................................................................................................................... 97
PARTS LIST – SUCTION MANIFOLD ....................................................................................................... 98
PARTS LIST – DISCHARGE MANIFOLD ................................................................................................... 99
PARTS LIST – BELT GUARD & CAFS MIXING MANIFOLD ...................................................................... 100
PARTS LIST – OIL FILTER & STRAINER ............................................................................................... 101
PARTS LIST – COMPRESSOR............................................................................................................. 102
PARTS LIST – SEPARATOR, OIL RESERVOIR ....................................................................................... 104
QUICK REFERENCE GUIDE/TROUBLESHOOTING ............................................................... 107
AIR INJECTION/CONTROL ............................................................................................................. 107
COMPRESSOR OPERATION ................................................................................................................ 110
CAFS OPERATION ....................................................................................................................... 114
LIMITED WARRANTY ............................................................................................................... 116

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
INTRODUCTION
This manual contains information relevant to HALE Series Pumps, when partnered with Compressed
Air Foam Systems (CAFS) Foam unit Models 3.3, 5.0 and 6.5 and the UV SmartCAFS control system.
Distinction between the models regarding Installation, Maintenance and Operation is clearly noted with
text and illustrations.
For further information on the Foam unit 3.3, 5.0 and 6.5 Foam Proportioning Systems, MDTII Manual
Dual Tank Selector, Compressor and Intelli-tank Water/foam level display unit, please see the separate
manuals supplied.
ATTENTION
Please read this manual before operating the pump.
CRITICAL: The pump, gearbox, separator tank and compressor assemblies are NOT filled with oil.
These assemblies must be properly filled before operation of the CAFS system is permitted.
Correct lubrication and maintenance is essential if satisfactory performance is to be maintained.
Do not run the pump without water in the pump casing.
WARNING
THIS DSD SMARTCAFS IS AN INCOMPLETE SYSTEM FOR INSTALLATION IN A FIRE FIGHTING
VEHICLE BY TRAINED INSTALLERS & DESIGNERS. THE INSTALLER OF THE SYSTEM IS
RESPONSIBLE FOR PROVIDING SIGNIFICANT ELEMENTS FOR THE SYSTEM TO BE FULLY
FUNCTIONAL AND OPERATIONAL. HALE PRODUCTS, INC. ASSUMES NO LIABILITY FOR
INCORRECTLY INSTALLED APPLICATIONS AND NO WARRANTY WILL BE AVAILABLE FOR
APPLICATIONS FAILING TO MEET THE CRITERIA OUTLINED WITHIN THIS MANUAL.
ENVIRONMENTAL PROTECTION
It is prohibited to pour engine oil and other contaminants onto the ground, down sewers, drains, or into
water courses.
Dispose of lubricants through authorised 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.

Page 8 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
SAFETY - RELEVANT DATA
Thank you for purchasing a HALE Pump.
HALE Pumps are designed to give safe and reliable service. BEFORE use however, it is essential that
the Operating and Installation Instructions are carefully read and understood.
MAINTENANCE
It is the responsibility of the user to ensure that the equipment is maintained in a safe operational
condition. Local legislative conditions may apply.
TRAINING
It is ESSENTIAL that HALE pumps are operated ONLY by TRAINED PERSONNEL. Please contact
HALE PRODUCTS, INC to discuss your training needs.
Follow the operating procedures outlined by the CAFS component suppliers in addition to the
information provided here.
ATTENTION
READ ALL INSTRUCTIONS THOROUGHLY BEFORE BEGINNING ANY INSTALLATION PROCESS.
• A compressed air foam system can be a valuable firefighting tool; however, proper operation
and proper tactical use of this tool needs to be addressed through training and education.
Further education and training on foam and compressed air foam is required for effective and
safe firefighting use of this equipment.
Dry foam is not recommended for structural fire suppression or direct fire attack.
• Make sure proper personal protective equipment is used when operating or servicing the
apparatus.
• Rotating drive line parts can cause injury. Be extremely careful that NO part of your body (head,
feet, arms, legs, finger, hair) is in an area of rotating parts where you could be subject to injury.
• Before attempting to start the CAFS system make sure to close all manual drains and discharge
valves.
• Adding compressed air to the hose line dramatically increases the energy content.
Hose lines charged with compressed air foam have very little weight but contain large amounts
of energy.
• CAFS systems add power to the water stream via compressed air. Proper education, training
and nozzle selection are required for operational effectiveness and safety. Greater nozzle
reaction can be expected from some nozzles.
• Nozzle selection – Hale does not recommend any specific type or brand of nozzle for use with
CAFS systems.
Each fire department must conduct its own evaluation to ensure an appropriate nozzle choice
for the various types of hazards they expect to encounter. Each fire department or the authority
having jurisdiction (AHJ) must develop associated operational procedures and guidelines. Hale
Products, Inc. does not recommend or claim suitability or fitness for any given nozzle brand or
style.

Page 9 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
WARNING
ONCE A NOZZLE HAS BEEN SELECTED IT IS IMPERATIVE TO PROVIDE AMPLE TRAINING IN
THE USE OF THE NOZZLE. OPEN CAFS NOZZLES SLOWLY AND MAKE SURE THE NOZZLE IS
SECURED AGAINST REACTION FORCE.
• Do not remove the cap from the FS series water strainer from the CAFS system while the unit
is running.
• Projectiles can cause injury. DO NOT use a blank hose cap on CAFS discharges. CAFS stores
energy in the form of compressed air in the piping that could turn a blank hose cap into a
projectile when removed.
• DO NOT perform maintenance on the CAFS system while the unit is running. Make sure the
system is shut down and components have cooled before attempting maintenance.
• The operating pressure range of the CAFS system is 75-150 PSI [5.1-10.3 Bar]. DO NOT
EXCEED 150 PSI (10.3 BAR).
CAUTION
THE PROPER OIL LEVEL MUST BE MAINTAINED IN THE AIR COMPRESSOR SYSTEM AT ALL
TIMES. LOW OIL LEVEL OR NO OIL COULD RESULT IN EXCESSIVE COMPRESSOR
TEMPERATURE AND POSSIBLE COMPRESSOR FIRE. OVER FILLING COMPRESSOR SYSTEM
CAN RESULT IN SYSTEM MALFUNCTIONING.
THE FIRE PUMP IS EQUIPPED WITH A MECHANICAL SEAL. DO NOT RUN PUMP DRY FOR
EXTENDED PERIODS OF TIME OR SEAL DAMAGE COULD RESULT.
DO NOT EXCEED 220oF [105oC] DURING COMPRESSOR SYSTEM OPERATION AS INDICATED
BY THE RED INDICATOR LAMP ON THE PANEL.
• DO NOT remove or alter any guard or insulating devices or attempt to operate the system
when these guards are removed. Make sure all access/service panels and covers are
installed, closed and latched tight where applicable.
• DO NOT remove or alter any hydraulic or pneumatic connections, electrical devices, etc. DO
NOT tamper with or disconnect safety features or modify protective guards (such as covers or
doors). DO NOT add or remove structural parts.
NOISE
Operators must wear suitable EAR PROTECTION when the pump is running.
GAUGES
Do not clean the glass surfaces of the gauges with abrasive or solvent cleaners. These will cloud the
glass surface. Use a mild detergent and water.
CLUTCH ENGAGEMENT
Clutch must be engaged between engine idle and engine 900 RPM to ensure clutch longevity.

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
GENERAL DATA
COMPRESSOR
Model Enduro 12
Maximum Operating Speed 6500 rev/min
Nominal speed of operation 5000 rev/min
Nominal power consumption 75HP [56.0kW]
Direction of rotation Counter-clockwise (viewed on pulley)
Volume output 210 SCFM [5946 l/min] @ 125 PSI [8.6 Bar]
Operational pressure range 75-150 PSI [5.1-10.3 Bar]
PUMP
Minimum idle speed 600-700 RPM
COOLING SYSTEM
Type Oil / Water Plate Heat Exchanger
Cooling water flow-rate 13 G/min at 100Psi [50 l/min at 7.0 Bar]
FOAM PROPORTIONING SYSTEM 3.3 - CLASS A AND B FOAM COMPATIBLE
Manufacturer Hale Products Inc.
Model Foam unit 3.3
Type Electronic foam proportioning system
Operating voltage 12 and 24 volt systems available
Fuse rating 12V / 24V 60 / 40 amp
Current draw (Operating) 12V / 24V 30 / 15 amp
Current draw (Max) 12V / 24V 60 / 30 amp
Wire size 12V / 24V Minimum 8.5mm2
Max. Foam Agent Flow rate 3.3 GPM [12.5 LPM]
FOAM PROPORTIONING SYSTEM 5.0 - CLASS A AND B FOAM COMPATIBLE
Model Foam unit 5.0
Max. Foam Agent Flow rate 5.0 GPM [19.0 LPM]
Other data as per Foam unit 3.3
FOAM PROPORTIONING SYSTEM 6.5 - CLASS A AND B FOAM COMPATIBLE
Model Foam unit 6.5 <1>
Max. Foam Agent Flow rate 6.5 GPM [24.6 LPM]
Current draw (Max) 12V / 24V 90 / 45 amp
NOTE <1> THE 12V SYSTEM USES A 24VDC MOTOR AND A 12 VDC TO 24 VDC CONVERTER.
For more information on the SmartFOAM units, refer to SmartFOAM Manual FSG-MNL-00158.
FOAM PROPORTIONING SYSTEM DUAL 6.5 - CLASS A AND B FOAM COMPATIBLE
Model Dual Foam unit 6.5
Max. Foam Agent Flow rate 13.0 GPM [49.2 LPM]
Other data as per Foam unit 6.5

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
LUBRICANTS
COMPRESSOR SYSTEM Recommended: SAE 15W-40 automotive multigrade oil.
Capacity: 8~9 Quarts [7.5~8.5 litres]
PUMP GEARBOX Recommended: SAE EP90, 80W-90 or 75W-140
Synthetic (Must meet service rating API GL-5)
Capacity: 4 quarts [3.8 litres] approximately.
CLUTCH HOUSING Recommended: Dextron III or Mercon ATF.
Capacity: 12 oz. [0.4 litres] approximately.
MAXIMUM INPUT RPM
WARNING
EXCEEDING THESE LIMITS OR FAILURE TO FOLLOW THE RECOMMENDATIONS
OUTLINED ON THIS DRAWING COULD DAMAGE THE PUMP AND RESULT IN
PERSONAL INJURY.
MAXIMUM GEARBOX SHAFT TORQUE (ROAD) = 16,000 LBS-FT [21,693 N-m]
MODEL
MAX GEARBOX
INPUT RPM
MODEL
MAX GEARBOX
INPUT RPM
23L
2630
23X
2580
21L
2920
21X
2810
19L
3220
19X
3060
SEE HALE TORQUE LIMIT CHART F-72 FOR ADDITIONAL DATA.
MAXIMUM ALLOWABLE HYDRODYNAMIC PRESSURE: 400 PSIG
MAXIMUM ALLOWABLE HYDROSTATIC PRESSURE: 600 PSIG

Page 12 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
MODEL IDENTIFICATION SYSTEM
The HALE type pumps are available at the following NFPA ratings:
QMAX150-23LC
PUMP MODEL
PUMP
GEARBOX
ACCESSORY
TERM
RATED CAPACITY (IMPERIAL)
L-GEARBOX
TERM
VARIANT
DSD
TERM
RATING
TERM
RATIO
C
CAFS
QMAX
75
750 GPM
19L
1.86
QMAXXS
100
1000 GPM
21L
2.05
QTWO
125
1250 GPM
23L
2.28
150
1500 GPM
X-GEARBOX
175
1750 GPM
TERM
RATIO
200
2000 GPM
19X
1.96
225
2250 GPM
21X
2.13
250
2500 GPM
23X
2.32
300
3000 GPM
350
3500 GPM
RATED CAPACITY (METRIC)
TERM
RATING
300M
3000 LPM
400M
4000 LPM
500M
5000 LPM
600M
6000 LPM
700M
7000 LPM
800M
8000 LPM
900M
9000 LPM
1000M
10000 LPM
1200M
12000 LPM
1400M
14000 LPM
For example, the QMAX pump specified above has a 1500 GPM rating with a 2.28 rear ratio in the
CAFS configuration. The pump model identification is at the bottom of the gearbox:
Figure 1: Gearbox Identification Placard

Page 13 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
RECOMMENDED FOAM AGENTS
Hale Foam unit Models 3.3, 5.0, 6.5 can be used with the foam concentrates specified on the Hale
Foam Proportioning System Foam Concentrate Compatibility List Hale Bulletin #650, Rev 33, 11-11-
11. Check Hale website for the latest updates.
The foam concentrates in the list have been tested by Hale Products to ensure compatibility with Foam
unit systems. This information is intended to assist the end user (AHJ) in selecting compatible foam
concentrate(s) but is not a determination of firefighting efficiency. Always consult local application and
environmental regulations before selecting the foam concentrate and refer to the Foam unit user
manual for additional information.

Page 14 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
MAJOR COMPONENTS AND CONTROLS
GENERAL ARRANGEMENT
Figure 2: Q-SERIES version shown. Drawing numbers are shown in brackets [FSG-PL-XXXXX].
Master Drain System
(Optional)
In Line Driven Gearbox
w/Integrated Cooler and
Clutch
Compressed Air / Oil
Separator Tank
[FSG-PL-01307]
Compressor Oil Filter
Rotary Twin Screw
Compressor
[FSG-PL-01306]
Tank to Pump
Valve
(Optional)
Plate Style Oil
Cooler
(Heat Exchanger)
Suction Manifold
w/MIV
Suction Manifold
w/MIV & Fill Thief
CAFS Manifold
Discharge Manifold
Anodes
(2) Suction
(2) Discharge

Page 15 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
SMARTCAFS MIXING MANIFOLD
(a) Volute Style Pump
Figure 3: DSD CAFS Mixing Manifold
Air injection
point
Foam Double
Check Valve
Foam injection
Flow sensor
ARC (Air Ratio Control) Valve
Water inlet
Mixing insert
Foam Solution outlet
outlet
Drain
CAFS outlet

Page 16 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
(b) High Pressure
Figure 4: QTWO High Pressure CAFS Discharge
(c) Standard Pressure
Figure 5: Standard Q-Series CAFS Discharge Manifold
Foam injection
Flow sensor
ARC (Air Ratio Control) Valve
Water inlet
CAFS outlet
Foam Solution outlet
outlet
CAFS check valve
(not shown)
Air injection
point
Mixing insert
(not shown)
Water bypass
Foam Check
Valves
Foam injection
Flow sensor
ARC (Air Ratio
Control) Valve
Water inlet
CAFS check valve
(not shown)
Foam
Solution
Discharge
CAFS outlet
Air injection
point
Mixing insert
(not shown)

Page 17 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
FOAM UNIT 3.3, 5.0, 6.5 FOAM PUMP COMPONENT GROUP
NOTE: Hale Foam unit 3.3, 5.0 or 6.5 foam pump is supplied loose for mounting by vehicle builder.
Figure 6: Foam Pump
Figure 7: In-Line Strainer
Figure 8: Water Strainer
Figure 9: ADT Selector
Figure 10: MDT Selector
Figure 11: MST Selector
Figure 12: Bottom Low Level Tank
Sensor
Figure 13: Side Low Level Tank Sensor
Figure 14: Top Low Level Tank Sensor

Page 18 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
CONTROL PANEL - SMARTCAFS
Figure 15: SmartCAFS Testing Panel
COMPONENT PANEL CUT-OUT DIMENSIONS
Figure 16: Installation Cut-out Dimensions
SmartCAFS
Control Display
Master Gauge
(Optional)
Audible
Overspeed Alarm
Master Drain Air
Switch (Optional)

Page 19 of 116
©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
SYSTEM OVERVIEW
The SmartCAFS is a Compressed Air Foam System comprising of two major components (in addition
to the main water pump) – Air compressor system (with separate heat exchanger and oil/water
separator) and Foam unit system (foam proportioning unit).
The Foam unit foam pump and motor assembly is mounted separately from the water pump and is
designed to be remotely mounted according to the Foam unit Installation Manual.
A metered amount of foam concentrate is introduced into the manifold and mixed with water from the
pump discharge manifold to produce a solution. The foam and water solution is then fed to a control
valve (ARC) where wet or dry foam may be selected (air ratio control section of manifold). Compressed
air is then injected and the resulting foam / water / air combination is completely mixed by the X-mixers
inside the discharge manifold creating CAFS discharge flow.
SAFETY INTERLOCKS ARE PROVIDED TO ENSURE THAT:
1. Foam concentrate cannot be introduced unless water is flowing through the unit. Compressed
air cannot be introduced unless foam concentrate is flowing.
2. ‘Slugging’ (unmixed air and water) in the discharge line is prevented. Air cannot be injected in
the absence of foam and water.
3. Air injection when the foam tank is empty is prevented. Foam tank low level switches are
provided and MUST be fitted.
COMPRESSOR
The rotary twin-screw compressor is rated at 210 SCFM [5946 l/min] @ 125 PSI [8.6 Bar] per NFPA
and is driven by a synchronous belt. The compressor is engaged, or disengaged from the pump drive
at idle, via an air-operated, oil lubricated friction plate clutch.
OIL COOLER
Compressor lubricating oil is cooled by water taken from the main pump, via the water supply line;
cooling water being supplied from pump delivery and returned to truck tank. The compressor will reject
up to 43HP [32.0 kW] of heat energy to cooling. The installer must consider this additional thermal load.
When the compressor is turned off, residual system pressure is vented by a blow-down valve. The
system should not store compressed air energy when shut off.
NOTE: The compressor should not be run without cooling water and proper oil level for both the
compressor and separator tank.
SEPARATOR TANK
The separator tank holds the oil required for lubricating the compressor and separates the oil from the
oil/air mix discharged from the compressor. The separator tank also has a minimum pressure valve
that ensures that air pressure is maintained above 43.5PSI [3 bar] to maintain correct lubrication.

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©HALE PRODUCTS, INC. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
MANIFOLD
The manifold incorporates an ARC Valve [air ratio control valve] through which degrees of wet or dry
foam mixture can be selected. Compressed air is then injected and the resulting foam / water / air
combination is thoroughly mixed by the X-mixers during discharge.
For salt water compatible foams or a specific solution’s effectiveness while using salt water, seek advice
from the foam agent manufacturers.
FOAM UNIT - FOAM PROPORTIONING SYSTEM
The Foam unit system consists of three main components:
1) Foam Pump / Motor Assembly.
2) Control Panel (integral with main pump control panel).
3) Flow measurement and injection manifold.
All three elements combine to provide accurate foam proportioning. From the control panel the
operator can initiate the system, adjust the foam ratio, monitor ‘real time’ water flow rate and record
total water and foam concentrate usage.
Foam concentrate is only injected when the foam button has the RED selector around the control
button.
Figure 17: SmartCAFS Foam/CAFS Screen
The Foam unit 3.3, 5.0, 6.5 system for Class A or B foams, will inject foam in the range of 0.1% to
10.0%.
Further information is available in the Foam unit Model 3.3/5.0/6.5 Description, Installation and
Operation manual.