OPERATING AND

OPERA
MAINTENANCE MANU AL
MANUAL

MODEL: MG
SERIAL NO._______________

Failure to follow the operating, lubrication,

and maintenance requirements set forth in
the operating and instruction manual may
result in serious personal injury and/or dam-
age to equipment.

A Hale pump is a quality product; ruggedly designed, accurately ma-

chined, carefully assembled and thoroughly tested. In order to maintain
the high quality of your pump and to keep it in a ready condition, it is im-
portant to follow the instructions on care and operation. Proper use and
good preventive maintenance will lengthen the life of your pump.

ALWAYS INCL
ALW UDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE
INCLUDE

HALE PRODUCTS INC. Fire Suppression Division

A Unit of IDEX Corporation
700 Spring Mill Avenue Conshohocken, PA 19428
610/825-6300 Fax: 610/825-6440
www.haleproducts.com
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TABLE OF CONTENTS
SECTION PAGE
1 INTRODUCTION........................................................................................................ 1-1

A. Description ............................................................................................................. 1-1

B. Principles of Operation ............................................................................................ 1-1
Centrifugal Force .................................................................................................... 1-1
Pump Stages ........................................................................................................... 1-1
Single-Stage Pump ..................................................................................................1-3
Single-Stage Pump Operation................................................................................... 1-3
Two-Stage Pump.....................................................................................................1-3
Two-Stage Pump Operation ..................................................................................... 1-5
Volume (Parallel) Operation .................................................................................... 1-5
Pressure (Series) Operation ...................................................................................... 1-5
Volume Versus Pressure Operation........................................................................... 1-5
Transfer Valve ........................................................................................................ 1-6
Choosing Between Volume and Pressure Operation................................................... 1-6
Transferring Between Volume and Pressure Operation .............................................. 1-6
Cavitation ............................................................................................................... 1-7
C. Parts of Pump..........................................................................................................1-8
Basic Parts of Hale Midship Centrifugal Pump .......................................................... 1-8
Pump Body ........................................................................................................ 1-8
Qmax and Qtwo Pumps ...................................................................................... 1-8
Qpak and Qflo Pumps......................................................................................... 1-9
Impeller ............................................................................................................. 1-9
Clearance Rings ................................................................................................. 1-9
Bearings ........................................................................................................... 1-10
Pump Seals ....................................................................................................... 1-10
Packing............................................................................................................. 1-10
Mechanical Seal................................................................................................ 1-11
Auto Lube ®..................................................................................................... 1-11
D. Pump Drives .......................................................................................................... 1-12
Pump Mounting Options ......................................................................................... 1-12
G-Series Gearbox ................................................................................................... 1-12
Principle of Operation............................................................................................. 1-12
LP and XP Gearbox................................................................................................ 1-12
Shifting.................................................................................................................. 1-12
J Series Gearbox..................................................................................................... 1-14
E. Accessories............................................................................................................ 1-14
Priming Pump ........................................................................................................ 1-14
Priming Valves ...................................................................................................... 1-15
Pressure Control Devices ........................................................................................ 1-15
Relief Valve System............................................................................................... 1-15
Hale Total Pressure Master (TPM) Relief Valve System........................................... 1-17
Cooling Options ..................................................................................................... 1-22
Model K Auxiliary Heat Exchanger/Cooler......................................................... 1-22
Thermal Relief Valve (TRV).............................................................................. 1-23
Valves ................................................................................................................... 1-24
Suction Valves .................................................................................................. 1-24

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TABLE OF CONTENTS (CONTINUED)

SECTION PAGE

1 INTRODUCTION (Continued)

Discharge Valves .............................................................................................. 1-24

Tank Suction Valves.......................................................................................... 1-25
In-line Valves ................................................................................................... 1-25
Drain Valves..................................................................................................... 1-26
Anodes .................................................................................................................. 1-26
Booster Pump ........................................................................................................ 1-27

2 OPERATING PROCEDURES ...................................................................................... 2-1

A. Overview................................................................................................................ 2-1
B. Operating Procedures .............................................................................................. 2-1
Pumping From a Hydrant, General Operation............................................................ 2-1
TPM Operation from a Hydrant................................................................................ 2-2
Pumping From Draft, General Operation................................................................... 2-2
Pumping From the Onboard Water Tank................................................................... 2-4
Pumping In Relay.................................................................................................... 2-5
Tandem Pumping Operation From a Hydrant ............................................................ 2-6
Pump to Road Shift Procedures................................................................................ 2-7
Standard Relief Valve Procedures............................................................................. 2-7
TPM Relief Valve Procedures.................................................................................. 2-7
TPM System with Engine Governor ......................................................................... 2-7
Emergency Pump Shift Procedures........................................................................... 2-8
Post Operation Procedures ....................................................................................... 2-9

3 PREVENTATIVE MAINTENANCE............................................................................. 3-1

A. Overview................................................................................................................ 3-1
B. Procedures.............................................................................................................. 3-1
Post Operation Maintenance..................................................................................... 3-1
Extreme Conditions Maintenance Guidelines ............................................................ 3-1
During Freezing Weather.................................................................................... 3-1
After Pumping from Salt Water, Contaminated Water, or with Foam Solution........ 3-1
Weekly Maintenance ............................................................................................... 3-1
Relief Valve and TPM Test................................................................................. 3-2
Governor Test .................................................................................................... 3-2
Transfer Valve Test............................................................................................ 3-2
Priming System Test........................................................................................... 3-2
Pump Shift Warning Indicator Lights................................................................... 3-2
Valve Lubrication............................................................................................... 3-3
Monthly Maintenance.............................................................................................. 3-3
Suction Check Valve Test................................................................................... 3-3
Lubrication ........................................................................................................ 3-3
Packing Gland Adjustment.................................................................................. 3-3
Drive Line and Flange Bolts................................................................................ 3-4

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TABLE OF CONTENTS (CONTINUED)

SECTION PAGE

3 PREVENTATIVE MAINTENANCE (Continued)

Pump Mounting Bolts......................................................................................... 3-4

Priming System Test (Dry Vacuum Test)............................................................. 3-4
Relief Valve System Check................................................................................. 3-4
Indicator Light Test ............................................................................................ 3-5
Annual Maintenance................................................................................................ 3-5
Performance Testing Overview ................................................................................ 3-5
Performance Testing Equipment and Materials .......................................................... 3-5
Performance Testing.......................................................................................... 3-10
Repacking......................................................................................................... 3-11
Annual MIV and 40BD Relief Valve Test and Adjustment................................... 3-11
Worn Clearance Rings and Impeller Hubs ........................................................... 3-12
Anode Check.................................................................................................... 3-13
TRV Test.......................................................................................................... 3-13

4 TROUBLESHOOTING................................................................................................ 4-1

5 CORRECTIVE MAINTENANCE................................................................................. 5-1

A. Midship Pump......................................................................................................... 5-1

Removal............................................................................................................ 5-1
Installation ......................................................................................................... 5-1
B. Gearbox.................................................................................................................. 5-3
G-Series.................................................................................................................. 5-3
Removal............................................................................................................ 5-3
Installation ......................................................................................................... 5-3
J-Series................................................................................................................... 5-6
Removal............................................................................................................ 5-6
Installation ......................................................................................................... 5-6
C. Packing Replacement .............................................................................................. 5-7
D. Mechanical Seal Replacement.................................................................................. 5-7
Qmax and Qtwo Pump Mechanical Seal................................................................... 5-7
Removal............................................................................................................ 5-7
Installation ......................................................................................................... 5-9
Qflo and Qpak Pump Mechanical Seal and Clearance Rings...................................... 5-10
Removal........................................................................................................... 5-10
Installation ........................................................................................................ 5-12
E. AutoLube® Service (Qmax/Qtwo) .......................................................................... 5-13
F. Impeller Assembly ................................................................................................. 5-15
Impeller and Clearance Rings Removal............................................................... 5-15
Disassembly (Single -Stage Pump) ...................................................................... 5-16
Assembly (Single -Stage Pump) .......................................................................... 5-16
Disassembly (Two-Stage Pump)......................................................................... 5-17
Assembly (Two-Stage Pump) ............................................................................. 5-18
Installation (Impeller and Clearance Rings)......................................................... 5-18
G. Relief Valve System............................................................................................... 5-20

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TABLE OF CONTENTS (CONTINUED)

SECTION PAGE

5 CORRECTIVE MAINTENANCE (Continued)

PM/PMD Control Valve .................................................................................... 5-20

QD Relief Valve................................................................................................ 5-21
QG Relief Valve................................................................................................ 5-23
PG30 Relief Valve ............................................................................................ 5-24
Sensing Valve ................................................................................................... 5-25
H. TRV Service.......................................................................................................... 5-26
I. Anode Replacement................................................................................................ 5-26
J. Qtwo Transfer Valve .............................................................................................. 5-27
K. Qtwo Check Valves (Two-Stage Only) .................................................................... 5-28
L. Tank To Pump Check Valve ................................................................................... 5-29
M. Suction Extension and Suction Tube ........................................................................ 5-29
N. Gearbox Disassembly and Assembly ....................................................................... 5-30
G-Series................................................................................................................. 5-30
Removal and Disassembly ................................................................................. 5-30
Assembly and Installation .................................................................................. 5-33
J-Series.................................................................................................................. 5-35
Removal and Disassembly ................................................................................. 5-35
Assembly and installation .................................................................................. 5-36
O. Primers.................................................................................................................. 5-37
ESP Priming Pump ............................................................................................ 5-37
SPV Priming Valve ........................................................................................... 5-38
PVG Priming Valve........................................................................................... 5-38
P. Accessories............................................................................................................ 5-39
Valves .............................................................................................................. 5-39
40BD Series Valve Maintenance ........................................................................ 5-40
40BD Valve Seat Replacement .......................................................................... 5-41
Valve Stem Seal Replacement............................................................................ 5-42
Drain Valve Repair Procedures .......................................................................... 5-42

6 PARTS LISTS.............................................................................................................. 6-1

GLOSSARY.................................................................................................................G-1

APPENDICES
Data for Practical Use A

Parts and Service Centers B

Warranty C

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1. INTRODUCTION

A. Description
Hale single -stage and two-stage midship pumps are
favorites of firefighters throughout the world.
Covering a range of capacities from 750 Gallons
Per Minute (GPM) (2,838 Liters Per Minute, LPM)
to 2,250 GPM (8,516 LPM), Hale pumps offer the
versatility, dependability, reliability, and ease of
operations necessary for effective fire fighting. Figure 1-1. Centrifugal Force From a Rotating Disk
This section reviews the principles of operation of
Hale’s single -stage and two-stage midship pumps.

B. Principles of Operation The centrifugal pump is preferred by the fire

protection service due to its ability to fully utilize
Centrifugal Force any positive suction inlet pressure, reducing the
amount of work done by the pump. For example, if
the required discharge pressure is 120 PSI (8
A centrifugal pump operates on the principle that
centrifugal force is created by a rapidly spinning BAR), and the inlet pressure is 45 PSI (3 BAR),
disk. Figure 1-1 shows that an amount of water has the pump must only produce the difference in
been placed at the center of a disk. The disk is pressures of 75 PSI (5 BAR). This contributes to
rotated at some speed, and the water is thrown low engine and pump speeds with reduced
from the center toward the outer circumference of maintenance. Decreased maintenance is aided by
the disk. The distance that the water travels from the fact a centrifugal pump has basically only two
moving parts the impeller and the shaft.
the center directly relates to the diameter of the
disk and the speed of rotation. When water is
confined in a closed container (such as the pump Pump Stages
body), its pressure rises to a level that depends on
the speed of rotation. There are three interrelated The number of impellers on a common shaft
factors that regulate the performance of a determines the number of pump stages. The Hale
centrifugal pump: series of single -stage pumps provides the same
normal operating and rating test pressures as the
q SPEED (RPM). If the speed of rotation Hale series of two-stage pumps. The two-stage
increases with flow held constant, the water pump provides an additional level of operating
pressure increases. pressures if required, but adds some operating
complexity.
q PRESSURE. Pressure is usually measured in
Pounds Per Square Inch (PSI) (BAR). If
pressure changes with speed held constant, the
flow (measured in GPM) (LPM) will change
inversely, that is, if pressure increases, flow
decreases.

q FLOW. Flow is usually measured in the

number of gallons of water per minute (GPM)
(LPM) that a pump can deliver when supplied
from draft. If the pressure is held constant, the
flow will increase with an increase in the speed
of rotation.

1-1
 Muscle Pumps

1-2
 Muscle Pumps

Single-Stage Pump pumps utilize an impeller with a single suction

channel where water enters. The impeller develops
There are three series of single -stage pumps. discharge pressure and directs the water to a single
cutwater and then to the discharge valves. The
q Qpak – 500 GPM to 1000 GPM impellers are radially and axially balanced. Radial
(1,892 LPM to 3,785 LPM) hydraulic balance in the Qmax and Qtwo is
q Qflo - 750 GPM to 1,250 GPM maintained by the opposed discharge volute
(2,838 LPM to 4,731 LPM) cutwaters. The cutwaters are wedge shaped and
q Qmax - 1,000 GPM to 2,250 GPM divide the water between the volute and the pump
(3,785 LPM to 8,516 LPM) discharge.
(See figure 1-2)
Two-Stage Pump
Hale single -stage pumps are of a size and design to
attach to the chassis rails of commercial and There is one series of two-stage pump:
custom chassis. The pump is driven from the
truck’s main driveline. Generally, the pump q Qtwo - 1,000 to 2,000 GPM
consists of the following major components: (3,785 LPM to 7,570 LPM)
(See figure 1-4)
q Pump body
q Impeller and Shaft Components Hale two-stage pumps are of a size and desig n to
q Gearbox mount on the chassis rails of commercial and
q Priming System custom chassis. The pump is driven from the
q Pressure Control Device truck’s main driveline. Generally, the pump
q Valves consists of the following major components:

Single-Stage Pump Operation q Pump Body

q Impeller and Shaft Components
Hale single -stage pumps use a single impeller to q Gearbox
develop the required volume and pressure. Figure q Priming System
1-3 shows the flow of water through the Hale q Pressure Control Device
Qmax single -stage pump. Water enters the suction q Transfer Valve System
channels on both sides of the impeller, thereby q Valves
maintaining axial balance. Dual cutwaters on the
Qmax strip water from the rotating impeller and
direct it to the discharge path. The Qflo and Qpak

1-3
 Muscle Pumps

1-4
 Muscle Pumps

Two-Stage Pump Operation (2 BAR Inlet Pressure + 10 BAR Pump Pressure =

12 BAR)
The primary difference between a single -stage and
a two-stage pump is that the former has only one Pressure (Series) Operation
impeller and no transfer valve to switch between
volume and pressure operation. A transfer valve is Pressure operation (figure 1-6), finds the impellers
a two-position valve that permits the impellers in a connected in series. That is, the output of the
two-stage pump to be operated in parallel (volume) impeller supplied from the pump intake is supplied
or series (pressure). Both types of operation are to the input of the next impeller. The pressure at
explained in the following paragraphs. the pump discharge is the sum of the pressure of
the two impellers plus the pressure of the intake.
Volume (Parallel) Operation The amount of water delivered to the discharge is
the same amount that entered the first impeller.
Volume operation (figure 1-5), results in the Using the example above when in series operation,
pressure at the pump intake being added to the the discharge pressure will be 330 PSI, (22 BAR)
pressure developed by both impellers, and the and the discharge volume will be 500 GPM (1,892
amount of water delivered to the discharge being LPM).
the sum of the flows of the two impellers. For
example, if the inlet pressure is 30 PSI (2 BAR) Volume Versus Pressure Operation
and the flow of each impeller is 500 GPM (1,892
LPM) at 150 PSI (10 BAR), the pressure and Selection of volume versus pressure operation is
volume at the discharge is: determined by three factors:

Flow/Impeller x # Impellers q Generally, the pump should be operated so

that the pump gives the desired perform-
1,000 GPM (3,785 LPM) at 180 PSI (12 BAR): ance at the lowest engine speed.
q Transfer to volume (parallel) operation for
500 GPM per Impeller X 2 Impellers = 1,000 higher flows (see figure 1-5).
GPM (1,892 LPM per Impeller X 2 Impellers = q Transfer to pressure (series) operation
3,785 LPM) when higher water pressures are required
30 PSI Inlet Pressure + 150 PSI Pump Pressure = (see figure 1-6).
180 PSI

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 Muscle Pumps

Transfer Valve operations. If your fire department does not have a

policy to follow, here are general guidelines:
A transfer valve, which is controlled from the
apparatus pump control panel, allows the operator 1. Hale pumps are designed to pump up to 200
of a two-stage pump to select volume or pressure PSI (13 BAR) net pressure in volume
operations. This valve is an all-bronze waterway operation at reasonable engine speeds.
device that can transfer between pumping modes
with two and one-half turns of its control hand 2. Generally, volume operation should be used at
wheel. The position of the valve is indicated on the any net pump pressure under 150 PSI (10
apparatus pump control panel via a positive BAR), especially when pumping from a
mechanical indicator. An optional power transfer hydrant.
valve is available.

Choosing Between Volume and Pressure 3. When pumping from draft or a water tank,
Operation pressure operation may be used when the
volume is less that one-half the pump capacity
In deciding which range to pump (pressure or and when the desired pressure is over 150 PSI
volume), choose the one that gives the desired flow (10 BAR).
and pressure at the lowest engine speed. When a
change of range is desired, slow down to idle 4. Be certain to warn everyone involved before
speed, and shift the transfer valve to the desired changing pump range.
range. When shifting the transfer valve from
volume to pressure operation, the pressure will be Transferring Between Volume and Pressure
doubled. You may hear a metallic click or two Operation
clicks, which will be the check valves closing. If
the clicks sound too harshly, you are changing the Transferring between volume and pressure
transfer valve while the pressure is too high. This operation is evidenced by a metallic click, which
happens when the truck engine is running at high results from the check valves closing. If the click is
speed. too loud or, perhaps, somewhat violent, the
pumping pressure is too high for switching. In this
Refer to your fire department policy for when to case, you should ease back on the engine throttle.
use volume operation and when to use pressure

1-6
 Muscle Pumps

Switching between volume and pressure operation the process begins to reverse itself. As the vapor
is generally governed by prevailing fire department reaches the discharge side of the pump, it is
policy. However, here are some general guidelines subjected to a high positive pressure, which
if our fire department does not have an established condenses the vapor back to a liquid. The sudden
policy: change from vapor pockets to a liquid generates a
shock effect which causes a significant noise that is
1. The pump should be operated so that characteristic of cavitation. This shock damages
engine speed is within its best operating the impeller and pump housing. This may happen
range. while pumping from draft or a hydrant. The
problem in either case is the pump running away
2. Transfer to volume (parallel) operation if from the supply and this causes a vacuum to occur.
the pump has to discharge more than 50 Cavitation is often referred to as “the pump
percent of its rated capacity. Be certain to running away from the water supply”. This means
warn everyone involved before switching that the operator is trying to pump more water out
between volume and pressure operation. of the pump than is going into the pump. To
eliminate cavitation, the operator must be aware of
3. Reduce the pump pressure to 50 to 60 PSI the warning signs and correct the situation, or
(3 to 4 BAR) before switching. The engine serious damage to the pump and impeller will
speed should especially be reduced when occur. The most reliable indication that a pump is
switching from volume to pressure approaching cavitation is when an increase in
operation with hand held hoses in use. engine RPM does not cause an increase in the
pump discharge pressure. The operator must not
Cavitation depend entirely on the vacuum gage to indicate
when a pump is nearing cavitation. This is because
Cavitation occurs when a centrifugal pump is the vacuum gage is usually tapped into the intake
attempting to discharge more water than it is chamber several inches away from the leading
receiving. When cavitation occurs, a vacuum is edge of the impeller eye where the greatest amount
created near the eye of the impeller. As the vacuum of vacuum occurs. The most common way to
increases, the boiling point of the water is lowered eliminate cavitation is to decrease the amount of
until it reaches a point near the impeller eye where water being discharged. This is accomplished by
it flashes into vapor and enters the impeller. Once decreasing engine speed or closing discharge
the vapor pockets, or bubbles, enter the impeller, valves. This will allow pressure to increase but
this will result in a reduction of flow.

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 Muscle Pumps

C. Parts of Pump Qmax and Qtwo Pumps

The Qmax and Qtwo pump body is split horizontally

Basic Parts of Hale Midship Centrifugal on a single plane in two sections for easy removal of
Pump the entire impeller assembly, including clearance
rings and bearings. The impeller assembly is
Figure 1-7 shows the basic parts of a Hale midship removed from the bottom of the pump to avoid
centrifugal pump. These parts are briefly described interference with the surrounding piping and pump
in the following text. mounting on the apparatus chassis.

Pump Body Two tank suction valve locations are available to

allow higher flows from the booster tank. Optional
The standard pump body and related parts are built-in check valves are available to prevent tank
constructed from fine grain alloy cast iron, with a over-pressurization.
minimum tensile strength of 30,000 PSI (207
N/mm2). All moving parts subject to water contact. The Qmax and Qtwo pumps have two large suction
The pumps are also available with a bronze body inlets, on the left and right side. Additional front
for use with saltwater or harsh water applications. and rear inlets may be added as requested by the
customer.

BALL BEARINGS PUMP GEAR

REAR BEARING
HOUSING
PUMP BODY GEARBOX

CLEARANCE
RINGS

AUTO
LUBE

OIL SEAL

SLINGER RING

PACKING OR
MECHANICAL SEAL

SLEEVE IMPELLERS
PUMP SHAFT BEARING (2 Stage)

Figure 1-7. Midship Two-Stage Centrifugal Pump

1-8
 Muscle Pumps

Impeller inlets are on opposite sides of the pump to Impeller

balance axial forces; discharges are on opposite
sides to balance radial forces. The impeller provides velocity to the water. This
part is mounted on a shaft that is rotated by the
Qpak and Qflo Pumps drive. Water enters the rotating impeller at the
intake (or eye), and is confined by the shrouds and
The Hale Qpak and Qflo pump body is a single the vanes mounted in the impeller to build
piece. Service of the impeller, clearance rings and pressure. The vanes guide water from the inlet to
mechanical seal is accomplished by removing the the discharge and reduce the turbulence of the
gearbox and rear pump head/bearing housing from spinning water. Vanes curve away from the
the pump. This can be accomplished without direction of rotation so water moves toward the
disturbing discharge or suction piping attached to outer edge. The shrouds form the sides of the
the pump. impeller, and keep the water confined to
centrifugal acceleration.
The Qpak and Qflo pump has two large suction
inlets on the left and right sides. The incoming Figure 1-8 traces a drop of water from the intake of
water is directed to the impeller through the the impeller to the discharge outlet. The impeller is
suction passages. mounted so that the discharging tube is widest at
the pump outlet. The increasing discharge path,
A tank suction valve opening, located on the rear
of the Qpak and Qflo pump allows for high flows known as the volute, collects the water at a
from the booster tank. An optional built-in check constant velocity. A further increase in pressure
valve is available to prevent tank over- and a decrease in velocity take place in the
diffuser.
pressurization.

Hale muscle pumps are “manifolded” type pumps Clearance Rings

meaning the pump volute, suction manifolding, Clearance rings prevent the water that is
and discharge manifolding are cast as one piece.
pressurized and leaving the pump volute from
This one-piece pump design simplifies installation
returning to the intake of the impeller. Centrifugal
of the pump and plumbing of the discharge piping.
pumps have clearance rings at the impeller intake
Discharge valves in the basic pump configuration to prevent leakage. This is accomplished by limiting
can be mounted at either side of the pump body. the radial clearance between the spinning impeller
However, the manifolded pump body provides and the stationary clearance ring. Refer to figure 1-7.
several additional discharge locations (facing front,
back, or up) that can accommodate additional
discharge valves.

CUT WATER DIFFUSER

DISCHARGE
VANES

EYE
INTAKE
Figure 1-8. Impeller Operation

1-9
 Muscle Pumps

A clearance ring usually has a radial clearance of Packing

about 0.0075-inch or a 0.015-inch diameter.
However, the clearance will increase over time as Packing available on Qmax and Qtwo pumps
the pump is operated. Wear is due to foreign forms a nearly watertight seal at the point where
material found in the water. Clearance rings are the shaft passes from the inside to the outside of
designed for replacement as the clearance increases the pump (see figure 1-9). Packing material is
from usage and wear. cooled with pump water. The packing gland should
not be excessively tightened, or the material will
If a pump is operated without water for extended lose its built-in lubrication and dry out, which may
periods or without discharging water, it may result in damage to the pump. The single packing
overheat. This may damage the pump and the drive gland is located on the low-pressure side of the
mechanism. pump. Its split design promotes ease of repacking.
The packing nut is full circle threaded type to exert
Bearings a uniform pressure on packing and to prevent
cocking and uneven packing load. The packing is
Bearings support and align the impeller shaft for easily adjusted with a rod or screwdriver. The
smooth operation (see figure 1-7). packing rings are made of a combination of unique
materials and have sacrificial zinc separators to
Pump Seals protect the pump shaft from galvanic corrosion.
Packing material may also deteriorate if the pump
There are two types of seals available for Hale is kept dry for long periods of time during winter
midship pumps, packing and mechanical. months (for example, to prevent freezing). In this
case, charging the pump with water at least once
weekly will prevent deterioration. See the
Maintenance Instructions in Section 3 for details.

PACKING LANTERN
SPLIT PACKING GLAND
(4) 7/16 SQUARE
PACKING RINGS SLOTTED PACKING NUT
PACKING HOUSING

IMPELLER END
(3) .005 THK FOIL PACKING PUMP SHAFT
SEPARATORS PER JOINT
(TOTAL 12 REQUIRED)
PACKING GLAND LOCK
PACKING COOLING PASSAGE

Figure 1-9. Pump Packing

1-10
 Muscle Pumps

Mechanical Seal Auto Lube ®

The mechanical seal is standard on the Qpak and A miniature centrifugal pump is built into the shaft
Qflo pumps and is available as an option on the of Hale Qmax and Qtwo model pumps (see figure
Qmax and Qtwo pumps. As shown in figure 1-10, 1-11). This miniature pump continuously forces oil
a stationary seal seat is in constant contact with a from the reservoir, through the bearing, and back
rotating carbon face to prevent leakage. The sealing again. A balancing chamber behind the oil reservoir
boot is made of a rubber elastomer that is specifically is connected by a passage to the inlet side of the
designed for high temperature operations. pump. This chamber always keeps the pressure in
the oil reservoir equal to water pressure – whether
you are pumping at high inlet pressure or pulling
vacuum.

The miniature pump adds enough extra pressure to

constantly keep the flowing oil a few PSI higher
than water pressure. Thus, oil pressure inside the
MINIATURE double lip-type seal is always slightly higher than
CENTRIFUGAL water pressure outside. Dirt and water are repelled
PUMP by this higher pressure.

Auto-Lube ® does more than just fight off dirt. It

DOUBLE LIP ensures continuous lubrication, even when you are
OIL SEAL pumping dry. It permits the use of a compact,
double lip-type oil seal, and maintains a constant
film of oil under this seal to prevent shaft wear.
OIL Because it is built into the main pump body, it
RESERVOIR BEARING completely eliminates the need for a second set of
packing, or a second mechanical seal.
BALANCING
CHAMBER

Figure 1-11. AutoLube

1-11
 Muscle Pumps

D. Pump Drives of the gearbox, gear set, and input and shafts
thatare both made of heat-treated nickel steel. This
unit can withstand the full torque of the engine in
Pump Mounting Options road operating conditions up to 16,000 pounds-feet
(21,693 N-m).
There are four common types of centrifugal pump
drives used with fire fighting apparatus:
Principle of Operation
q Operation from the truck chassis drive
shaft (split-shaft gearbox). Midship pumps are so named because of their
location on the fire apparatus. They are nor mally
q Operation from a separate engine. driven through an integral transmission that has a
sliding gear shaft and sliding gear that selectively
q Operation from the front of the truck directs the engine power to the pump or the rear axle.
chassis engine (front engine PTO) Figure 1-13 shows the typical midship pump split-
crankshaft. shaft arrangement on a typical chassis.

q Operation from a PTO from the truck The midship transmission is capable of handling
transmission, a PTO before the engine full engine horsepower, enabling the pump to meet
drive transmission or a PTO from the optimum performance levels as well as all torque
four-wheel drive transfer case. requirements for over the road applications.

G-Series Gearbox LP and XP Gearbox

In addition to the standard Hale gearboxes there is
The most common pump drive is the split-shaft also available a “P” series gearbox. The “P” series
gearbox. gearbox contains a third stage “power take-off”
that permits the mounting of an air compressor or
The Hale G-Series split-shaft gearbox is available
other auxiliary drive component.
as a short (S), long (L), or extra long (X) model.
The model designation S, L, or X, provides for
different distances from the pump centerline/mount Shifting
location to the center of the drive shaft for proper
drive line angles. The location, pump and drive If the gearbox is equipped with a power shift
line angle determine the optimum gearbox length system, an in-cab control valve is provided for
selection. mode selection. This control locks in place for
pump operation. Indicator lights are provided to
Hale offers a variety of pump gear ratios to accom- alert the operator when the gearbox has fully
modate a wide range of apparatus manufacturer shifted from road to pump position. Additionally,
requirements based on engine speed and available provision is provided for manual shift due to
horsepower. The gearbox (figure 1-12) consists failure of the power shift system.

1-12
Muscle Pumps

1-13
 Muscle Pumps

J-Series Gearbox turns toward the discharge, it recedes into the rotor.
As the rotor continues past the discharge, the vane
The Hale J-Series Gearbox, available for the Qpak advances outward from its groove and against the
pump, is a heavy duty gearbox that is driven from body housing. During this cycle, the space between
a transmission-mounted PTO allowing for pump the rotor and housing cases fills with air, and the
and roll applications. This gearbox has a wide vanes, acting as wipers, force air out of the
range of ratios available to allow for use on discharge, creating a vacuum in the main pump
different engine and transmission combinations. allowing atmospheric pressure to push water into
the hose and into the suction side of the main
pump.
E. Accessories
A Hale priming pump has a single control that both
Priming Pump opens the priming valve between the midship
pump and the priming pump and starts the priming
Priming pumps are used to create a vacuum: they motor.
are designed to evacuate air in the suction hose
and the pump. The vacuum created allows
atmospheric pressure to push water from the open
source through the suction hose and into the
pump. Hale centrifugal midship pumps use
Rotary Vane Positive Displacement pumps for
priming. A positive displacement pump moves a
specified amount of air or fluid with each
revolution. As shown in figure 1-14, the priming
pump has a single rotor mounted off-center
(eccentric) to the pump body housing.The vanes
in the rotor slide in groves and are held against
the body housing by centrifugal force. As a vane

1-14
 Muscle Pumps

Priming Valves Relief Valve System

Hale priming valves open when the primer is The Hale Standard Relief Valve System is shown
operated, to allow the primer to evacuate air in the in figure 1-15. The relief valve system consists of a
pump. There are two priming valves available. panel mounted control valve (PM) and an internal
relief valve, either a QG as shown or a QD.
The Hale Semi-Automatic Priming Valve (SPV)
can be mounted directly to the priming connection The relief valve system works as follows: The
on the midship pump, or can be remotely mounted strainer mounted in the pump discharge pressure
using a universal mounting adapter. When the SPV tap provides pressure to the diaphragm in the PM
is installed, a single electric push-button on the Control Valve. The handwheel on the PM control
operator’s panel starts the priming pump motor. either increases or decreases spring tension on the
When the primer motor starts and produces a diaphragm. The seat of the QD or QG relief valve
vacuum, the SPV opens. Releasing the push-button is kept closed by pump discharge pressure.
stops the priming pump and the SPV closes.
As pump pressure increases, more pressure is
The Hale PVG Priming Valve is mounted on the applied to the diaphragm in the PM Control Valve.
operator’s panel. The PVG is a combination valve As the pressure on the diaphragm increases beyond
and switch. When the panel handle on the PVG is the set point, the stem will move off it’s seat,
pulled out the valve opens and the switch energizes allowing pump pressure to push on the piston in
the primer motor. Pushing the handle de-energizes the relief valve. The pressure on the piston will
the motor and closes the valve. cause the relief valve seat to lift allowing excess
discharge pressure to dump back to the pump
Pressure Control Devices suction.

Two basic types of pressure control devices are The amber indicator light on the PM control
used with Hale Midship pumps: illuminates when the relief valve is open.

q Relief valve system (standard).

q Hale Total Pressure Master Relief Valve
System (optional).

1-15
 Muscle Pumps

1-16
 Muscle Pumps

Hale Total Pressure Master (TPM) Relief The system self-restores to the non-relieving
position when excessive pressure is no longer
Valve System
present.
This system, figure 1-16, includes a sensing valve
The TPM relief valve system is a mechanical
connected to the inlet side of the pump that works
system, consisting of an internal relief valve (QG)
in conjunction with a Pressure Master Control on
which bypasses water to the suction side of the
the pump panel to give complete control over the
pump, an external relief (dump) valve (PG30, wit h
entire system. The operating point is set by the sensing valve attached) to discharge water to the
Pressure Master Control. Small changes in pump atmosphere, and a single panel mounted control
pressure are normally handled internally by the
valve (PMD) to provide control of pump pressure,
recirculating relief valve (QG). Large changes on
within NFPA required limits, to the pump operator.
either the inlet or discharge side of the pump are
controlled by dumping excess pressure to the
The PMD control permits the pump operator to
atmosphere from the discharge side of the pump
“set” a desired relief pressure for both internal and
through the PG30 Relief Valve. external relief valves. The panel control has an
easy to read and easy to set adjustment with an
The Hale TPM Relief Valve System is designed to approximate indication of pressure setting.
automatically relieve excess pump pressure when
operating from draft or positive incoming flows.

1-17
 Muscle Pumps

During normal operation, both the QG relief valve The external relief valve (PG30) is mounted on the
and PG30 relief valve are closed (as shown in discharge side of the pump where discharged water
figure 1-17). flowing through the valve provides a self-cleaning
process and virtually eliminates the possibility of
The TPM system functions by monitoring and the valve remaining in an open position due to
controlling pump pressure and relieves excessive contamination.
pressure by first utilizing the internal relief valve
(QG) (returning flow to the pump suction, see The amber light on the PMD control illuminates
figure 1-18). If excessive pressure remains and when the QG relief valve is open. The same light
there is positive pressure on the suction, a flashes when both the QG and PG30 valves are
secondary external relief valve (PG30) responds by open.
discharging excessive pressure to the atmosphere
(shown in figure 1-19). The staging of the internal
and external relief valves to operate in series
ensures maximum protection against over pressure
and eliminates the indiscriminate discharging of
water to the ground.

1-18
Muscle Pumps

1-19
 Muscle Pumps

1-20
Muscle Pumps

1-21
 Muscle Pumps

Cooling Options

Model K Auxiliary Heat Exchanger/Cooler

NFPA 1901 requires a supplementary heat

exchanger cooling system for the pump drive
engine during pumping operations. Hale model
“K” heat exchangers, figure 1-20, meet NFPA
1901 requirements. The units can be used with any
size radiator and use water from the pump to help
maintain the proper temperature of the engine
coolant during pumping. The cast-iron housing and
copper-tubing coil keeps the water and coolant
from contaminating each other. A valve is
normally supplied on the operator’s panel to allow
the operator to control the amount of water
supplied to the model “K” heat exchanger.

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 Muscle Pumps

Thermal Relief Valve (TRV) The TRV-L model includes a chrome panel
placard with warning lamp and lamp test button,
An optional Thermal Relief Valve (TRV), figure 1- and a preassembled wiring harness. The light
21, can be attached to the main pump body. This illuminates whenever the TRV is open and
valve prevents the overheating of the pump under discharging water. An optional buzzer provides
certain operating conditions. The valve monitors audible warning. The buzzer mounts in a 1-1/8
and controls the temperature of the water in the inch opening on pump panel.
pump. When the temperature exceeds 120°F, the
valve automatically opens and discharges a small
amount of water either to the ground or into the
water tank, allowing cooler water to enter the
pump. After the temperature reduces to a safe
level, the valve closes until the temperature is
exceeded again.

INSTALLER SUPPLIED WIRING

POWER CONNECTION FOR AUDIBLE ALARM OPTION ONLY.
THRU 10 AMP 12V FUSE (14 GA. SXL OR GXL SAE J1128)
BODY-INDICATOR LIGHT
BULB LENS

SWITCH-PUSH BUTTON
ALARM-AUDIBLE
NAME PLATE, TEST
SWITCH, AND LIGHT
TO CHASSIS GROUND

WIRING HARNESS

TO CHASSIS GROUND
INSTALLER SUPPLIED WIRE
(14 GA. SXL OR GXL SAE J1128)

PRESSURE SWITCH CONNECTION FOR

RELIEF VALVE
DISCHARGE LINE
ELBOW-1/8 NPT X 1/4 FNPT
REDUCING STREET
FITTING-1/8 NPT X 1/8 FNPT
TRV

Figure 1-21. Thermal Relief Valve (With Light Kit Installed)

1-23
 Muscle Pumps

Valves figure 1-22 for Master Intake Valve. Further

information on the MIV can be found in manual
P/N 029-0020-35-0.
Suction Valves
At least one full flow suction valve with locking
Hale has available valves that mount in the suction handle is normally mounted on the pump. The
of the midship pump. body of each suction valve connects into the pump
suction with a maximum of one long sweep 90°
The Hale Master Intake Valve (MIV) becomes an elbow between the valve and the pump suction.
integral part of the fire pump. When the valve is
ordered as part of a Hale Midship fire pump, the Discharge Valves
pump will pass UL requirements up to 1500 GPM
(5678 LPM) from draft through a single 6 inch Discharge valves regulate the amount of water
NST suction hose with the valve in place. When leaving a pump. Each valve includes a locking device
two valves are mounted to the fire pump the pump that permits operation in any position from fully
can achieve NFPA Performance Point flows of opened to fully closed. The 2-1/2-inch discharge
2000 GPM (7580 LPM) from draft with dual 6 valves are quarter-turn ball-type with a locking
inch NST suction hoses. NFPA Performance Point handle. As the valve handle is moved the ball can
flows of 2250 GPM (8516 LPM) is achieved with rotate from being in-line with the waterway to a
two MIVs and three 6 inch NST suction hoses. The position 90° to the waterway, or any position in
Hale MIV meets NFPA requirements for between, thus reducing or stopping the flow of water.
operations using a large diameter supply hose. See In-line valves are also quarter-turn ball-type valves.

3/4 NPT (FEMALE)

PRIMING CONNECTION
SUCTION EXTENSION
3/4 NPT (FEMALE)
BLEED CONNECTION

MIV VALVE HALE TYPE "115" SERIES

FLANGE WITH 2 1/2
NPT(FEMALE) THREAD FOR
REMOTE MOUNTING

NITRILE RUBBER COATED DISK

DRAIN CONNECTION
PANEL PLACARD
AND INDICATORS

12 VOLT DC MOTOR

SEAL GEAR ACTUATORS

ELECTRICALLY
OPERATED

SUCTION TUBE

MANUAL OVERRIDE
HANDWHEEL
PANEL PLACARD
AND INDICATORS
MANUALLY OPERATED

HANDWHEEL

Figure 1-22. MIV Valve

1-24
 Muscle Pumps

These valves can be used in either suction or q Manual gear operator (see figure 1-24).
discharge lines. q Electric gear operator with optional
manual override (see figure 1-25).
Each discharge valve on a Hale pump may be
equipped with a drain. Opening the drain before
uncoupling the hose relieves the pressure in the
line. Also, water must be drained from the pump
during freezing conditions through the main drain
valve.

Tank Suction Valves

There are two different Hale valves that can be

used as tank suction.

The first valve is the Hale 30BPF, this valve is an

integral flanged valve that mounts to the 8-bolt
flange pattern at the tank suction port of the
midship pump. The valve is a lever operated 3-inch
full flow ball valve and can be connected to the
tank using a 4-inch Victualic™ coupling or 3 inch
NPT pipefitting or a 4 inch hose.

Another option for the tank suction valve, is the

40BDS Model valve. The 40BDS valve is a 4-inch
full flow ball valve that is available lever operated
or can be equipped with an electric motor gear
operator. The nature of the 40BDS permits
mounting to the tank suction opening on the pump
using an 8-bolt 3.5° angled flange or an 8-bolt
straight flange. Tank connection is by use of 4 inch
NPT threaded pipe fittings or 4 inch or 5 inch
Victualic™ clamps.

The 30BPF and 40BDS valves are provided with an

optional check valve flapper to prevent pressurization
of the water tank.

In-line Valves
Hale has several types, sizes, manual, and
electrically operated in-line valves. The BP series-
bronze valves range in size from one inch to three
inch in half-inch increments.

Hale type 40BD 4 inch in-line valves have many

options:

q Inlet and outlet sizes.

q Lever operated for tank and suction line
(see figure 1-23).
q Direct mount (Deck Gun) valve.

1-25
 Muscle Pumps

Anodes
The Hale Anode System helps prevent damage
caused by galvanic corrosion within the pump.
Galvanic action pits the pump and pump shaft
material through the electrolysis of water in the
pump. The popularity of non-corrosive water tanks
and piping has increased the incidences of this type
of corrosion in today’s fire pumps. The Hale
Anode System provides a sacrificial metal, which
helps to diminish or prevent pump and pump shaft
galvanic corrosion. The Hale Anode will fit on any
Hale truck mounted pump, regardless of age or
model. It is designed to be easily installed
requiring just four bolts and a gasket. Total time to
install is just fifteen minutes, yet it will provide
Drain Valves years of protection for your pump. The Anode kit
(figure 1-26) is designed for installation in the
There are two types of drain valves available from standard Hale 115 series flange openings. On
Hale. They are either the sliding plug type (HD, fabricated manifolds and similar applications, the
DV5) or a screw knob style (DV7). installer is to provide 1-1/4 NPT openings and
install anodes directly. It is recommended that one
The sliding plug type valves have a pull handle anode is installed on the suction side and one is
mounted on the operator’s panel. Pulling the installed on the discharge side. Anodes can be
handle out opens the valve allowing the component mounted in any position (horizontal or vertical).
to drain. The Model DV5 has connections for up to
five drain lines. When the DV5 is either open or
closed, the possibility for “cross talk” exists. This HALE 115 SERIES FLANGE GASKET
drain valve cannot be used with either relief valves
or other pilot pressure valves. The screw knob HALE 115 SERIES FLANGE
style drain valve (DV7) has facilities to connect up
to seven individual drain lines. Each connection to
the DV7 is individual and the possibility for “cross
talk” does not exist. The control knob is located on
the operator’s panel. Turning the control knob
counterclockwise will open the drain valve.

ZINC ANODE

PUMP BODY, SUCTION TUBE, ETC.

Figure 1-26.
Hale Anti-Corrosion Anode

1-26
 Muscle Pumps

Booster Pump
Hale booster pumps offer the added dimension of
low volume and high pressure for use with the
midship pumps. The booster is ideal for high
pressure, hose reel operation.

As shown in figure 1-27, the booster pump is

designed for direct mounting at the accessory port
of the Hale "L" series gearbox. The booster pump
is driven by the gearbox intermediate gear to
provide a positive drive. Water is directed to the
booster pump through a pre-piped supply hose.

1-27
 Muscle Pumps

2. OPERATING PROCEDURES 2. Bring the truck to a complete stop before you

attempt to shift from road to pump.
A. Overview 3. Apply the truck parking brake.
This section supplies information and procedures 4. Shift the truck transmission to the NEUTRAL
for the operation of Hale single -stage and two- position.
stage pumps. Included in this section are
procedures for pumping from a hydrant, pumping 5. Move the in-cab pump shift control valve from
from draft, pumping from a booster tank, pumping the ROAD position to the PUMP position. The
in relay, tandem pumping from a hydrant, and shift warning lights should come on in a
post-operation procedures. second or two, indicating a complete shift.

B. Operating Procedures If the truck manufacturer has used another in-

cab valve to achieve pump shift or has an
THE PROCEDURES IN THIS SECTION ARE electric switch, follow the instructions supplied
GENERAL OPERATING PROCEDURES. THEY with that valve.
DO NOT REPLACE THE PROCEDURES AND
POLICIES ESTABLISHED BY YOUR FIRE 6. After pump shift is completed, put the truck
DEPARTMENT, NOR DO THEY REPLACE transmission in the proper pump operating
THE RECOMMENDATIONS AND PROCEDURES range or gear. For most pumpers this will be
PROVIDED BY THE FIRE TRUCK MANUAL. direct drive (1:1) ratio. In addition, the
speedometer should read 5 to 15 MPH after the
Pumping From a Hydrant, General shift has been completed. If the shift does not
seem to be completed, shift truck transmission
Operation
to “N” and repeat the entire procedure. Note
that some vehicles drive the speedometer
1. Position the truck for the best hydrant hookup
and discharge hose layout. from the front wheel of the chassis. In this
case, the speedometer will not read 5 to 15
MPH after shifting to the pump position. See
the chassis manual for details.

REFER TO THE FIRE DEPARTMENT

PROCEDURES ON SETTING WHEEL CHOCKS
AS WELL AS LAY OUT AND CONNECTION
OF SUCTION AND DISCHARGE HOSES. DO NOT LEAVE THE CAB OR ATTEMPT TO
PUMP UNTIL ALL THE GREEN PUMP
ALL VALVES, DRAIN COCKS, AND CAPS LIGHTS IN THE CAB AND PANEL ARE ON.
SHOULD BE CLOSED.
7. Exit the driving compartment only after all the
above steps are completed and you are sure
that the shift completed lights in the cab and
panel are on.
NEVER ATTEMPT TO SHIFT THE PUMP
TRANSMISSION WHILE THE TRUCK
TRANSMISSION IS IN GEAR. ALWAYS
SWITCH THE TRANSMISSION TO “N” AND
VERIFY THE SPEEDOMETER IS “0” BEFORE
MAKING PUMP TRANSMISSION SHIFT. DO NOT OPEN THROTTLE UNLESS ALL
GREEN PUMP INDICATOR LIGHTS ARE ON.

2-1
 Muscle Pumps

8. Verify that the pump panel shift indicator the pump auxiliary cooling system, or slightly
green "OK TO PUMP" light is on. open the tank fill line.

9. Open the hydrant. 17. After completion of pumping procedures,

gradually reduce the pump pressure until the
10. If necessary, open the suction valve. engine is at an idle speed. Use the “Pump to
11. If applicable, set the transfer valve to either Road Shift Procedure” and “Post Operation
volume or pressure, as required. Procedure” provided later in this section.

12. If necessary to eliminate air pockets open

TPM Operation from a Hydrant
valve to let air out or prime the pump: see When operating from a positive inlet pressure,
“Pumping From Draft” for instructions. during some operational conditions, it may be
necessary to adjust the TPM Relief Valve to a
13. Note the intake and discharge pressures then point where water is dumping to the ground. The
open the engine throttle gradually until the internal relief valve will always open first, and if it
master discharge gauge indicates the desired cannot handle the pressure rise, the external relief
pressure. valve will dump water on the ground. When the
internal relief valve opens, the panel light will be
14. Set the automatic relief valve according to your on, and when the external dump valve opens, the
fire department policy. If your fire department pilot light on the panel will flash.
does not have a policy to follow, see the “Relief
Valve or TPM Procedures” later in this section Pumping From Draft, General Operation.
1. Get as close to the water source as possible.
The pump can do better than its rated capacity
with less than a 10-foot vertical lift. As the
DO NOT REDUCE THE PRESSURE ON THE vertical lift increases to above 10 feet, the
INTAKE GAUGE TO ZERO; SERIOUS DAMAGE maximum pump capacity will be reduced.
TO THE WATER MAIN COULD RESULT.

If the master intake gauge shows a vacuum before

the desired discharge pressure or flow is reached,
this is an indication that you are getting all the water REFER TO THE FIRE DEPARTMENT
that the hydrant will supply. To increase the PROCEDURES IN SETTING WHEEL CHOCKS
pressure when this occurs, reduce the pump flow. AS WELL AS LAY OUT AND CONNECTION OF
The master intake gauge reading must be SUCTION AND DISCHARGE HOSES.
maintained at 5 PSI (.5 BAR), minimum.
ALL VALVES, DRAIN COCKS, AND CAPS
As the throttle is opened, the pressure gauge reading SHOULD BE CLOSED.
increases with the engine speed. If the engine speed
increases without an increase in pressure, the pump
may be cavitating. In this case, close the throttle
slowly until the pressure begins to drop, and the
engine returns to an idle. If this does not correct the
problem you are trying to pump more capacity than is NEVER ATTEMPT TO SHIFT THE PUMP
available from the hydrant. TRANSMISSION WHILE THE TRUCK
TRANSMISSION IS IN GEAR. ALWAYS
15. Open the discharge valves. SWITCH THE TRANSMISSION TO “N” AND
VERIFY THE SPEEDOMETER IS “0” BEFORE
16. If the pump overheats and is not equipped with MAKING PUMP TRANSMISSION SHIFT.
the Hale TRV valve, open the valve to access

2-2
 Muscle Pumps

2. Bring the truck to a complete stop before you 9. Activate the priming pump by pulling the
attempt to connect suction hoses or shift from control handle located on the pump panel or
road to pump. depressing the push button.

3. Apply the truck parking brake. The departmental manual for pumping should
specify the correct RPM for priming, but in
4. Shift the truck transmission to the NEUTRAL general, for priming the pump should be
position. operated at idle with an engine speed of about
1,000 to 1,200 RPM.
5. Move the in-cab pump shift control valve from
the ROAD to the PUMP position. The shift 10. Watch the intake and discharge master gauges.
warning light should come on in a second or When the pump is primed, the intake
two, indicating a completed shift. If the truck indication reading falls below zero, and the
manufacturer has used another in-cab valve to discharge pressure starts to increase. You may
achieve pump shift, follow the instructions also hear water discharging on the ground,
supplied with that valve indicating that the pump is primed.

6. After pump shift is complete, put the truck Running the engine at speeds higher than
transmission in the proper pump operating 1,200 RPM during priming is not
range or gear. For most pumpers this will be recommended, because it will not improve
direct drive (1:1) ratio. In addition, the priming operation. Running the pump at higher
speedometer should read 5 to 15 MPH after the RPM will increase wear.
shift has been completed. If the shift does not
seem to be completed, shift truck transmission
to “N” and repeat the entire procedure. Note
that some vehicles drive the speedometer from
the front wheel of the chassis. In this case, the IF THE DISCHARGE GAUGE READING DOES
speedometer will not read 5 to 15 MPH after NOT INCREASE, THE INTAKE GAUGE
shifting to the pump position. See the chassis READING DOES NOT FALL BELOW ZERO, OR
manual for details. THE PRIMING PUMP DOES NOT DISCHARGE
WATER ON THE GROUND IN 30 SECONDS, DO
NOT CONTINUE TO RUN THE PRIMING PUMP.
STOP THE PUMP, AND CHECK FOR AIR
LEAKS OR POSSIBLE PUMP TROUBLE.

DO NOT LEAVE THE CAB OR ATTEMPT TO 11. After priming, select the desired transfer
PUMP UNTIL ALL THE GREEN PUMP valve position (for two-stage pumps).
LIGHTS IN THE CAB AND PANEL ARE ON.
12. Gradually open the discharge valve until
7. Exit the driving compartment only after all the water emerges as a steady stream. Then
the above steps are completed and you are open the other discharge valves to the
sure that the shift completed lights in the desired setting.
cab and panel are on.
13. Open the engine throttle gradually until the
desired pressure or flow is reached.

DO NOT OPEN THROTTLE UNLESS ALL

GREEN PUMP INDICATOR LIGHTS ARE
ON.

8. Verify that the pump shift indicator light is on.

2-3
 Muscle Pumps

17. After completion of pumping procedures,

gradually reduce the engine RPM until it is at
an idle speed. Use the “Pump to Road Shift
DO NOT PUMP ENOUGH WATER TO CAUSE A Procedure” and “Post Operation Procedure”
WHIRLPOOL AT THE STRAINER. THIS provided later in this section.
ALLOWS AIR INTO THE PUMP, RESULTING IN
ROUGH OPERATION AND PULSATION. Pumping From the Onboard Water Tank
REPOSITION THE STRAINER OR REDUCE
FLOW TO CORRECT THE SITUATION. 1. Position the truck for convenient discharge
hose layout, and bring the truck to a complete
As the throttle is opened, the pressure gauge stop.
reading increases with the engine speed. If the
engine speed increases without an increase in
pressure, the pump may be cavitating.

If the pump is cavitating, warn personnel that the

pressure is being dropped. In this case, close the REFER TO THE FIRE DEPARTMENT
throttle slowly until the pressure begins to drop, PROCEDURES ON SETTING WHEEL CHOCKS
and the engine returns to an idle. If this does not AS WELL AS LAY OUT AND CONNECTION OF
correct the problem, here are two possibilities that SUCTION AND DISCHARGE HOSES.
can also lead to this condition:
2. Bring the truck to a complete stop before you
a. Cavitation can occur with large nozzle attempt to shift from road to pump.
tips. Solve this problem by reducing flow.
3. Apply the truck parking brake.
b. Cavitation can also occur when you are
pumping if air enters with the water. Even 4. Shift the truck transmission to the NEUTRAL
though the pump may be primed, air leaks position.
can cause rough operation and an increase
of engine speed without an increase in 5. Move the in-cab pump shift control valve from
pressure or flow. If an air leak is the ROAD position to the PUMP position. The
suspected, discontinue pumping and refer shift warning light should come on in a second
to Section 4 for maintenance. or two, indicating a completed shift. If the
truck manufacturer has used another in-cab
14. If a pump shutdown is desired while pumping valve to achieve pump shift, follow the
from draft, reduce the engine speed to idle, and instructions supplied with that valve.
close the discharge valves. To resume pumping,
open the throttle and discharge valves. If the 6. After pump shift is complete, put the truck
pump overheats from continued churning transmission in the proper pump operating
without water flow, open the discharge valves range or gear. For most pumpers this will be
periodically to release hot water. direct drive (1:1) ratio. In addition, the
speedometer should read 5 to 15 MPH after the
15. Set the automatic relief valve according to shift has been completed. If the shift does not
your fire department policy. If your fire seem to be completed, shift truck transmission
department does not have a policy to follow, to “N” and repeat the entire procedure. Note
see the “TPM or Relief Valve Procedures” that some vehicles drive the speedometer from
later in this section. the front wheel of the chassis. In this case, the
speedometer will not read 5 to 15 MPH after
16. If the pump overheats and is not equipped with shifting to the pump position. See the chassis
the Hale TRV valve, open the valve to access manual for details.
the pump auxiliary cooling system, or slightly
open the tank fill line.

2-4
 Muscle Pumps

12. Open the engine throttle gradually until the

desired pressure or flow is reached. As the
throttle is opened, the discharge pressure gauge
reading increases with the engine speed. If the
DO NOT LEAVE THE CAB OR ATTEMPT TO engine speed increases without an increase in
PUMP UNTIL ALL THE GREEN PUMP
pressure, the pump may be cavitating.
LIGHTS IN THE CAB AND PANEL ARE ON.
If the pump is cavitating, warn personnel that the
7. Exit the driving compartment only after all the pressure is being dropped. In this case, close the
above steps are completed and you are sure throttle slowly until the pressure begins to drop,
that the shift completed warning lights in the and the engine returns to an idle. If this does not
cab and panel are on. correct the problem, reduce flow.

DO NOT OPEN THROTTLE UNLESS ALL DO NOT OPEN THROTTLE UNLESS ALL
GREEN PUMP INDICATOR LIGHTS ARE ON.
GREEN PUMP INDICATOR LIGHTS ARE ON.
8. Verify that the pump panel shift indicator light 13. Gradually open the discharge valves until the
is on. water emerges as a steady stream. Then open
the discharge valves to the desired setting.
9. Open the tank suction valve.
14. Set the automatic relief valve according to
10. For two-stage pumps, select the desired your fire department policy. If your fire
transfer valve position. department does not have a policy to follow,
see the “TPM or Relief Valve Procedures”
11. Check the master discharge gauge to see if later in this section.
priming is necessary. If necessary, start the
priming pump by pulling the control handle 15. If the pump overheats and is not equipped with
located on the pump panel or depressing the the Hale TRV valve, open the valve to access
prime push button or just crack the tank fill the pump auxiliary cooling system, or slightly
valve. open the tank fill line.

16. After completion of pumping procedures,

gradually reduce the engine RPM until it is at
an idle speed. Use the “Pump to Road Shift
IF THE DISCHARGE GAUGE READING DOES Procedure” and “Post Operation Procedure”
NOT INCREASE, THE INTAKE GAUGE provided later in this section.
READING DOES NOT FALL BELOW ZERO, OR
THE PRIMING PUMP DOES NOT DISCHARGE Pumping In Relay
WATER ON THE GROUND IN 30 SECONDS, DO
Relay operations are necessary when the water
NOT CONTINUE TO RUN THE PRIMING PUMP.
source is too far away from the fire to be pumped
STOP THE PUMP, AND CHECK FOR AIR
efficiently by one pumper. Relay pumping is the
LEAKS OR POSSIBLE PUMP TROUBLE.
movement of water through a number of
Watch the intake and discharge pressure gauges. consecutive pumpers, from suction to discharge.
The number of pumpers is determined by how far
When the pump is primed, the compound gauge
the water source is from the fire.
indication falls below zero, and the pressure starts
to increase. You may also hear water splashing on
In some cases, when you are on the receiving end
the ground, indicating that the pump is primed.
of a relay, it may help to set the suction dump or

2-5
 Muscle Pumps

TPM (if available) very low in order to limit the 7. Adjust the discharge pressure or flow at the
incoming pump pressure by dumping water on the fire scene to supply the lines being used.
ground before you have discharge hose lines
connected and are flowing water. Then, as you are 8. Observe the gauges carefully, and adjust the
able to use the ni coming water, the relief valve pressure or flow as needed.
control can be moved up to the desired operating
pressure and set as instructed. This technique will 9. Shutdown starts from the fire ground pump
also help you to purge the air from the incoming and works toward the water source. Gradually
hose and the pump before it can get to a reduce pressure at the fire ground pump until
dangerously high pressure. you can disengage it. Follow this procedure for
every pump in the relay until the pump at the
Use this procedure after the hose is laid, the water source is shut down.
apparatus are in position, and the pumps are
engaged. See the “Pumping from a Hydrant”
procedure for setup and engagement instructions
for apparatus receiving pressurized water.
LOCAL TRAINING PROCEDURES MAY
1. Open two discharge gates on all pumps, except VARY SLIGHTLY FROM ABOVE.
on the pump at the source, to get rid of air
from hose lines and pumps. Tandem Pumping Operation From a
Hydrant
2. On each pump, attach the hose lines to one of
the discharges, and leave the other discharge 1. Using the large intake hose, connect the first
uncapped (only for trucks without a relay pumper to the hydrant steamer. Open the
valve). hydrant until the pump is primed, then partially
close the hydrant.
3. Watch the intake gauge for a high-pressure
reading. If this is reached, open the gate 2. Position the second pumper intake-to-intake
controlling the uncapped discharge to remove with the first pumper.
excess water. 3. Open a discharge to flow water.
4. Supply the pump at the water source with 4. With the hydrant partially closed, adjust the
water; prime if necessary. The discharge throttle on the first pumper until the intake
pressure must not be over 150 PSI (10 BAR) gauge reads about 5 PSI (.5 BAR)
or the maximum pressure rating of the relay
hose to start water moving. Use either the 5. Remove the unused intake cap.
“Pumping From Hydrant” or “Pumping From
Draft” procedures that appear earlier in this 6. Connect the second pumper to the unused
section. steamer intake of the first pumper, using a
large intake hose.
5. When the water reaches the second pump,
close the uncapped discharge gate. Repeat this 7. Open the hydrant completely. Both pumpers
step for all pumps until the water reaches the pump water to the fire, (refer to the procedure
fire ground. on “Pumping From a Hydrant”).

6. Adjust the throttle on the pump at the water

source for the required operating pressure.
Watch the gauges to avoid cavitation. (The
pump operator at the fire scene will advise all LOCAL TRAINING PROCEDURES MAY VARY
other pump operators of the amount of water FROM ABOVE.
needed at the fire ground).

2-6
 Muscle Pumps

Pump To Road Shift Procedures TPM Relief Valve Procedures

1. Verify that the operator’s hand throttle or These procedures cover the Hale TPM Relief
governor control has returned to idle speed. Valve System. Be sure to select the correct
procedure, according to relief valve.
2. Shift the truck transmission into the
NEUTRAL position, and wait four seconds. TPM System (only)
Check to make sure the speedometer reads 0.
1. Set the pressure indicator on the PMD control
3. Moving pump shift control valve lever to the valve to a position slightly above the normal
ROAD position. The in-cab and panel pump operating pressure (even before water starts to
indicator lights should go out when the pump flow).
transmission starts to shift into the ROAD
position. 2. After normal operating pressure has been
achieved (as indicated on the master pressure
gauge and with the pump discharging water),
slowly move the adjusting handwheel
counterclockwise until the relief valve opens,
REFER TO THE FIRE DEPARTMENT the amber pilot light comes on, and the master
PROCEDURES ON REMOVING WHEEL CHOCKS pressure gauge reading drops a couple of PSI
AS WELL AS LAY OUT AND CONNECTION OF (BAR).
SUCTION AND DISCHARGE HOSES.
3. Turn the handwheel slowly clockwise until the
master pressure gauge reading is at the correct
Standard Relief Valve Procedures operating pressure and the pilot light goes out.
The relief valve will operate at the set pressure.
These procedures are for setting the operating
point of the standard relief valve.

1. Increase the engine RPM to reach the desired

pump operating pressure while reading the
discharge pressure gauge. THE INDICATOR ON THE PANEL IS ONLY
A ROUGH INDICATION OF TPM SETTING.
ALWAYS USE THE ABOVE PROCEDURE
2. Turn the hand wheel slowly counterclockwise
until the relief valve opens, the pilot light TO PROPERLY SET THE TPM RELIEF
comes on, and the master pressure gauge drops VALVE SYSTEM.
a couple of PSI (BAR).
TPM System with Engine Governor
3. Turn the hand wheel slowly clockwise until the
master pressure gauge rises to the desired 1. Set the pressure indicator on the PMD control
pressure and pilot light goes out. The relief valve to a position slightly above the normal
valve will now operate at the set pressure. operating pressure (even before water starts to
flow).
4. When the pump is not in operation, turn the
hand wheel clockwise so that the control is set 2. Power on the governor control.
slightly above the normal operating pressure.
When the pump is put into operation again, 3. Set the discharge pressure using the RPM
reset the control valve to the desired operating mode of the pressure governor control.
pressure.
4. Move the TPM handwheel counterclockwise
until the relief valve opens and the amber pilot
light comes on.

2-7
 Muscle Pumps

5. Turn the hand wheel slowly clockwise, until Decreasing Pressure

the amber light just goes out. Then turn the
hand wheel one additional full turn clockwise a. Put the governor control in the RPM
for proper operation. mode, and reduce the speed to the new
pressure.

b. Move the TPM handwheel counterclockwise

until the relief valve opens and the amber
THE TPM PRESSURE CONTROL VALVE pilot light comes on.
MUST BE SET SLIGHTLY HIGHER THAN
THE GOVERNOR CONTROL FOR PROPER c. Turn the handwheel slowly clockwise,
OPERATION. until the amber light just goes out. Then
turn the handwheel one additional full turn
6. Put the governor control in the Pressure clockwise for proper operation.
Governor mode; the system is now set.

7. Use the following procedures to change the set

pressure while running:
THE TPM PRESSURE CONTROL VALVE
Increasing Pressure MUST BE SET SLIGHTLY HIGHER THAN
THE GOVERNOR CONTROL FOR PROPER
a. Set the TPM to a pressure (by the OPERATION.
indicator) slightly higher than the desired
new pressure. d. Put the governor control in the Pressure
Governor mode; the system is now set.
b. Put the governor control in the RPM
mode, and increase the speed to the new Emergency Pump Shift Procedures
pressure.
Before implementing manual override shift
c. Move the TPM handwheel counterclockwise procedures, repeat recommended procedures. If the
until the relief valve opens and the amber shift fails to take place, follow these procedures.
pilot light comes on.
1. Bring the truck to a complete stop.
d. Turn the handwheel slowly clockwise,
until the amber light just goes out. Then 2. Apply the truck parking brake, and chock the
turn the handwheel one additional full turn wheels.
clockwise for proper operation.
3. Shift the truck transmission to the NEUTRAL
position.

4. For Pump or Road position, put the in-cab shift

THE TPM PRESSURE CONTROL VALVE control in the Neutral position. (Neutral
MUST BE SET SLIGHTLY HIGHER THAN position is exactly in the middle of the road
THE GOVERNOR CONTROL FOR PROPER and pump position.
OPERATION.
5. Shut down the engine.
e. Put the governor control in the Pressure
Governor mode; the system is now set.

2-8
 Muscle Pumps

a. Open discharge valves, remove suction

tube caps, and discharge valve caps.

DO NOT ATTEMPT EMERGENCY SHIFT b. Open the pump body drain cocks or Hale
PROCEDURES WHILE THE ENGINE IS multiple drain valve. If a multiple drain
RUNNING. valve is used, all pump drain lines should
be connected to this valve.
6. Employ manual override procedure at the shift
cylinder on the pump gearbox as follows: c. On two-stage pumps, move the transfer
valve back and fourth to both the volume
An eyebolt is provided in the shift shaft to and pressure positions.
accept a drift punch or screwdriver. By
inserting this tool into the hole provided, it will d. If installed, drain the gearbox cooler.
enable you to pull or push the shaft manually.
Pull the shift shaft Out for Pump Position e. After the pump is completely drained,
(after in-cab control valve selection), or push replace all caps and close all valves.
shift shaft for Road Position (after in-cab
control valve sele ction). If the shift stroke 3. Fill out the pump run log, indicating total
cannot be completed manually, turn the pumping time and total out-of-station time.
driveshaft slightly by hand to realign the
internal gears and repeat the manual shift 4. Report all pump, vehicle equipment mal-
effort. functions, and irregularities to the proper
authority.

Post Operation Procedures

1. If you have been pumping seawater, dirty

water, alkaline water, or using an around the
pump proportioner, flush the pump with clean
water.

2. After using the pump, drain the pump as

follows (especially important in freezing
weather):

2-9
 Muscle Pumps

3. PREVENTATIVE Extreme Conditions Maintenance

MAINTENANCE Guidelines

Extreme conditions occur when the pump has been

A. Overview operated during freezing weather and as a result of
pumping from a water source that contains
Hale Midship Pumps require very little care and material that will be harmful to the pump if not
maintenance. However, the little required is purged.
extremely important. Preventive maintenance tasks
require very little time to accomplish and consist During Freezing Weather
mainly of testing for leaks, lubrication, and
cleaning. In freezing weather, drain the pump as follows:
The procedures supplied in this section are for 1. Open all discharge and suction valves, remove
normal use and conditions. Extreme conditions suction tube caps, and discharge valve caps.
may indicate a need for increased maintenance.
The procedures in this section identify some 2. Open pump body drain cocks and/or Hale
extreme conditions and the additional measures multiple drain valve.
needed to ensure lengthened pump life and
continuing dependability. 3. On two-stage pumps, move the transfer valve
back and forth to both the volume and the
The first part of this section includes some extreme pressure positions.
condition maintenance guidelines. Sections with
recommended activities to be accomplished on a 4. After the pump is completely drained, replace
weekly, a monthly, and an annual basis follow this. all caps and close all valves.
A separate maintenance checklist is provided to
record completed maintenance actions. After Pumping from Salt Water, Contaminated
Water, or With Foam Solution
B. Procedures
After drafting from sea water, contaminated, sandy
Post Operation Maintenance or dirty water, flush the pump and suction hoses by
using water from a hydrant or other clean water
1. If necessary, follow the procedures in the source. After pumping foam through the pump,
Extreme Maintenance Conditions paragraph. flush as above until all residues of foam have gone.

2. On two-stage pumps, remove the suction tube Weekly Maintenance

strainers, and reach in to ensure that check
valves are free to swing. Also, verify that no Weekly maintenance consists of testing the relief
foreign matter is caught between the valve and valve system or governor, the transfer valve on
the seat. two-stage pumps, the priming system, and the
pump shift warning indicator lights. If testing
3. Inspect the suction hose rubber washers and criteria is not met, refer to Section 4 for corrective
washers in the suction tube caps. Remove maintenance.
foreign matter from under these washers.
Replace worn, damaged, or dry washers.

4. Verify that all discharge valves, booster line

valves, drain valves, and cocks are closed.

5. Tighten suction caps.

3-1
 Muscle Pumps

Relief Valve and TPM Test d. Verify that the discharge pressure gauge
readings have approximately doubled.
When the relief valve is not in operation, maintain
a setting above the normal operating pressure. 2. For power transfer valves:

1. Set up to pump from the onboard water tank a. With the apparatus engine turned off, use
with the discharge valve back to the water tank either a 3/8-inch socket on the indicator
open less than 1/2 way. See the procedures in hex nut or a rod in the hole in the indicator
Section 2 for assistance. hex nut to manually transfer the valve to
verify that the valve operates freely.
2. Bring the pump pressure up to 150 PSI (10
BAR) per normal operating procedures. b. Set the truck up for pumping per the
procedures in Section 2, with the transfer
3. Turn the control valve handwheel counterclockwise valve in the volume position. Note the
until the relief valve opens and the pilot light is lit. discharge gauge readings.
Master pressure gauge should drop at least 5 to 10
PSI (0.5 to 1 BAR). c. Leave the engine at idle speed, and move
the transfer valve to the pressure position.
4. Turn the control valve handwheel clockwise
then counterclockwise a few times to ensure that d. Verify that the master intake gauge
the handwheel turns freely. Master pressure readings have approximately doubled.
gauge should increase and pilot light should go
out. This action also ensures proper valve Priming System Test
operation.
1. Tighten all pump caps, and close all pump
5. Reset the relief valve to its normal operational valves.
setting.
2. Pull the primer control while you watch for a
Governor Test below-zero reading on the master intake gauge.

If your apparatus is equipped with an electronic 3. Verify that the master intake gauge readings
governor, follow the manufacturer’s instructions hold for approximately 5 minutes after you
for weekly preventive maintenance. release the primer control. A drop of 10 inches
hg in this 5 minute period is anticipated per
Transfer Valve Test (Two Stage Pumps Only) NFPA 1901.

1. For manual transfer valves: Pump Shift Warning Indicator Lights

a. With the apparatus engine turned off, turn
the handwheel between the volume and
pressure positions a few times to verify
that the valve operates freely. BE SURE THAT THE PARKING BRAKE IS SET
AND EVERYONE IS CLEAR OF THE TRUCK
b. Set the truck up for pumping per the BEFORE SHIFTING TO THE PUMP POSITION.
procedure in Section 2, with the transfer THE WHEELS MUST BE BLOCKED TO
valve in the volume position. PREVENT ANY MOVEMENT OF THE TRUCK.

c. Leave the engine at idle speed, and move 1. Follow the operating procedures in Section 2 to
the transfer valve to the pressure position. engage the pump.

3-2
 Muscle Pumps

2. Verify that the warning indicators in the cab and Packing Gland Adjustment
the pump control panel are on.
The packing gland is adjusted for a leakage of
3. Switch to non-pumping operations, and verify about 8 to 10 drops per minute at 150 PSI (10
the warning indicators are off. BAR). This slight leakage will lubricate and cool
the shaft and packing to prevent burning and
Valve Lubrication scoring the shaft. First, check the leakage rate, and
adjust the packing gland only if necessary. If the
1. Spray all moving parts of the suction, discharge, leakage rate cannot be adjusted within satisfactory
hose drain, and multi drain valves with a good limits, replace the packing per the instructions
grade of lithium base grease. under Repacking in this section, page 3-6. Packing
should be replaced every three years. The packing
2. Lubricate all of the valve linkages. gland is adjusted as follows.

Monthly Maintenance 1. Connect the pump to a hydrant or some other

source of water of about 150 pounds of
Monthly maintenance includes the Weekly pressure. If this is not possible, operate the
Maintenance procedures plus lubrication, the packing pump at about 150 pounds from draft or from
gland adjustment, dry vacuum testing, and checking the booster tank discharging through the
the drive line bolts. The Weekly Maintenance booster line, another small nozzle, or
includes testing the relie f valve system or governor, circulating back to the tank. Count the drops
the transfer valve on two-stage pumps, the priming per minute.
system, and pump shift warning indicator lights.
2. Shut down engine to make adjustments.
Suction Check Valve Testing

On two-stage pumps remove the suction tube

strainers, and reach inside the pump to ensure that
the check valves are free to swing. Also, verify that DO NOT RUN ENGINE WHILE MAKING
no foreign matter is caught between the valve and PACKING ADJUSTMENTS.
the seat.
3. Loosen the packing nut lock. The lock is either
Lubrication a spring-loaded pin or a screw and locknut.
The end of the lock fits into a slot in the gland.
1. On handwheel-type valves, including PM, PMD,
and Transfer Valve Controls, if necessary, first 4. To loosen or tighten the packing gland:
remove old grease and paint, use a dry
lubricating spray on gears. a. Insert a screwdriver or rod into one of the
slots. Refer to the Hale Service Chart.
2. Remove the gearbox oil fill plug (refer to the
Hale Service Chart), and check the level of the b. To loosen the nut, turn it in the direction
oil in the gearbox. The level should be up to the of engine rotation.
plug hole. If necessary, add oil, using only a
good grade of SAE EP 90 (oil should meet GL-5 c. To tighten the nut, turn it in the direction
requirements). that is opposite to engine rotation.

3. Lubricate suction threads with a light coat of 5. Repeat step 1 and verify that leakage is correct.
grease. Tighten for less leakage, loosen for more
leakage.

3-3
 Muscle Pumps

Drive Line and Flange Bolts a. Attach the suction hose to the pump.

Check all drive line and flange bolts to ensure: b. Place the suction tube cap on the end of
the hose in place of a strainer.
1. No bolts are missing.
c. Close all valves and drains. Cap all
2. All bolts are tight. suction openings and the outlet of the
suction side relief valve (if so equipped).
3. Bolts used are “Grade 8” strength.
d. Connect a test vacuum gauge or
Pump Mounting Bolts manometer to the intake test gauge
connection on the pump panel.
1. No bolts are missing.
e. Engage the priming pump until the gauge
2. All bolts are tight. indicates at least 22 inches mercury.

Priming System Test (Dry Vacuum Test) f. Watch the gauge. If the vacuum falls more
then 10 inches in 5 minutes, it is a certain
indication of at least one air leak. Vacuum
leaks may often be detected by ear if the
apparatus engine is turned off. Correct
IN THE FOLLOWING PRIMING SYSTEM TEST, leaks immediately to return the pump to a
IF LEAKS CANNOT BE DETECTED BY serviceable condition.
FOLLOWING THE PROCEDURE BELOW, IT IS
ADVISABLE TO TEST THE PUMP Relief Valve System Check
HYDROSTATICALLY. TO DO THIS CONNECT
THE PUMP TO A SOURCE OF WATER, AND 1. Place apparatus out of service in accordance
LOOK FOR LEAKS. with departmental procedures.

1. Close all valves and drains. Cap all suction 2. Test relief valve system in accordance with
openings and the outlet of the suction side relief Weekly Maintenance Check. If the relief valve
valve (if so equipped). is not working, clean the strainers as follows:

2. Connect a test vacuum gauge or manometer to a. Open pump compartment panel and locate
the intake test gauge connection on the pump the relief valve system strainer(s). (On all
panel. relief valve systems the strainer is located
in one of the pump pressure taps. On TPM
3. Engage the priming pump until the gauge an additional strainer is located in one of
indicates 22 inches or more mercury vacuum. the pump vacuum taps).

4. Watch the gauge. If the vacuum falls more then b. Disconnect tubing then remove strainer
10 inches in 5 minutes, it is a certain indication from respective tap.
of at least one air leak. Vacuum leaks may often
be detected by ear if the apparatus engine is c. Clean any debris from strainer and check
turned off. Correct leaks immediately to return strainer for damage.
the pump to a serviceable condition.
d. Using a suitable thread sealant (Loctite
5. Test the suction hose as follows: PST or equal) reinstall strainer.

e. Reconnect tubing.

3-4
 Muscle Pumps

f. Test apparatus and check for leaks around testing criteria refer to the latest version of NFPA
strainer fittings 1911 pamphlet. Pumpers are rated at capacities of
500, 750, 1000, 1250, 1500, 1750, 2000, or 2250
3. Place apparatus back in service. GPM (1892, 2839, 3785, 4731, 5678, 6624, 7570,
or 8516 LPM). See Table 3-1.
Indicator Light Test
Performance Testing Equipment and
1. Operate component with indicator lights and
Materials
observe the respective indicator lights. If the
indicator light fails to light replace the bulb and To accurately test pumper performance, you will
test again. require a pitot gauge, a pump master pressure
gauge, and a master vacuum gauge or manometer.
Annual Maintenance ALL gauges must be carefully tested for accuracy.
Gauge testing is appropriately accomplished with a
Annual maintenance consists of post-operation, dead weight gauge tester, which is usually
weekly, and monthly maintenance. Maintenance available at the local water works.
for extreme conditions may also apply. In addition,
the annual maintenance includes the following Pumpers should be tested from draft at not over a
tasks. 10-foot lift with 20 feet of suction hose. Pumpers
rated at 1500 GPM and over often require two
• Gauge calibration check. separate 20-foot lengths of suction hose and a
• Autolube® assembly oil level check: fill or lower lift height.
replace with SAE EP 90 or 80W90 weight oil.
• Lubricating the power transfer cylinder, power Use smooth bore test nozzles of accurate size with
shift cylinder, and shift control valve with air the pitot gauge. The volume pumped is then
cylinder oil. determined by reference to discharge tables for
• Replacing the pump gearbox oil: use SAE EP smooth nozzles. Refer to Table 3-2 for Nozzle
90 or 80W90 weight oil (GL-5 equivalent). Flow Rates. Preferably, nozzles will be used on a
• Checking individual drain lines from the pump Siamese deluge gun for greatest accuracy. A
to the multi-drain to ensure proper drainage stream straightener, just upstream of the nozzle is
and protection from freezing. advisable.
• Running the yearly pump test to check
performance levels. (See NFPA 1911 pamphlet The amount of discharge hoses required for the
for more details). service tests is dependent on the flow requirements
• Repacking the pump at three-year intervals. and capacity test point. The most common
discharge hose used is 2-1/2 inches in diameter 100
Performance Testing Overview feet long. The number of hoses and length should
be sufficient to reduce nozzle pressure to between
30 and 85 PSIG (2 and 6 BAR). In general refer to
The yearly standard performance test consists of
the hose friction loss chart in Table 3-3 for a
checking the pumper, according to rating, at three
determination as to the friction loss in 100 feet of
capacities and comparing the results to when the
hose. Refer to Table 3-4 for suggested nozzle sizes
pump was new. This provides some measure of
for service testing of common size pumps.
performance deterioration, if any. For performance

3-5
 Muscle Pumps

TABLE 3-1.

PUMP RATING GPM (LPM)

PRESSURE
CAPACITY 500 750 1000 1250 1500 1750 2000 2250
PSI (BAR)
500 750 1000 1250 1500 1750 2000 2250
FULL 150 (10)
(1892) (2839) (3785) (4731) (5678) (6624) (7570 (8516)
500 750 1000 1250 1500 1750 2000 2250
FULL 165 (11)
(1892) (2839) (3785) (4731) (5678) (6624) (7570 (8516)
350 525 700 875 1050 1225 1400 1575
70% 200 (13)
(1325) (1987 (2650) (3312) (3974) (4637) (5299) (5961)
250 375 500 625 750 875 1000 1125
50% 250 (17)
(946) (1419) (1893) (2366) (2839) (3312) (3785) (4258)

TABLE 3-2.

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS ½” 5/8” ¾” 7/8” 1" 1 1/8" 1 ¼” 1 3/8”

30 41 64 92 125 163 206 254 308

35 44 69 99 135 176 222 275 332

40 47 73 106 144 188 238 294 355

45 50 78 112 153 199 252 311 377

50 53 82 118 161 210 266 328 397

55 55 86 124 169 220 279 344 417

60 58 90 130 176 230 291 360 435

62 58 91 132 179 234 296 366 442

64 59 93 134 182 238 301 371 449

66 60 94 136 185 241 305 377 456

68 61 96 138 188 245 310 383 463

70 62 97 140 190 248 315 388 470

72 63 99 142 193 252 319 394 477

74 64 100 144 196 255 323 399 483

76 65 101 146 198 259 328 405 490

3-6
 Muscle Pumps

TABLE 3-2. (Continued)

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS ½” 5/8” ¾” 7/8” 1" 1 1/8" 1 ¼” 1 3/8”

78 66 103 148 201 262 332 410 496

80 66 104 150 203 266 36 415 502

85 68 107 154 210 274 347 428 518

90 70 110 159 216 282 357 440 533

95 72 113 163 222 289 366 452 547

100 74 116 167 228 297 376 464 562

105 76 119 171 233 304 385 476 575

110 78 122 175 239 311 394 487 589

115 80 125 179 244 319 403 498 602

120 81 127 183 249 325 412 509 615

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS 1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3"

30 366 430 498 572 651 824 1017 1464

35 395 464 538 618 703 890 1098 1581

40 423 496 575 660 751 951 1174 1691

45 448 525 610 700 797 1009 1245 1793

50 473 555 643 738 840 1063 1313 1890

55 496 582 675 774 881 1115 1377 1982

60 518 608 705 809 920 1165 1438 2071

62 526 618 716 822 935 1184 1462 2105

64 535 628 728 835 950 1203 1485 2138

66 543 637 739 848 965 1222 1508 2172

68 551 647 750 861 980 1240 1531 2204

70 559 656 761 874 994 1258 1553 2236

3-7
 Muscle Pumps

TABLE 3-2. (Continued)

NOZZLE GPM AT VARIOUS NOZZLE SIZES

PRESS 1 ½” 1 5/8” 1 ¾” 1 7/8” 2” 2 1/4" 2 ½" 3"

72 567 666 772 886 1008 1276 1575 2268

74 575 675 783 898 1022 1293 1597 2299

76 583 684 793 910 1036 1311 1618 2330

78 590 693 803 922 1049 1328 1639 2361

80 598 702 814 934 1063 1345 1660 2391

85 616 723 839 963 1095 1386 1711 2465

90 634 744 863 991 1127 1427 1761 2536

95 651 765 887 1018 1158 1466 1809 2605

100 668 784 910 1044 1188 1504 1856 2673

105 685 804 932 1070 1217 1541 1902 2739

110 701 823 954 1095 1246 1577 1947 2803

115 717 841 976 1120 1274 1613 1991 2867

120 732 859 997 1144 1301 1647 2034 2928

3-8
 Muscle Pumps

TABLE 3-3.

HOSE FRICTION LOSS (PSI PER 100 FEET)

2 1/2" Couplings
1 1/2” Couplings

1 1/2” couplings
1 ¾” Hose with
GPM Flowing

GPM Flowing

GPM Flowing
3" Hose with
2” Hose with

2 1/2” Hose

3 1/2" Hose
1 1/2” Hose
¾” Booster

1” Booster

3" Hose

4" Hose

5" Hose
10 13.5 3.5 95 14 8 500 9.5 3

20 44 6 125 24 13 750 20 11 5

30 99 14 150 35 18 1000 34 20 8

40 176 24 4 175 47 25 6 1250 53 31 13

50 38 7 200 62 32 8 1500 74 45 18

60 54 9 225 10 1750 61 25

70 12 250 13 5 4 2000 32

80 15 275 15

95 22 300 18

125 38 325 22 8

150 54 350 25 8

500 20 17

750 45 38

1000 80 68

NOTE: Add 5 PSI for each story of building and each wye or siamese. Friction Loss
Calculations courtesy of IFSTA.

3-9
 Muscle Pumps

TABLE 3-4.

SUGGESTED NOZZLE SIZE (INCHES)

PUMP RATING FULL CAPACITY 70% CAPACITY 50% CAPACITY
750 1-3/4 1-3/8 1-1/4
1000 2 1-5/8 1-3/8
1250 (2) 1-1/2 or 2-1/4 1-7/8 1-1/2
1500 (2) 1-3/4 or 2-1/4 2 1-3/4
1750 (2) 2 (2) 1-1/2 or 2-1/4 1-7/8
2000 (2) 2 (2) 1-3/4 or 2-1/4 2
2250 (2) 2-1/4 (2) 1-3/4 or 2-1/4 2

The following general guidelines should be used BAR) requires 72-PSI (5 BAR) nozzle pressure on a
when testing the apparatus. one-inch tip. To reduce the pressure from 250 PSI
(17.2 BAR) at the pump to 72 PSI (5 BAR) at the
For 750 GPM (2839 LPM) test, two 2-1/2-inch nozzle would require approximately 1100 feet of 2
lines should be laid from the pumper to the nozzle. 1/2-inch hose. Therefore, it is common practice to
For 1000 GPM (3785 LPM) test, three lines are use 50 to 100 feet of hose and gate the discharge
required, and for the 1250 (4731 LPM) and 1500 valves as required.
GPM (5677 LPM) tests, four or more lines are
required between the pumper and the nozzle. For Performance Testing
1750 (6624 LPM) and 2000 GPM (7570 LPM)
tests four or more hose lines and two nozzles are Note that the NFPA standards require a 10 percent
required. For testing a 2250 GPM (8516 LPM) reserve in pressure at the capacity run when the
pumper up to six hose lines into two separate apparatus is delivered.
nozzles should be used.
1. Check the relief valve according to the Relief
Because deluge guns are not always available, Valve Testing procedure under Weekly
other hose layouts may be used, such as one, 2 1/2- Maintenance.
inch line to a 1-3/8-inch nozzle for 500 GPM
(1892 LPM). Generally, the nozzle used on one, 2 2. Perform steps 1 and 2 of the Post Operation
1/2-inch line should not be larger than 1 1/2 inches Maintenance procedures in this section.
for accuracy in measuring GPM (LPM). Another
alternative when a deluge gun is not available 3. Run the standard pump test in accordance with
consists of a 1 1/4 inch nozzle on one and a 1 1/2 NFPA standards to check pump performance.
inch nozzle on the other to pass 1000 GPM (3785
LPM). The sum of the flow from both nozzles is 4. Run the engine for 20 to 30 min utes to
the GPM (LPM) delivered by the pump. For good stabilize the engine temperature. Then run the
pilot gauge accuracy, the nozzle pressures should pump for 20 minutes at capacity, 10 minutes at
be between 30 and 85 PSIG (2.1 and 5.8 BAR). 70 percent capacity, and 10 minutes at 50
percent capacity.
Because NFPA standards specify both GPM
5. If the apparatus does not reach performance
(LPM) and pressure, it is usually necessary to
levels, refer to the Hale diagnostic/service
restrict the flow somewhat to build up the pump
chart (Section 4).
pressure. In normal pumping, this restriction would
be caused by the friction loss in the lines. 6. Compare the results of this test to those from
However, depending on line loss alone would when the apparatus was delivered. It maybe
require a large amount of hose for some tests. For
that the apparatus did not show the 10
example, testing a 500 GPM (1892 LPM) Class A
percent reserve at delivery. If the apparatus
pumper at 250 GPM (946 LPM) and 250 PSI (17.2

3-10
 Muscle Pumps

performance has dropped appreciably joint one-third ofthe way around from the
compared to its original performance, it firstjoint. Put a foil separator between each
needs to be serviced. (Apparatus test results packing ring. The foil separator must be cut
should be on file with the delivery documents. tofit the shaft. Install the other rings, again
If not, they may be obtained from the staggering the joints.
apparatus manufacturer or from the original
certifying authority). 6. Replace the gland and adjust it according to
the Packing Gland Adjustment procedure in
Repacking this section.

Refer to figure 1-9 for a cross-section showing the 7. Operate the pump normally for about 15
packing arrangement and number of packing rings. minutes at 130 PSI (9 BAR), and check the
The three rings adjacent to the packing gland can packing gland. If necessary, adjust the packing
be replaced without disassembling the pump. The nut again according to the Packing Gland
ring in front of the lantern does not need to be Adjustment procedure in this section.
replaced. Repack the pump as follows.
Annual MIV and 40BD Relief Valve Test and
Adjustment

DO NOT RUN ENGINE WHILE MAKING

PACKING ADJUSTMENT.
NEVER SET RELIEF VALVE ABOVE
1. Loosen the packing nut lock. HOSE MANUFACTURERS RATED
WORKING PRESSURE. ALWAYS USE THE
2. Loosen the packing gland. If necessary, soak LOWEST POSSIBLE RELIEF VALVE
the threads with penetrating oil and work the SETTING TO ENHANCE OPERATOR AND
nut back and fourth to loosen it. Loosen the EQUIPMENT SAFETY.
adjusting gland just enough to remove the split
glands. If the front part of the gland is of the
split type, remove the two halves.

3. Remove the old packing rings with a packing PER NFPA 1962 REQUIREMENTS, LARGE
hook. The hook can be made from a bent piece DIAMETER HOSE MARKED “SUPPLY HOSE”
of stiff wire or small pointed rod. Another type 3-1/2 TO 5 INCHES (89 TO 127 MM)
of packing hook consists of a corkscrew on the DIAMETER SHALL NOT BE USED AT
end of a flexible shaft. Be sure to remove all OPERATING PRESSURES EXCEEDING 185
shreds of old packing, and clean out the PSI (13 BAR).
packing housing as much as possible.

4. Remove all old packing, dirt, and foreign

matter from the bearing housing under the
gland.
PER NFPA 1962 REQUIREMENTS, LARGE
5. Repack using the Hale packing kit DIAMETER HOSE MARKED “SUPPLY HOSE” 6
recommended for your particular pump. For INCHES (152 MM) DIAMETER SHALL NOT BE
most pumps, the packing is 7/16 inch square USED AT OPERATING PRESSURES
cut to the proper length. Wrap one length of EXCEEDING 135 PSI (9 BAR).
packing around the shaft to form a ring, and
push the ring into the packing housing. Install The 40BD MIV relief valve is factory set to open
the second ring the same way, but stagger the at 125 PSI (9 BAR). The relief valve can be
adjusted to open from 75 to 250 PSI (5 to 17

3-11
 Muscle Pumps

BAR). Test and set relief valve as necessary using 8. Lock the pressure setting by turning the
the following procedures and figure 3-1. adjustment locking screw until tight. Lock
screw in place with Loctite #290 or equivalent.
1. Open operator panel and gain access to the
relief valve adjustment cap screw. 9. Turn off water source and relieve pressure
through the air bleeder allowing relief valve to
2. Make sure the valve is closed and install a reset.
pressure test cap on the suction tube or
discharge fitting. 10. Reenergize water source and return the

3. Connect a pressurized water source or hydrostatic pressure to the relief valve set point to verif y
test pump and water supply to the pressure test cap valve-opening point. Repeat adjustment
fitting. procedures as necessary to verify relief valve
operation.
4. Open water supply valve and air bleed valve.
Fill suction tube or discharge connection until 11. Open drain valve and drain water from suction
water flows from air bleed. Close air bleed. tube or discharge connection.

5. Pressurize to desired set pressure in 12. Disconnect water supply and remove test cap
accordance with the above warnings. Observe from suction tube or discharge connection.
whether relief valve opens or remains closed at
the desired pressured. 13. Close operator panel and return apparatus to
normal ready condition.
6. Using a 3/16 inch allen wrench loosen, BUT
DO NOT REMOVE, the set screw that locks Worn Clearance Rings and Impeller Hubs
the pressure adjustment cap screw.
Because clearance ring replacement requires pump
7. Using 7/8 inch open end wrench, turn pressure disassembly, it is advisable to thoroughly check
adjustment cap screw to set relief valve other possible causes (see Table 4-1) of low
pressure (clockwise to increase opening performance before assuming that clearance ring
pressure or counterclockwise to decrease wear is at fault.
opening pressure). Turn cap screw until relief
valve just opens or closes. Clearance (that is, sealing) rings limit the internal
bypass of water from the discharge side of the
Once relief valve opens or closes turn pressure pump back to the suction. The radial clearance
adjustment cap screw 1/4 turn in the clockwise between the impeller hub and the clearance rings is
(increase pressure) direction. only a few thousandths of an inch when new,
effectively preventing a large bypass.

3-12
 Muscle Pumps

In clear water, the clearance rings continue to 1. Close all discharge valves including pump and
effectively seal for hundreds of hours of pumping. engine coolers so there is no flow through the
In dirty or sandy water, the impeller hub and pump.
clearance rings will wear faster than in clear water.
The more the wear, the greater the bypass and the 2. Use care that engine does not overheat, set the
lower pump performance. Also, the greater the pump discharge pressure to one of the
pressure at which each stage is operated, the larger pressures listed.
will be the bypass and the more the performance
will be lowered. Time in Minutes
PRESSURE TRV120 TRV170
When new, the radial clearance between the TRVM120 TRVM170
impeller hubs and the clearance ring is from 0.005 200 PSIG (13.8 Bar) 10 20
to 0.007 inch per side. Any increase will allow 400 PSIG (27.6 Bar) 4 8
more bypass and result in lower performance. But 600 PSIG (41.4 Bar) 2 4
when the pump is adequately powered, it should
not be necessary to replace clearance rings and
3. The thermal relief valve should discharge
impellers until the average radial clearance reaches
water through the 1/8 NPT or metric discharge
0.015 to 0.020 inch or more per side, as measured
line approximately within the time specified.
by a feeler gauge.
4. The table is for midship type pumps. The
Often, replacement of the clearance rings is all that thermal relief valve will open faster on smaller
is necessary. This will largely reduce the bypass pumps, dependent on how close it is to the
and restore the pump to near original performance.
impeller.
A complete restoration requires that oversize
clearance rings be installed and the impeller turned
5. The table is based on 70°F (21°C) water and
or the impeller may also be replaced.
70°F (21°C) air temperature. The thermal
relief valve will open faster in hotter
Anode Check conditions and slower in cooler conditions.
The zinc anodes should be inspected every 12 6. Units equipped with TRV-L kit will flow up to
months. Replace when over 75% of the zinc has
1-2 GPM (3-7 LPM) of water before lamp turns
been consumed (Refer to figure 6-15 for original
on.
dimensions). Performance of the anode life will
vary with water quality and pH. Anodes conform
If unit fails to open in time allotted, remove TRV
to MIL Spec A180001.
in accordance with Procedures in Section 5.
TRV Test Place TRV-120 on work area with inlet facing up.
Pour water of 120°-130°F (66° to 72°C) into opening
The TRV should be tested every 12 months. The
of TRV. Element should open allowing water to flow
following procedure should be used to test the
out, if valve does not open replace valve. For TRV-
TRV. Before testing, make sure a clear view is
available to the TRV discharge. 170, use water at 170o to 180 o (77 o to 82 o C).

Refer to figure 3-2 for a service chart including

recommended service points and intervals.

DO NOT RUN PUMP FOR LONGER THAN IS

SHOWN IN THE TABLE, AS OVERHEATING
COULD OCCUR AND SERIOUS DAMAGE TO
PUMP WILL RESULT.

3-13
 Muscle Pumps

3-14
 Midship Pump Maintenance Check List
Truck Manufacturer ________________________
Pump Model & Serial Number ________________
Year __________ Unit# _____________________

RECOMMENDED WEEKLY PROCEDURES

q Test relief valve system or governor at 150, 200, 250 PSIG.
q Test transfer valve (if applicable).
q Test the priming system (check lubrication level in priming tank were installed).
q Lubricate all valves, discharge, suction, hose, drain, and multi-drain.
q Check pump shift warning indicator lights.

RECOMMENDED
MONTHLY PROCEDURES JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Complete weekly checks

Lubricate threads on PM relief valve panel
control and check light
Lubricate remote valve controls
Check controlled packing leakage and adjust if
necessary (8 to 10 drops per minute)
Perform dry vacuum test*
Check drive flange bolts to ensure tightness
Lubricate suction tube threads
Clean strainer
Inspect gaskets
Check oil level in pump gearbox; add oil if
necessary
If necessary, replace oil with SAE EP 90 oil

*Per NFPA-1911, 22 inches Hg minimum vacuum: loss not to exceed 10 inches Hg vacuum in 5 minutes.

RECOMMENDED ANNUAL PROCEDURES

q Complete all previous checks on all questions.
q Check gauge calibration.
q Check oil level in AutoLube® assembly (SAE-EP 90 or 80W-90); see operation and maintenance manual
for details.
q Lubricate power transfer cylinder, power shift cylinder, and shift control valve with vacuum cylinder oil, if
applicable.
q Change pump gearbox oil and refill (SAE-EP 90 oil or 80W-90).
q Check individual drain lines from pump to multi-drain to ensure proper drainage and protection from
freezing.
q Lubricate transfer valve mechanism on two stage pumps. Dry moly spray is preferred.
q Run yearly standard pump test (per NFPA-1911) to check pump performance levels – chart provided
below.
q Repacking of pump is recommended every two or three years.
NOTE: The above general recommendations are provided for normal use and conditions. Extreme conditions
or variables may indicate a need for increased maintenance. Good preventative maintenance lengthens pump
life and ensures greater dependability. Consult service or diagnostic chart in operator’s manual for detailed
information.
ANNUAL PUMP TEST RESULTS
Capacity @ 150 PSI 70% Capacity @ 200 PSI 50% Capacity @ 250 PSI
Hose Layout
Nozzle Size
Nozzle Pressure
Gallons Per Minute
Pump Pressure Current Engine Speed
Engine Speed from Original Test Documents
Lift and Suction Hose Size and Number
 Muscle Pumps

4. TROUBLESHOOTING
Table 4-1 lists the symptoms of some common problems and possible corrective measures. Before calling Hale
or a Hale authorized parts service center for assistance, eliminate problem causes using Table 4-1. If you
cannot correct a problem, please have the following information ready prior to calling the Hale Customer
Service Technician Department for assistance. Customer Service Number: 610-825-6300.

q Pump Model and Serial Number

q Pump Configuration Information

q Observed Symptoms and Under What Conditions The Symptoms Occur

TABLE 4-1. HALE MIDSHIP PUMP TROUBLE ANALYSIS

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

PUMP WILL NOT Clutch not fully disengaged or Check clutch disengagement. Drive shaft
ENGAGE malfunction in shift linkage must come to a complete stop before
attempting pump shift
Standard transmission
with Manual Pump Shift
Automatic Transmission Automatic transmission not in Repeat recommended shift procedures with
with Manual Pump Shift neutral position transmission in neutral position
Standard Transmission Insufficient air supply in shift Repeat recommended shift procedures.
with Power Shift System system

Check system for loss of air supply.

Clutch not fully engaged or Check clutch disengagement. Drive shaft

malfunction in shift linkage. must come to a complete stop before
attempting pump shift

Turn the engine off and employ shift override

procedures as follows:
1. Hole is provided in shift shaft to
accomplish emergency shifting.
2. Complete shift of control in cab to neutral
and proceed to complete shift of lower
control manually.
Automatic Transmission Repeat recommended shift procedures with
With Power Shift System transmission in neutral position.

Release braking system momentarily. Then

reset and repeat recommended shifting
procedures.

Release braking system momentarily. Then

reset and repeat recommended shifting
procedures.

4-1
 Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

Automatic Transmission Insufficient air in shift system Repeat recommended shift procedures.
With Power Shift System
(continued) Air leaks in shift system Check system for loss of air. Check of leak in
system. Employ manual override procedures
if necessary. See Standard Transmission with
Power Shift System.

Attempt to locate and repair leak(s). Leakage,

if external, may be detected audibly. Leakage
could be internal and not as easily detected.

DO NOT LEAVE THE CAB AFTER PUMP SHIFTING UNLESS THE SHIFT INDICATOR LIGHT
IS ON, OR A SPEEDOMETER READING IS NOTED.

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

PUMP LOSES PRIME Electric Priming System No recommended engine speed is required to
OR IT WILL NOT operate the electric primer, however, 1,000
PRIME engine RPM will maintain truck electrical
system while providing enough speed for
NOTE: Weekly priming initial pumping operation
pump operation is
recommended to provide Defective Priming System Check priming system by performing “Dry
good operation. Vacuum Test” per NFPA standards. If pump
is tight, but primer pulls less than 22 inches of
vacuum, it could indicate excessive wear in
the primer.
Do not attempt lifts exceeding 22 feet except
Suction lifts too high
at low elevation.
Remove obstruction from suction hose
Blocked suction strainer strainer.

Clean and tighten all suction connections.

Suction connections Check suction hose and hose gaskets for
possible defects.

Proper priming procedures should be

Primer not operated long followed. Do not release the primer control
enough. before assuring a complete prime. Open the
discharge valve slowly during completion of
prime to ensure same.
NOTICE: Do not run the primer over 45
seconds. If prime is not achieved in 45
seconds, stop and look for causes (for
example, air leaks or blocked suction).

4-2
 Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

PUMP LOSES PRIME Air Trap in Suction Line Avoid placing any part of the suction hose
OR IT WILL NOT higher than the suction intake. Suction hose
PRIME (CONTINUED) should be laid with continuous decline to
water supply. If trap in hose is unavoidable,
repeated priming may be necessary to
eliminate air pocket in suction hose.

Pump Pressure too low when Prime the pump again and maintain higher
nozzle is opened pump pressure while opening discharge valve
slowly.

Air Leaks Attempt to locate and correct air leaks using

the following procedure.

1. Perform dry vacuum test on pump per

NFPA standards with 22 inches minimum
vacuum required with loss not to exceed
10 inches of vacuum in 5 minutes.
2. If a minimum of 22 inches of vacuum
cannot be achieved, the priming device or
system may be defective, or the leak is
too big for the primer to overcome (such
as an open valve). The loss of vacuum
indicates leakage and could prevent
priming or cause loss of prime.
3. Attempt above dry prime and shut off
engine. Audible detection of a leak is
often possible.
4. Connect the suction hose from the hydrant
or the discharge of another pumper to
pressurize the pump with water, and look
for visible leakage and correct. A pressure
of 100 PSI (6.9 BAR) should be
sufficient. Do not exceed pressure
limitations of pump, pump accessories, or
piping connections.
5. Check pump packing during attempt to
locate leakage. If leakage is in excess of
recommendations, adjust accordingly
following instructions in Section 3.
6. The suction side relief valve can leak. Plug
the valve outlet connection and retest.

4-3
 Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

INSUFFICIENT PUMP Insufficient engine power Engine power check or tune up may be
CAPACITY required for peak engine and pump
performance.

Transfer Valve not in proper TWO STAGE PUMPS ONLY. Place

“Volume” position transfer valve in “Volume” position (parallel)
when pumping more than 1/2 rated capacity.
For pressure above 200 PSI (13.8 BAR),
pump should be placed in “Pressure” (series)
position.

Relief Valve improperly set If relief valve control is set for too low a
pressure, it will allow relief valve to open and
bypass water. Reset Relief Valve control per
the procedures in Section 3. Other bypass
lines (such as foam system or inline valves)
may reduce pump capacity or pressure.

Engine Governor set Engine governor, if set too low a pressure

incorrectly when on automatic, will decelerate engine
speed before desired pressure is achieved.
Reset the governor per manufacturer’s
procedures.

Truck transmission in wrong Recheck the pumping procedure for the

gear or clutch is slipping recommended transmission or gear range; see
Section 3 for assistance.

Use mechanical speed counter on the pump

panel to check speed against possible clutch
or transmission slipping or inaccurate
tachometer. (Check the truck manual for the
proper speed counter ratio).

Air Leaks See air leaks under “PUMP LOSES PRIME

OR WILL NOT PRIME”.
INSUFFICENT Check similar causes for Recheck pumping procedure for
PRESSURE insufficient capacity recommended transmission gear or range. Use
mechanical speed counter on pump panel to
check actual speed against possible clutch or
transmission slippage or inaccurate
tachometer. (Check the truck manual for
proper speed counter ratio).

Transfer Valve not in TWO STAGE PUMPS ONLY. For desired

“Pressure” position pump pressure above 200 PSI (13.8 BAR),
transfer valve should be in “Pressure”
position.

4-4
 Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

LEAK AT PUMP Packing out of adjustment or Adjust the packing per the procedure in
PACKING worn. Section 3 of this manual (8 to 10 drops per
minute leakage at 150 PSI (10 BAR)
preferred).

Replace pump packing per Section 3 of this

manual. Packing replacement is recommended
every 2 or 3 years depending on usage.
REMOTE CONTROL Lack of lubrication Lubricate the remote control linkages and
DIFFICULT TO collar with oil.
OPERATE
ENGINE SPEEDS TOO Truck transmission in wrong Check recommended procedures for correct
HIGH FOR range or gear transmission selection; see Section 3 and
REQUIRED truck manual.
CAPACTICTY OR
PRESSURE Lift too high, suction hose too Higher than normal lift (10 feet) will cause
small higher engine speeds, high vacuum and rough
operation. Use larger suction hose.

Defective suction hose Inner line of suction hose may collapse when
drafting and is usually undetectable. Try a
different suction hose on same pump; test for
comparison against original hose.

Blockage of suction hose entry Clean suction hose strainer of obstruction and
follow recommended practices for laying
suction hose. Keep off the bottom of the water
supply but a least 2 feet below the surface of
the water.

Worn pump impeller(s) and Installation of new parts required.

clearance rings

Impeller blockage Blockage in the impeller can prevent loss of

both capacity and pressure. Back flushing of
pumps from discharge to suction may free
blockage. Removal of one half of the pump
body may be required (this is considered a
major repair).

RELIEF VALVE DOES Incorrect setting of Control Check and repeat proper procedures for
NOT RELIEVE (Pilot) Valve setting relief valve system. (see Section 3)
PRESSURE WHEN
VALVES ARE Relief Valve inoperative Possibly in need of lubrication. Remove relief
CLOSED valve from pump; dismantle; clean and
lubricate. Weekly use of the Relief Valve is
recommended.

4-5
 Muscle Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

RELIEF VALVE DOES Dirt in system causing sticky Relief valve dirty or sticky. Follow
NOT RECOVER AND or slow reaction instructions for disassembling, cleaning, and
RETURN TO lubricating.
ORGINAL PRESSURE
SETTING AFTER Blocked relief valve. Clean the valve with a
OPENING VALVES small wire or straightened paper clip.
RELIEF VALVE Drain hole in housing, piston, Clean the hole with a small wire or
OPENS WHEN or sensing valve blocked straightened paper clip.
CONTROL VALVE IS
LOCKED OUT Dismantle and clean the sensing valve.
UNABLE TO OBTAIN Wrong procedure Check instruction for setting the relief valve
PROPER SETTING and reset.
ON RELIEF VALVE
Blocked strainer Check and clean the strainer in the supply line
from the pump discharge to the control valve.
Check the truck manual for the exact location.
Check and clean tubing lines related to the
relief valve and control valve.

Foreign matter in the Control Remove the control valve and clean.
Valve

Hunting condition Insufficient water supply coming from the

pump to the control valve. Check the strainer
in the Relief Valve system.
Remove the control valve and clean.
WATER IN PUMP Leak coming from above Check all piping connections and tank
GEARBOX pump overflow for possible spillage falling directly
on the pump gearbox.
Follow the procedures in Section 3 of this
manual for adjustment or replacement of
packing. Excess packing leakage permits the
flushing of water over the gearbox casing to
the input shaft area. Induction of this
excessive water may occur through the oil
seal or speedometer connection.
If mechanical seal is installed, there should be
no leaks. Inspect the oil seal and replace if
necessary.
DISCHARGE VALVES Lack of lubrication Recommended weekly lubrication of
DIFFICULT TO discharge and suction valve, use a good grade
OPERATE of petroleum base or silicone grease.
Valve in need of more Add gasket to the valve cover per the truck
clearance manual. Multi-gasket design allows additional
gaskets for more clearance and free operation.
NOTE: Addition of too many gaskets to the
valve will permit leakage.

4-6
 Muscle Pumps

c. Remove valve operators, discharge

5. CORRECTIVE piping suction piping and valves that
MAINTENANCE would interfere with pump removal.

A. Midship Pump d. Disconnect drive shafts, airlines,

electrical wiring and cooling lines as
necessary from the gearbox.
Tools Required
e. Install 1/2-13UNC eyebolts into
q Lifting gear-Lever hoist or chain hoist, and
lifting holes on the pump body (see
short chokers.
figure 5-1). Attach proper lifting gear
q Ball peen hammer
to these eyebolts.
q Center punch
q Allen Wrenches
q Pry bars (2) f. Locate and remove fasteners that hold
q Ratchets and wrenches for disassembly the pump to the apparatus chassis frame.
q Torque wrench, with sockets for cap screws, g. Carefully lift pump and gearbox
capable of 40, 65, and 135 ft-lb (54, 88, and assembly from apparatus. Place the
183 N-m) entire assembly on a work stand of
q Pan (to catch drip oil). suitable capacity.
q Disposable -rags and oil dry.
NOTE: Before beginning removal, you may want
NOTE: Due to the nature of a Hale Midship pump to make a sketch of plumbing and component
most service can be performed without removing configuration to aid in assembly.
the pump assembly from the apparatus.
2. Installation
If a catastrophic failure to the pump (cracked pump
body) requires removal of the entire pump a. Make sure the chassis mounting point
assembly from the apparatus use the following and area around the apparatus is clean
procedure. and free of obstructions.

b. Attach suitable lifting device to the

pump and gearbox assembly.
THE MIDSHIP PUMP AND GEARBOX c. Lift pump and gearbox assembly and
ASSEMBLY WITH ASSOCIATED COMPONENTS guide onto apparatus at proper
WEIGHS 1,500 LBS. (680 KG) TO 2,000 LBS. mounting point.
(909 KG). MAKE SURE PROPER CAPACITY
LIFTING APPARATUS IS PROVIDED TO d. Install and tighten fasteners that secure
REMOVE PUMP AND GEARBOX FROM pump assembly to chassis frame.
APPARATUS.
e. Once pump is secure remove lifting
1. Removal device and eyebolts.

a. Place apparatus out of service in f. Connect all components to gearbox.

accordance with department
procedures. g. Attach valves, suction piping,
discharge piping and valve operators.
b. Remove body panels and framework
to gain access to the pump h. Reinstall apparatus frame work and
compartment and pump. Make sure body panels.
there is sufficient clearance above the
apparatus to lift the pump and gearbox
assembly out of the apparatus.
5-1
 Muscle Pumps

5-2
 Muscle Pumps

i. Test operate apparatus and certify f. After the gearbox is removed,

pump performance as required. carefully inspect bearings and other
parts for excessive wear or damage
j. Return apparatus to service.
Order new components from Hale if
B. Gearbox replacement is required.

2. Installation
G-Series
(Refer to figures 5-2 and 5-3) a. Install a new gasket onto the gearbox
seating surface of the rear bearing
1. Removal housing. Apply a light coat of grease
to the gasket to hold it on place.
a. Place apparatus out of service in ac-
cordance with department procedures. b. Place a new gasket on the seating
surface of the gearbox and gearbox
b. Drain oil, disconnect drive shafts, cover. Check the fit of the gasket and
shift switches, air connection, cooling carefully trim the gasket to match the
lines, and tachometer from gearbox as contour of the gearbox.
necessary. Make sure to mark
connections for reassembly. c. Carefully lift the gearbox into place
around the rear bearing housing.
Insert two or three 7/16-14 x 1-1/4
inch long cap screws through the rear
bearing housing to help hold the
THE GEARBOX WEIGHT IS ABOUT 500 LBS gearbox in place.
(228 KG) BEFORE BEGINNING DISASSEMBLY
PROPERLY SUPPORT GEARBOX WITH d. Position the gearbox cover and insert
LIFTING GEAR TO AID IN LOWERING six 1/2-13 x 1-1/2 inch long cap
GEARBOX AND TO PREVENT PERSONNEL screws. Tighten cap screws hand
INJURY. tight.

c. Remove six 1/2-13 x 1-1/2 inch long e. Insert the remainder of the 7/16-14 x
cap screws on the cover of the 1-1/4 inch long cap screws through
gearbox, remove the spacer plate if the rear bearing housing and gasket
installed. into the gearbox and cover. Tighten
the 7/16-14 x 1-1/4 inch long cap
NOTE: The number of cap screws that hold the screws. Torque the 7/16-14 x 1-1/4
rear bearing housing to the gearbox depends on the inch long cap screws to 40 ft-lb (54
model gearbox. The short gearbox uses seven cap N-m). Tighten the 1/2-13 x 1-1/2 inch
screws and the long gearbox uses eight cap screws. long cap screws to 65 ft-lb (88 N-m).

d. Remove 7/16-14 x 1-1/4 inch long cap f. Connect drive shafts, cooling lines, air
screws that hold the rear bearing hoses, and electrical connections to
housing to the gearbox. Remove the gearbox.
gearbox cover.
g. Fill gearbox with oil.
e. Carefully lower the gearbox from the
apparatus. Place a temporary cover h. Test operate apparatus observing
over the gearbox to prevent dirt and packing or mechanical seal, oil seal,
debris from entering the gearbox. and gaskets for leaks.
Move gearbox to suitable work area.
5-3
 Muscle Pumps

5-4
Muscle Pumps

5-5
 Muscle Pumps

J-Series Gearbox 2. Installation

(Refer to figure 6-6)
a. Make sure the dowel pins are properly
1. Removal seated and install new ones if
necessary.
a. Place apparatus out of service in
accordance with department b. Install new gaskets onto the seating
procedures. surface of the lower gearbox housing.
Apply a light coat of grease to the
b. Drain oil, disconnect drive shaft. gasket to hold it in place.
Make sure to mark connections for
reassembly. c. Install the spacer, if required, and
install a new gasket on the seating
surface of the spacer.

d. Carefully lift the gearbox into place

aligning the dowel pins with the holes
THE J-SERIES GEARBOX WEIGHS 350 LBS in the upper gearbox housing.
(159 KG). BEFORE BEGINNING DISASSEMBLY,
PROPERLY SUPPORT GEARBOX WITH LIFTING e. Insert the eight 1/2-13 cap screws.
GEAR TO AID IN LOWERING GEARBOX AND TO Tighten cap screws to 65 ft-lb (88 N-
PREVENT PERSONNEL INJURY. m).

c. Note the locations and remove eight f. Connect drive shaft to gearbox.
1/2-13 cap screws which hold the
upper housing and lower housing g. Fill gearbox to proper level with oil.
together.
h. Test operate apparatus observing
d. Carefully lower the lower gearbox mechanical seal, oil seal, and gaskets
housing from the apparatus making for leaks.
sure the spacer (if installed) does not
get damaged. Place a temporary
cover over the gearbox to prevent dirt
and debris from entering the gearbox.
Move gearbox to suitable work area.

e. After the gearbox is removed,

carefully inspect dowel pins, bearings
and other parts for visible signs of
excessive wear or damage. Order
new components from Hale if
replacement is required.

5-6
 Muscle Pumps

C. Packing Replacement separators between each packing ring. The

foil separators must be cut to fit the shaft.
When the packing adjustment has been taken up, a Install the other rings, again stagge ring the
single ring of packing can be added. However, it is joints.
usually more satisfactory to repack the pump.
Refer to figures 1-9 and 5-3 for a cross-section 6. Replace the gland and adjust it according
showing the packing arrangement and number of to the Packing Gland Adjustment
packing rings. The three rings adjacent to the procedure in this section.
packing gland can be replaced without
disassembling the pump. The ring in front of the 7. Operate the pump normally for about 15
lantern does not need to be replaced. Repack the minutes, and check the packing gland. If
pump as follows. necessary, adjust the packing nut
according to the Packing Gland
Adjustment procedure in Section 3.

D. Mechanical Seal Replacement

DO NOT RUN ENGINE WHILE MAKING
PACKING ADJUSTMENT NOTE: Before starting disassembly matchmark
with a center punch the rear bearing housing,
1. Loosen the packing nut lock. mechanical seal housing, and pump body for
proper alignment during reassembly.
2. Loosen the packing nut. If necessary, soak
the threads with penetrating oil and work Qmax and Qtwo Pump Mechanical Seal
the nut back and fourth to loosen it.
Loosen the adjusting nut just enough to 1. Removal (Refer to figure 5-4)
remove the split glands. If the front part of
the gland is of the split type, remove the a. Remove gearbox in accordance with
two halves. paragraph B.1, this section.

3. Remove the old packing rings with a b. Remove the 5/8-11 x 1-1/4 inch long
packing hook or blow the packing out. The cap screw and bearing retainer washer
hook can be made from a bent piece of stiff from the end of the impeller shaft.
wire or small pointed rod. Another type of
packing hook consists of a corkscrew on the c. Remove twelve 1/2-13 x 1-3/4 inch
end of a flexible shaft. Be sure to remove all long cap screws that hold the rear
shreds of old packing, and clean out the bearing housing to the pump body.
packing housing as much as possible.
d. Install two 1/2-13 x 2-1/2 inch long
4. Remove all old packing, dirt, and foreign cap screws into the 1/2-13UNC
matter from the bearing housing under the threaded holes on the rear bearing
packing gland. housing to use as jacking screws.
Install a 1/2-13 x 2-1/2 inch long cap
5. Repack using the Hale packing kit screw into one of the holes on the rear
recommended for your particular pump. bearing housing into the pump body
For most pumps, the packing is 7/16-inch to keep the mechanical seal housing
square cut to the proper length. Wrap one from rotating while removing rear
length of packing around the shaft to form bearing housing.
a ring, and push the ring into the packing
housing. Install the second ring the same NOTE: It may be necessary to use prybars to
way, but stagger the joint one-third of the loosen the back bearing and gear before attempting
way around from the first joint. Put foil to remove the rear bearing housing.

5-7
 Muscle Pumps

e. Slowly and evenly turn the jacking i. Using a center punch, matchmark the
screws clockwise to move the rear mechanical seal cover and mechanical
bearing housing away from the pump seal housing. Remove four 7/16-14 x
body. 1-1/4 inch long cap screws that secure
the mechanical seal cover to the
f. As the rear bearing housing moves mechanical seal housing.
back remove the gear and gear key
from the impeller shaft and bearing j. If necessary, use pry bars in the slots
housing as they clear the shaft. Do not provided to loosen the mechanical
allow the weight of the rear bearing seal cover from the mechanical seal
housing to rest on the oil seal. housing. Remove the mechanical seal
cover from the impeller shaft.
g. After the gear and key are removed,
carefully remove the rear bearing k. Remove the old mechanical seal from
housing from the impeller shaft being the mechanical seal housing and
careful not to damage the oil seal. impeller shaft. Two small hooks will
aid in removal of these components.
h. Remove the slinger from the impeller
shaft. l. After all components are removed,
carefully inspect bearings and other
parts for excessive wear or damage.
Order new components from Hale if
replacement is required.

5-8
 Muscle Pumps

1. Installation

INSTALLATION NOTES:
q Apply a light coat of grease to the gaskets DO NOT TOUCH THE SEALING SURFACE OF
to hold them in place during assembly. Use THE CARBON SEAL RING OR THE METAL
only lithium based grease with 1 to % SEAT WHILE HANDLING OR INSTALLING
molybdenum disulfide. Some examples of THE MECHANICAL SEAL.
correct greases are: Dow Corning BR2-
PLUS, Lubriplate-Fiske #3000, Shell IMPORTANT: Always replace the entire
Super Duty Grease, Imperial #777, Mobil - mechanical seal with a complete new Hale
Mobil Grease Special and Sun Oil - mechanical seal assembly.
Sunoco MOLY #2EP.
q Apply a light coat of grease to the seal b. Lubricate the inside of the mechanical
rings before assembly. seal bellows and impeller shaft using
q When installing the cap screws make sure Ethylene-Glycol (anti-freeze) or
they are locked in place using a suitable soapy water solution.
thread locking compound such as Loctite
#242 or equal. c. Slide new mechanic al seal bellows
q If cap screws require replacement they end over the impeller shaft making
shall be replaced with grade 5, zinc plated sure the spring is oriented towards the
steel, nylon locking type. impeller. Using a soft pusher tube (2
q Oil and grease will damage the Ethylene- inch PVC pipe) and keeping fingers
Propylene (EPT) bellows on the away from carbon seal ring, carefully
mechanical seal. Use only Ethylene-Glycol push the mechanical seal assembly
(anti-freeze) or soapy water to lubricate into the mechanical seal housing. If
the impeller shaft and bellows during binding occurs apply more lubricant
assembly. to the impeller shaft and bellows.
q Do not touch the sealing face of the carbon
seal ring or seat while handling or d. Being careful not to touch the face of
installing the mechanical seal. the seat, install the cup and seat into
the mechanical seal cover. Lubricate
a. Clean all oil, dirt, and grease from the the cup and mechanical seal cover
end of the impeller shaft. Make sure with Ethylene-Glycol or soapy water
the impe ller shaft is smooth and free solution.
of burrs at the gear key slot and
bearing journals. e. Replace the seal rings in the groves on
the mechanical seal cover. Apply a
light coat of grease to the seal rings
being careful not to get grease on the
impeller shaft. Slide the mechanical
OIL AND GREASE WILL DAMAGE THE seal cover over the impeller shaft
ETHYLENE-PROPYLENE (EPT) BELLOWS making sure the mechanical seal
ON THE MECHANICAL SEAL. USE ONLY remains seated in the bore of the
ETHYLENE-GLYCOL (ANTI-FREEZE) OR cover. Make sure there is no oil or
SOAPY WATER TO LUBRICATE THE grease on the faces of the mechanical
IMPELLER SHAFT AND BELLOWS DURING seal.
ASSEMBLY.
f. Screw a 7/16-14UNC stud into one of
the holes in the mechanical seal
housing to aid in bolt hole alignment.

5-9
 Muscle Pumps

g. Insert the mechanical seal cover in o. Place the gear key into slot on
mechanical seal housing making sure impeller shaft then install the gear
to line up the bolt holes and center onto the impeller shaft making sure
punch marks. the key lines up with the key way in
the gear.
h. Install four 7/16-14 x 1-1/4 inch long
cap screws into the holes. Tighten cap p. Install 409 bearing over the impeller
screws evenly and torque to 40 ft-lb (54 shaft and properly seat in bearing
N-m). When installing the cap screws housing.
make sure they are locked in place
using a suitable thread locking q. Install bearing retainer washer on
compound such as Loctite #242 or impeller shaft end and secure using
equal. If cap screws require replacement 5/8-11 x 1-1/4 inch long cap screw.
they shall be replaced with grade 5, zinc Tighten cap screw and torque to 135
plated steel, nylon locking type. ft-lb (183 N-m).

i Slide the slinger onto the impeller r. Install gearbox in accordance with
shaft. paragraph B.2, this section.

j. Install new oil seal into the rear Qflo and Qpak Pump Mechanical Seal and
bearing housing. Clearance Rings
k. Place a new gasket over the mating 1. Removal (Refer to figure 5-5)
surface of the mechanical seal
housing and rear bearing housing. a. Place apparatus out of service in
Apply a light coating of grease to the accordance with department pro-
gaskets to hold them in place during cedures.
assembly. Use only lithium based
grease with 1 to 3% moly bdenum b. Open drains and drain pump body.
disulfide. Some examples of correct
greases are: Mobile Grease Special c. Drain gearbox oil.
and Sun Oil – Sunoco MOLY #2EP.
d. Tag and disconnect air lines and
l. Install two 1/2-13UNC studs into electrical connections.
mechanical seal housing in pump body
to aid in alignment of the rear bearing e. Disconnect drive shafts.
housing. Slide the rear bearing housing
over the impeller shaft making sure the
oil seal aligns properly. Do not allow
the weight of the rear bearing housing
to rest on the oil seal. Align the bolt GEARBOX AND IMPELLER ASSEMBLY
holes and center punch marks. WEIGHS ABOUT 500 LBS (228 KG). MAKE
SURE PROPER LIFTING DEVICES ARE USED
m. Insert twelve 1/2-13 x 1-3/4 inch long FOR REMOVAL AND INSTALLATION OF
cap screws into the holes. Evenly tighten GEARBOX.
the cap screws to 65 ft-lb (88 N-m).
f. Attach proper lifting device to
n. Install 310 bearing onto the impeller gearbox.
shaft and properly seat into bearing
housing. g, Remove the twelve 7/16-14UNC X 1-
1/4 inch long screws from the bearing
housing and pump body.
5-10
 Muscle Pumps

h. Install 7/16-14UNC screws into n. Remove the cup and seat from the
threaded holes on bearing housing to bearing housing.
use as jacking screws.
o. Clean impeller shaft and all com-
i. Turn the jacking screws clockwise ponents.
evenly to back the bearing housing
out of the pump body. Make sure the p. Measure the impeller wear surfaces
gearbox and bearing housing stay and the wear rings. The wear rings
straight as the assembly is backed out. should be replaced if the radial
clearance is 0.015 to 0.020 inch per
j. Remove the gearbox and impeller side or overall.
assembly to a suitable work area.
q. If necessary, remove and replace the
k. Remove cotter pin and nut from wear rings in the pump body and rear
impeller shaft. bearing housing.

l. Using a suitable puller remove the r. Inspect the oil seal in the rear bearing
impeller and impeller key from the housing and replace if necessary.
shaft.

m. Use hooks that fit around the shaft

and seal then remove the spring and
spring retainer then the remainder of
the mechanical seal assembly.

5-11
 Muscle Pumps

2. Installation f. Install a new gasket on the rear

bearing housing, holding it in place
with a light coating of grease.

g. Thread two 7/16-14UNC studs in the

pump body to help guide the rear
bearing housing onto the pump body.
WHEN APPLYING THE ETHYLENE GLYCOL
OR SOAP AND WATER SOLUTION, MAKE
h. Using proper lifting device lift
SURE ALL SHAFT SURFACES AND THE
gearbox and impeller assembly into
INSIDE OF THE SEALING BOOT ARE
place. Use studs to guide the rear
COATED.
bearing housing into the pump body.
a. Being careful not to touch the sealing
i. Insert the 7/16 –14UNC X 1-1/4 inch
surface of the mechanical seal seat,
long cap screws into the rear bearing
apply a solution of ethylene glycol
housing. Tighten screws to 40 ft-lb
(anti-freeze) or soap and water to
(58 N-m) torque.
lubricate the pump shaft and inside of
the seat assembly. Slide the cup and
j. Reconnect drive shafts, electrical, and
seat assembly over the impeller shaft.
air lines to gearbox.
Using a soft clean pusher tube (a short
length of 2 inch PVC pipe) make sure
k. Refill the gearbox with oil.
the cup and seat assembly are seated
squarely in the rear bearing housing.
l. Test operate apparatus and watch for
b. Keeping fingers away from the carbon leaks.
seal ring apply a solution of ethylene
glycol (anti-freeze) or soap and water
to lubr icate the shaft and inside of the
seal bellows. Orient the carbon seal
ring towards the seal and slide the
bellows and spring over the impeller
shaft. Use the pusher tube to make
sure the assembly is pushed all the
way in. If resistance is felt, add more
ethylene glycol (anti-freeze) or soap
and water to keep the shaft and
bellows lubr icated.

c. Insert impeller key in the impeller

shaft and install the impeller on the
shaft.

d. Install impeller nut and tighten to 135

ft-lb (183 N-m) Lock the impeller nut
in place using a cotter pin.

e. Apply a light coating of grease to the

seal ring groove and install a new seal
ring on the rear bearing housing.

5-12
 Muscle Pumps

E. AutoLube® Service (Qmax/Qtwo)

1. Park the vehicle on a level surface. Shut
down the engine. Set the parking brake DO NOT USE A CHISEL TO SEPARATE THE
and chock the front and rear wheels. AUTOLUBE® FROM THE PUMP BODY
BECAUSE THE MATING SURFACES MAY BE
2. Drain water from the pump. SCRATCHED OR GOUGED, WHICH COULD
RESULT IN A LEAK. ALSO, THE AUTOLUBE®
3. Remove the fill and drain plugs from the IS MANUFACTURED FROM CAST METAL,
AutoLube® reservoir and drain oil. BODY, PRY BETWEEN THE AUTOLUBE®
AND THE PUMP BODY OR AT THE AND IF IT
4. Use a center punch to mark the BECOMES NECESSARY TO PRY THE
AutoLube® cover and the front bearing AUTOLUBE® APART FROM THE PUMP
cover housing (for proper alignment AUTOLUBE® “NOTCHES’
during assembly).
5. Remove the cap screws attaching the
AutoLube®, figure 5-6, to the pump body
and gently pry AutoLube® from the pump
body and impeller shaft.

5-13
 Muscle Pumps

6. Place the AutoLube® face down on a 18. Install the new gasket on the AutoLube®,
work bench and remove the two allen- and position the assembly (with the top
head cap screws from the impeller side. up) onto the impe ller shaft. Attach the
Separate the two halves and remove the AutoLube® with cap screws and tighten
diaphragm. to 64 ft-lb (87 N-m).

7. Remove the oil seal lock ring.

8. Remove the oil seal from the inner half of

the AutoLube®. DO NOT DAMAGE THE OIL SEAL. A
DAMAGED OIL SEAL COULD RESULT IN
9. Check the impeller shaft bushing for wear. DAMAGE TO THE AUTOLUBE® ASSEMBLY,
AS WELL AS THE PUMP.
10. Clean the inner and outer halves of the
AutoLube®.

11. Clean the gasket surfaces of the

AutoLube® and pump body. PURGE THE AIR FROM THE AUTOLUBE®
WHILE FILLING IT WITH OIL OR A “FALSE-
12. Check for restrictions in the water FILL” SITUATION WILL DEVELOP, WHICH
passages to the rear half of the COULD CAUSE DAMAGE TO THE
AutoLube®. AUTOLUBE® AND OTHER COMPONENTS

13. If it is necessary to replace the impeller 19. To fill the AutoLube® with 90w oil, pump
shaft bushing, press the bushing from the the oil in from the bottom plug opening
inner side of the inner half of the until the oil spills from the top opening.
AutoLube® (on the side opposite of the This eliminates air pockets and false
impeller). Install the bushing from the readings.
impeller side of the inner half of the
AutoLube®. See figure 5-6. 20. Add water to the pump.

21. Operate the fire pump and check the

AutoLube® for water or oil leaks.

THE IMPELLER SHAFT BUSHING SEATS 22. Remove the tire chocks.
AGAINST A SHOULDER IN THE INNER HALF
OF THE AUTOLUBE® AND CAN ONLY BE 23. Return apparatus to service.
REMOVED AND INSTALLED AS DIRECTED
OR THE AUTOLUBE® MAY BE DAMAGED.

14. Install the new oil seal in the inner half of

the AutoLube®.

15. Install the seal lock ring.

16. Position the diaphragm on the inner half

of the AutoLube®.

17. Line up the marks, and place the outer half

of the AutoLube® onto the inner half.
Apply Loctite® 242 to the two allen-head
cap screws. Tighten to 26 ft-lb (35 N-m).
5-14
 Muscle Pumps

F. Impeller Assembly g. Remove the 1/2-13UNC X 1-3/4 inch

long cap screws from the upper half
1. Impeller and Clearance Rings Removal of the rear bearing housing and pump
(Qmax (refer to Figure 6-3 and Qtwo body.
Pumps (Refer to Figure 6-4)
h. Remove the 1/2-13UNC X 1-1/4 inch
a. Park the vehicle on a el vel surface. long cap screws, from the lower
Shut down the engine. Set the parking pump body.
rake and chock the front and rear
wheels.

b. Drain the water from the pump.

DO NOT REMOVE THE FOUR CAP SCREWS,
ONE IN EACH CORNER OF THE LOWER
PUMP BODY, UNTIL THE LIFTING DEVICE
IS IN POSITION. FAILURE TO DO SO COULD
THE GEARBOX ASSEMBLY WEIGHS 500 LBS RESULT IN THE LOWER PUMP BODY AND
(228 KG). SUPPORT THE LOWER GEARBOX IMPELLER ASSEMBLY FALLING, WHICH
ASSEMBLY WITH A LIFTING DEVICE. COULD RESULT IN PERSONNEL INJURY OR
FAILURE TO DO SO COULD RESULT IN THE PROPERTY DAMAGE.
ASSEMBLY FALLING, WHICH COULD RESULT
IN PERSONAL INJURY OR PROPERTY i. Position the lifting device into place
DAMAGE. with the lower pump body-lifting
adapter between the lifting device and
c. Remove the gearbox, refer to para- the lower pump body.
graph B.1, this section.
j. Remove the 5/8-11UNC X5 inch long
cap screws in each corner of the
lower pump body.

k. Lower the lower pump body and

THE LOWER PUMP BODY WEIGHS 100 LBS impeller assembly so that it does not
(46 KG). SUPPORT THE LOWER PUMP BODY tip from the lifting device. Remove
AND IMPELLER ASSEMBLY WITH A the assembly to a suitable work area.
LIFTING DEVICE. FAILURE TO DO SO
COULD RESULT IN THE LOWER PUMP l. Remove the remaining cap screws
BODY AND IMPELLER ASSEMBLY from the lower half of the
FALLING, WHICH COULD RESULT IN AutoLube®, the rear bearing housing,
PERSONAL INJURY, OR PROPERTY and the lower pump body.
DAMAGE.

d. Remove the drain lines from the lower

pump body.

e. Mark lower pump body, Autolube® THE IMPELLER ASSEMBLY IS HEAVY. DO

housing, and rear bearing housing for NOT ATTEMPT TO LIFT THE ASSEMBLY
reassembly. WITHOUT THE AID OF ANOTHER PERSON
OR PERSONS. FAILURE TO DO SO COULD
f. Drain the oil from the AutoLube®, RESULT IN THE IMPELLER ASSEMBLY
and remove the 1/2-13UNC X2 inch FALLING, WHICH COULD RESULT IN
long cap screws from the upper half PERSONNEL INJURY OR PROPERTY
of the AutoLube® and pump body. DAMAGES.
5-15
 Muscle Pumps

m. Remove the remaining screws from

the rear bearing housing, and the
lower pump body.
DO NOT OVER HEAT THE IMPELLER. THE
n. Lift the impeller assembly from the IMPELLER IS CONSTRUCTED OF BRONZE.
lower pump housing. Set the IF THE IMPELLER IS OVERHEATED (AND
assembly aside. TURNS RED OR BLUE DURING REMOVAL
FROM THE SHAFT), IT HAS BEEN
o. Clean the gasket surfaces of the upper WEAKENED AND MUST BE REPLACED.
and lower pump bodies, as well as
those on the AutoLube® and the rear d. Using an acetylene torch, carefully
bearing housing face. heat the “eye” and hub of the impeller
in an even fashion for approximately
p. Clean the clearance ring and clearance two minutes.
ring seats in both the upper and lower
pump body halves to remove all the e. When heated properly, the impeller
“build up” material so that the new should be removed from the shaft
clearance ring will seat properly. using a gear puller. If the m i peller
moves but does not slide free, do not
NOTE: Pitting of the clearance rings may occur immediately reheat. Allow the
from the “build up” of material and the effects of complete assembly to cool to room
corrosion. Once the seats are cleaned, any pitting temperature, then reheat and continue
on the clearance rings is considered normal. removing the impeller.
2. Disassembly (Single -Stage Pump) f. Allow the components to cool to room
temperature.
a. Place the impeller shaft assembly on a
workbench. Note the orientation of
impeller vanes and clearance rings. g. Remove the inner clearance ring.

b. Carefully remove the AutoLube® h. Remove the impeller key.

assembly from pump shaft end.
3. Assembly (Single -Stage Pump)
c. Remove the outer retaining ring and
outer clearance ring. a. Clean the impeller shaft and the
keyway.
NOTE: Before removing impeller, note the
orientation of vanes for proper reassembly. The b. Check the water way in the seal
vanes will turn in a clockwise manner when housing for restrictions.
viewed from the front.
c. Install the inner retaining ring.

d. Install the new gasket on the seal

housing face.
WEAR PROTECTIVE, HEAT-RESISTANT
GLOVES WHILE HEATING THE IMPELLER e. Verify the key is free to slide in the
TO REMOVE OR INSTALL IT INTO THE impeller keyway, then install the key
IMPELLER SHAFT. HEATED METAL CAN into the keyway.
CAUSE INJURY TO YOUR HANDS.

5-16
 Muscle Pumps

IMPORTANT: Mark the impellers as to whether

they are the primary or secondary impeller in
relation to the AutoLube®. Improper or backward
IF THE IMPELLER OR CLEARANCE RINGS installation of the impellers affects pump
ARE DROPPED, DAMAGED OR DEFORMED, performance.
THEY WILL NEED TO BE REPLACED.
b. Place the impeller shaft assembly on a
f. Install the inner clearance ring over workbench. Note position of impellers
the impeller shaft with proper and mark for reassembly.
orientation.
c. Remove impeller retaining rings.

WEAR PROTECTIVE, HEAT-RESISTANT

GLOVES WHILE HEATING THE IMPELLER TO WEAR PROTECTIVE, HEAT-RESISTANT
INSTALL IT INTO THE IMPELLER SHAFT. GLOVES WHILE HEATING THE IMPELLER TO
HEATED METAL CAN CAUSE INJURY TO REMOVE OR INSTALL IT INTO THE IMPELLER
YOUR HANDS. SHAFT. HEATED METAL CAN CAUSE INJURY
TO YOUR HANDS.
g. Using the torch, heat the “eye” and
hub of the new impeller in an even
fashion for approximately two
minutes. Then, slide the impeller onto
the shaft with vanes in proper DO NOT OVER HEAT THE IMPELLER. THE
orientation. (Note: vanes will turn in IMPELLER IS CONSTRUCTED OF BRONZE.
clockwise direction when viewed IF THE IMPELLER IS OVERHEATED (AND
from the front of the impeller TURNS RED OR BLUE DURING REMOVAL
assembly). If the impeller does not FROM THE SHAFT), IT HAS BEEN
fully slide onto the shaft allow the WEAKENED AND MUST BE REPLACED.
assembly to cool to room temperature
before re-heating. d. With an acetylene torch, carefully
heat the “eye” and hub of the first
h. Install the outer retaining ring. impeller in an even fashion for
approximately two minutes.
i. Install the outer clearance ring in the
proper orientation. e. When heated properly, remove
impeller from shaft using a gear
j. Carefully slide the AutoLube® puller. If the impeller moves but fails
assembly over pump shaft. to slide free, do not immediately
reheat. Allow the complete assembly
k. Install the impeller shaft assembly on to cool to room temperature, then
the pump. reheat and continue removing the
impeller.
4. Disassembly (Two-Stage Pump)
f. Remove the center support bearing.
a. Remove AutoLube® assembly from Then rotate the impeller shaft
front of impe ller shaft. assembly end for end and heat and
remove the second impeller.

g. Remove the impeller key.

5-17
 Muscle Pumps

5. Assembly (Two-Stage Pump) 6. Installation (Impeller and Clearance

Rings)
a. Clean the impeller shaft, the keyway,
and the seal housing and face. a. Install the pump body gaskets to the
lower pump body, trimming as
b. Check the waterway in the seal necessary to fit.
housing for restrictions.

c. Install the new gasket on the seal

housing face.
FAILURE TO LINE UP THE CLEARANCE
d. Install the key into the keyway. RING LOCK NOTCHES WITH THE PUMP
BODY TABS (AS DESCRIBED IN THE NEXT
STEP) MAY RESULT IN PUMP DAMAGE AND
PUMP FAILURE.

IF THE IMPELLERS OR THE CLEARANCE b. Install the impeller assembly into the
RINGS ARE DROPPED, DAMAGED OR lower pump housing, carefully
DEFORMED, THEY WILL NEED TO BE aligning the clearance ring lock
REPLACED. notches with the clearance ring lock
tabs in the lower pump body. Then,
e. Install the inner clearance ring with rotate the clearance rings to one side
proper orientation. to open up lock notches to line up
with the lock tabs in the upper pump
body.

c. through the rear bearing housing and

WEAR PROTECTIVE, HEAT-RESISTANT the seal housing. Do not tighten.
GLOVES WHILE HEATING THE IMPELLER
TO INSTALL IT INTO THE IMPELLER SHAFT. d. Install the 1/2-13UNC X2 inch long
HEATED METAL CAN CAUSE INJURY TO cap screws into the AutoLube®
YOUR HANDS. housing and lower pump body.

f. Using the torch, heat the “eye” and e. Make sure the dowel pins are in the
hub of each impeller for approxi- upper pump body to assist in aligning
mately two minutes. Then, slide the the lower pump body with the upper
individual impellers onto the shaft pump body.
making sure they are in the correct
orientation. Make sure the center sup- f. Using a lifting device, slowly raise the
port bearing is installed between lower pump body and the impeller
impellers. If an impeller does not fully assembly into place, making sure that
slide onto the shaft allow the the lower pump body aligns with the
assembly to cool to room temperature dowel pins and the clearance ring
before reheating. notches align with the clearance ring
lock tabs in upper pump body.
g. Install the outer retaining ring.
g. Rotate the impeller shaft and check
h. Install the outer clearance ring with for freedom of movement when the
proper orientation. lower pump body and the impeller
assembly is in place.
i. Slide AutoLube® assembly over
pump shaft.

5-18
 Muscle Pumps

h. Apply Loctite 242 and install the four

5/8-11UNC X5 inch long cap screws
(one in each corner of the lower pump
body). Tighten snug but do not fully
torque.

i. Install the 1/2–13UNC X 1-3/4 inch

long screws in the rear bearing
housing and mechanical seal housing,
also install the 1/2-13UNC X2 inch
long cap screws into the AutoLube®.
Tighten to 53 ft-lb (72 Nm).

j. Remove the lifting device.

k. Apply Loctite 242 to the 1/2-13UNC

X 1-3/4 inch long screws, lower pump
body cap screws and install them.
Tighten snug but do not fully torque.

l. Torque the 5/8-11UNC X5 inch long

cap screws to 150 ft-lb (203 Nm),
then, starting from the center and
moving outward tighten the lower
pump body cap screws to 65 ft-lb (88
Nm).

THE GEARBOX ASSEMBLY WEIGHS

OVER 500 LBS (228 KG). SUPPORT THE
LOWER GEARBOX ASSEMBLY WITH A
LIFTING DEVICE. FAILURE TO DO SO
COULD RESULT IN THE ASSEMBLY
FALLING, WHICH COULD RESULT IN
PERSONAL INJURY OR PROPERTY
DAMAGE.

m. Install the gearbox, refer to paragraph

B.1, this section.

n. Operate the pump and check for leaks.

5-19
 Muscle Pumps

G. Relief Valve Systems

1. PM/PMD Control Valve
(Refer to figure 6-14) DO NOT USE PLIERS TO UNSCREW THE
CONTROL VALVE FROM THE DIAPHRAGM
a. Park the vehicle on a level surface. CLAMP. DAMAGE TO THE CONTROL
Shut down the engine. Set the parking VALVE WILL RENDER THE PILOT VALVE
brake and chock the front and rear INOPERATIVE.
tires.
2) Unscrew the control valve from
b. Drain the fire pump. Tag and the diaphragm clamp. Remove
disconnect wires to indicator light. the diaphragm washer and the
diaphragm.
c. Rotate the adjustment handwheel
counterclockwise to remove the 3) Remove the retaining ring, the
spring tension. seal and the bearing.

d. Remove the cap screw and nut

attaching the adjustment handwheel to
the adjustment shaft. Then, remove
the handwheel. USE A SPRING COMPRESSOR TO
REMOVE THE CONTROL SPRING. THE
SPRING IS UNDER COMPRESSION, AND
COULD BECOME UNCOMPRESSED, WHICH
COULD RESULT IN PERSONNEL INJURY.
IDENTIFY AND MARK THE LINE
CONNECTIONS ON THE CONTROL BODY 4) Turn the adjustment handwheel
BEFORE REMOVING. IMPROPER CONNECTION clockwise to unscrew the adjust-
OF LINES MAY RESULT IN THE FAILURE OF ment shaft from the adjustment
THE PILOT VALVE, WHICH COULD CAUSE nut. From the handwheel end,
DAMAGE TO THE FIRE PUMP. remove the adjustment shaft from
the spring housing.
e. Remove the pump discharge pressure
line and the relief valve line from the 5) Remove springs, the adjustment
control body of the pilot valve. nut, and diaphragm clamp as an
assembly from the spring housing,
f. While holding the pilot valve, remove and then separate.
the four 1/4-20UNC X5/8 inch long
machine screws attaching the valve h. Clean all the control components.
and cover plate to the Pump Inspect and lubr icate with grease the
Operator’s Panel, and separate the threads on the adjustment shaft.
valve, plate, and the relief valve
setting indicator (if equipped with i. Assemble the control valve.
PMD) from the panel.

g. Disassemble the Control Valve.

1) Remove the four 5/16-18UNC X

1 inch long allen-head cap screws
securing the control body to the
rear of the spring housing. Then,
remove the control body.
5-20
 Muscle Pumps

5) Install the control body. Apply

Loctite 242 to the four 5/16-
18UNC X 1 inch long allen-head
cap screws attaching the control
USE A SPRING COMPRESSOR TO INSTALL body to the rear of the spring
THE PILOT VALVE SPRING. COMPRESSION, housing.
AND COULD BECOME UNCOMPRESSED,
WHICH COULD RESULT IN PERSONAL
j. Holding the pilot valve, and PMD
INJURY. indicator assembly if installed, align
the cover plate and install the four
1/4-20UNC X 1 inch long allen-head
cap screws attaching the spring
housing to the pump panel.
ALWAYS REMOVE THE PILOT VALVE
DISCHARGE PRESSURE STRAINER, WHICH
k. Install the pump discharge pressure
IS LOCATED IN THE TOP OF THE line and relief valve line to control
DISCHARGE SIDE OF THE PUMP. CLEAN OR body of the pilot valve, attach
REPLACE, AS NECESSARY. FAILURE TO DO electrical wires to the indicator light.
SO COULD RENDER THE PILOT VALVE
INOPERATIVE. l. Slide the adjustment handwheel onto
the adjustment shaft, and then install
1) Combine both springs, the
the retaining cap screw and nut.
adjustment nut, and the discharge
clamp as an assembly and install m. Fill the pump and test the valve for
into the spring housing. Align the proper operation and leaks.
guide pin adjustment nut with the
slot in the spring housing. 2. QD Relief Valve
(Refer to figure 6-15)
2) Slide the adjustment shaft into the
spring housing from the hand- a. Drain the pump.
wheel end. Turn the adjustment
handwheel counterclockwise in b. Note the location of the wires and
order to screw the adjustment disconnect the indicator light switch.
shaft into the adjustment nut until
it bottoms in the diaphragm c. Disconnect the relief valve supply line
clamp. Do not put the springs from the pilot valve and drain the line.
under tension.
d. Remove the two 7/16-14UNC X 1-1/4
3) Lubricate the new bearing, and inch long cap screws attaching the
slide the new bearing and bearing relief valve indic ator light switch and
washer over the adjustment shaft the mounting bracket assembly to the
into the spring body housing. relief valve cover. Remove the light
Install the retaining ring. Then, switch and the bracket.
install the new seal washer and
rotate the adjustment shaft in both e. Compress the relief valve return
directions to check for freedom of spring (by hand), and remove the E–
movement. clip and washer. Then, remove the
return spring.
4) Install the new diaphragm washer
and diaphragm. Screw the control
valve into the diaphragm clamp.

5-21
 Muscle Pumps

f. Remove the two remaining 7/16- the relief valve stem, install the
14UNC X 1-1/4 inch long cap screws retaining ring.
retaining the relief valve cover to the
pump body. Using a twisting motion, k. Operate the relief valve by hand to
carefully remove the relief valve check freedom of movement.
cover
l. Slide the relief valve cover gasket and
cover over the top of the relief valve
stem to align the relief valve supply
line from the pilot valve in the
DO NOT PUSH THE RELIEF VALVE TOO FAR original position. Then, apply Loctite
INTO THE PUMP BODY AS IT MAY FALL 242 to two 7/16-14UNC X 1-1/4 inch
INTO THE PUMP BODY AND BECOME long cap screws and install opposite
LODGED OR DAMAGED. THE RELIEF of each other. Tighten, but do not
VALVE IS MADE OF BRASS AND IS EASILY torque.
DAMAGED BY PRYING OR HAMMERING.
DAMAGED VALVES MUST BE REPLACED. m. Compress and install the return
spring, and secure it with a washer
g. Remove the retaining ring securing and E-clip.
the relief valve piston to the relief
valve. Gently push the relief valve n. Align the indicator light switch
into the pump body approximately 1 bracket with the two empty holes in
inch (25 mm), and then pull it back the relief valve cover. Install the two
out in a snap motion. This should pop remaining 7/16-14UNC X 1-1/4 inch
the relief valve piston out of the relief long cap screws. Tighten all cap
valve body. Repeat if necessary. screws to 53 ft-lb (72 Nm).

NOTE: It is not necessary to remove the relief o. Connect the relief valve supply line
valve unless it is damaged. To remove the relief from the pilot valve. Also, connect the
valve, the relief valve body will have to be drain line.
removed and the complete relief valve assembly
will need to be replaced (as it will be necessary to p. Assemble indicator light switch and
pry the relief valve body from the pump body, the switch strap. Securely tighten the
which will likely damage it). two screws.

h. Clean and inspect all of the relief q. Install the switch strap and light
valve assembly components. switch in the switch bracket. Leave
the two screws attaching the switch
i. Clean all sealing surfaces and install strap to the switch bracket slightly
new O-rings and quad ring seals. loose to allow the switch to move in
and out for adjustment.
j. Install the relief valve piston ni the
stem of the relief valve. Do not push r. Connect the panel mounted indicator
the relief valve into the pump body. light or a suitable test light to the switch
As it is necessary to start the piston terminals. With the light switch plunger
onto the relief valve stem, push the not in contact with the end of the
piston until you can grasp the relief poppet, the light should be lit.
stem. Then, pull the relief valve stem
outward while pushing on the relief s. With the pump not running and the
valve piston. Once the relief valve relief valve fully closed, push the light
piston is seated against the shoulder of switch in until the switch plunger
makes contact with the end of the
5-22
 Muscle Pumps

poppet and the light goes out. The k. Clean all sealing surfaces and install
switch is now in the proper position. new O-ring seals.
Tighten the screws holding the switch
strap to the bracket. l. Install the relief valve into the relief
valve body.
t. Fill the pump and test the valve for
proper operation and leaks. m. Install the piston spring by sliding the
piston into the relief valve body while
3. QG Relief Valve at the same time sliding the piston
(Refer to figure 6-16) onto the relief valve stem.

a. Before removal match mark the relief n. Apply light pressure to the piston to
valve housing and pump body for compress the piston spring and install
proper assembly. the piston-retaining ring.

b. Disconnect the line to the sensing o. Slide the cover into the relief valve
valve and drain valve. Make note of body. Then, install the cover-retaining
the wire connections. ring.

c. Disconnect the indicator light switch. p. Slide the relief valve assembly into
the pump body with the side marked
d. Remove the four 7/16-14UNC X 1- “top” up, being careful not to damage
1/4 inch long cap screws attaching the the O-rings.
relief valve assembly to the pump
body. q. Apply Loctite 242 to the four 7/16-
14UNC X 1-1/4 inch long cap screws
e. Using a twisting motion, remove the and install the assembly in the pump
relief valve assembly. body. Tighten to 53 ft-lb (72 Nm).

f. To disassemble the valve, remove the r. Install collet fitting tight into the valve
indicator light switch, remove the cover. Back off 1 to 1-1/2 turns.
cover-retaining ring and slide the
cover out of the relief valve body. s. Install the light switch in the collet
fitting. Leave the collet holding the
g. Apply a small amount of pressure to light switch slightly loose to allow the
the relief valve piston and remove the switch to move in and out for
piston-retaining ring. Carefully adjustment.
release the pressure held to the piston
by the spring. t. Connect the panel mounted indicator
light or a suitable test light to the
h. Remove the relief valve stem from the switch terminals. With the light
opposite end, sliding the relief valve switch pulled nearly all the way out,
stem out of the piston. the light should be lit.

i. Reach through the center hole of the u. With the pump not running and the
piston and pull the piston out of the relief valve fully closed, push the light
indicator switch end of the relief valve switch in until the light goes out. Hold
body. Then, remove the piston spring. the collet fitting with a wrench to
prevent it from turning, and tighten
j. To assemble and install the valve, first the collet.
clean and inspect all components.

5-23
 Muscle Pumps

v. Disconnect the electrical connector. m. Remove the relief valve from the
Tighten the entire collet fitting 1 to 1- opposite end, sliding the relief valve
1/2 turns. The switch is now in the stem out of the piston.
proper position. Reconnect the
electrical connector. n. Reaching through the center hole of
the piston, gently pull the piston from
w. Fill the pump and test the valve for the indicator switch end of the relief
proper operation and leaks. valve body.

4. PG30 Relief Valve o. Before assembling and installing the

(Refer to figure 6-12) valve, clean and inspect all
components of the relief valve
a. Drain the pump. assembly.

b. Disconnect the indicator light switch. p. Clean all sealing gasket surfaces and
install new O-rings and gaskets.
c. Disconnect the line to the sensing
valve. q. Install the relief valve into the relief
valve body.
d. Remove the 7/16-14UNC X2 inch long
sensing valve mounting cap screw. r. Slide the piston into the relief valve
body while at the same time sliding
e. Remove the four 7/16-14UNC X 1- the piston onto the relief valve stem.
3/4 inch long cap screws retaining the Then, install the piston-retaining ring.
relief valve assembly to the
atmosphere dump. s. Install the new gasket, and then install
the cover onto the relief valve body.
f. Remove the four 7/16-14UNC X 1-
1/2 inch long relief valve mounting t. Install two 7/16-14UNC X 1-3/4 inch
cap screws to remove the relief valve long cap screws finger-tight (to keep
from the pump body. the relief valve cover aligned with the
valve body).
g. Remove the relief valve assembly.
u. Install the valve spring over the relief
h. Remove the four 7/16-14UNC X 1-3/4 valve stem. Then, apply pressure to
inch long cap screws retaining the relief the valve spring to compress the
valve cover to the relief valve body. spring.
i. Remove the indicator light switch v. Install the spring washer and the
assembly. retaining ring.
j. Apply a small amount of pressure to w. Remove the two 7/16-14UNC X 1-3/4
the relief valve spring, and remove the inch long cap screws installed to keep
spring retaining ring and washer. the relief valve cover aligned with the
Carefully release the pressure held on valve body. Place the indicator switch
the spring and then remove the spring. bracket into position on the relief
valve cover. Apply Loctite 242 to the
k. Remove the relief valve cover. four cap screws, install, and tighten to
53 ft-lb (72 Nm).
l. Remove the piston-retaining ring.
x. Apply Loctite 242 to the four 7/16 x
1-1/2 inch long cap screws and install
the new gasket and the relief valve to
the pump surface.
5-24
 Muscle Pumps

y. Apply Loctite 242 to the four 7/16- 5. Sensing Valve

14UNC X 1-1/2 inch long cap screws (Refer to figure 6-13)
and install the new gasket and relief
valve assembly to the atmosphere a. Disconnect the following lines at the
dump. Tighten to 53 ft-lb (72 Nm). sensing valve:
q Pilot valve discharge line
z. Apply Loctite 242 to the 7/16-14UNC q QG relief valve line
X2 inch long cap screw, install the q PG relief valve line
sensing valve and tighten. Make sure q Sensing valve pump suction line
the arrow on the sensing valve points q Drain lines
upward.
b. Remove the 7/16-14UNC X2 inch
aa. Assemble indicator light switch and long sensing valve mounting cap
the switch strap and securely tighten screw.
the two screws.
c. Remove the four 5/16-18UNC X 1
bb. Install the switch strap and light inch long cap screws attaching the
switch assembly in the switch bracket. control body to the rear of the spring
Attach flasher assembly to bracket. housing. Remove the control body,
Leave the two screws attaching the being careful not to lose the sensing
switch strap to the switch bracket valve spring.
slightly loose to allow the switch to
move in and out for adjustment. d Remove the control valve from the
sensing valve body.
cc. Connect the panel mounted indicator
light or a suitable test light to the e. Unscrew the sensing valve from the
switch terminals. With the light diaphragm, being careful not to
switch plunger not in contact with the damage the control valve. Remove the
end of the poppet, the light should be diaphragm.
lit.
f. Before installing the sensing valve,
dd. With the pump not running and the clean all components.
relief valve fully closed, push the light
switch in until the switch plunger
makes contact with the end of the
poppet and the light goes out. The
switch is now in the proper position. ALWAYS REMOVE THE SENSING VALVE
Tighten the screws holding the switch SUCTION INLET SCREEN. CLEAN OR
strap to the bracket. REPLACE AS NECESSARY. THE SCREEN IS
LOCATED IN THE SUCTION SIDE OF THE
ee. Connect the line to the sensing valve. PUMP. FAILURE TO DO SO MAY RENDER
COMPONENTS INOPERATIVE.
ff. Fill the pump and test the valve for
proper operation and leaks. g. Install a new diaphragm on the
diaphragm clamp. Apply Loctite to
the threads on the control valve and
install the control valve into the
sensing valve body.

h. Install the sensing valve spring into

the valve body cover.

5-25
 Muscle Pumps

i. Apply Loctite 242 to the four 5/16- b. Install elbow into fitting and tighten
18UNC X 1 inch long cap screws and so elbow outlet is positioned in the up
attach the control body to the rear of position.
the spring housing. Make sure that the
sensing valve spring properly aligns c. Install pressure switch in elbow outlet.
with the diaphragm clamp.
7. Reconnect drain tubing, discharge line,
j. Make sure the “up” arrow is aligned and electrical wiring.
properly.
8. Fill the pump and test the valve for proper
k. Apply Loctite 242 to the 7/16-14UNC operation and leaks.
X2 inch long sensing valve mounting
cap screw. Tighten to 40 ft-lb (51 Nm). I. Anode Replacement
(Refer to figure 6-17)
l. Connect the lines.
1. Consumable zinc anodes should be
m. Fill the pump and test the valve for proper inspected at least every 12 months.
operation and leaks.
2. A minimum of two anodes per pump is
H. TRV Service recommended.
(Refer to figure 6-11)
3. One anode should be installed on the
1. Disconnect electrical wiring, discharge suction side and the other on the discharge
line and drain tubing. side of the pump.

2. If TRV-L kit is installed. 4. To inspect the anodes, drain the pump.

a. Unscrew pressure switch from fitting. 5. Remove four 7/16-14UNC X 1-1/4 inch
long cap screws and remove the anode and
b. Remove elbow. flange assembly.
c. Remove 1/8 MNPT x 1/8 FNPT 6. Inspect the consumable zinc anode and
fitting. replace when over 75% of zinc has been
consumed (the original anode is 1.25
3. Unthread thermal relief valve from inches diameter by 2.125 inches long).
attachment flange.
7. Clean all gasket surfaces.
4. Check inlet strainer for blockage. This
should be accomplished once a year or 8. Replace all gaskets, replace anode
more frequently in pumping water with assembly if required, apply Loctite 242 to
impurities. the four 7/16-14UNC X 1-1/4 inch long
cap screws, install, and tighten to 40 ft-lb
5. Apply coating of Loctite PST (or equal (54 Nm).
thread sealer) rethread thermal relief valve
into attachment flange. 9. Fill the pump and test for leaks.
6. If TRV-L kit is installed, apply coating of
Loctite PST to threads of fitting before
assembly of parts.

a. Install 1/8 MNPT x 1/8 FNPT fitting

into TRV body.
5-26
 Muscle Pumps

J. Qtwo Transfer Valve stem. Remove the woodruff key from

the transfer drum stem.
1. Drain the pump
e. Separate the transfer bracket from the
IMPORTANT: The transfer valve is a timed transfer drum by sliding it from the
device. It is therefore important during transfer drum stem.
disassembly to note the location of the transfer
bracket locating pin, the transfer drum stop pin, the f. Slide the transfer drum from the transfer
sleeve.
transfer drum sleeve-locating pin, and the transfer
drum stem key. It is not necessary to remove the 7. Assemble the Valve
transfer bracket locating pin, the transfer drum
sleeve locating pin, or the transfer drum stop pin a. Clean and inspect all sealing surfaces
during disassembly. and the mating surfaces of the
transfer valve drum and sleeve. Clean
2. Turn the adjustment handwheel clockwise and inspect the transfer bracket
until it stops. The transfer indicator should bushings and bushing surface on the
be at the top of the slotted guide in the transfer valve stem and the transfer
cover plate. valve adjustment stem.
3. Remove the two allen-head setscrews b. Install new O-ring seals on the
from the transfer indicator guide. Slide the transfer valve drum stem and the
transfer indic ator guide (on an adjustment transfer valve bracket.
stem) towards the transfer valve.
c. Slide the transfer drum into the
4. Remove the stem drive gear lock pin. transfer bracket, being careful not to
Slide the adjustment stem from the stem damage the bearing surfaces. Then,
drive, the support, and the transfer rotate the transfer drum until the
indicator guide, being careful not to drop drum stop pin is in the correct
or damage the transfer indicator guide and position.
transfer indic ator.
d. Install the woodruff key into the
5. Remove the four 7/16-14UNC X 1-1/4 transfer drum stem. Install the
inch long cap screws retaining the transfer transfer drum gear onto the transfer
bracket assembly to the pump body. drum stem. Apply Loctite 242 to the
Carefully remove the transfer bracket and allen-head set screw and install the
the transfer valve drum. transfer drum gear.

6. Disassemble the valve. e. Assemble the countershaft gear spring

in the countershaft gear, and position
a. Remove the locating pin that secures the assembly into place in the transfer
the countershaft in place. bracket. Then, install the countershaft
and the countershaft-locating pin to
b. Remove the countershaft from the lock the countershaft in place.
countershaft gear.
8. Install the Transfer Valve
c. Remove the countershaft gear and the
countershaft gear spring from the a. Align the transfer drum stop pin, the
transfer bracket assembly. transfer bracket-locating pin, and the
transfer drum sleeve locating pin into
d. Remove the allen-head setscrew from proper position.
the transfer drum gear. Slide the
transfer drum gear from the drum
5-27
 Muscle Pumps

b. Install the transfer valve drum and K. Qtwo Check Valves (two-stage
bracket assembly into the pump body.
only)
c. Apply Loctite 242 to the four 7/16- (Refer to figure 6-4)
14UNC X 1-1/4 inch long transfer
bracket cap screws, and install and 1. Drain the pump.
tighten to 53 ft-lb (72 Nm).
NOTE: there are two check valves (one on each
d. Slide the adjustment stem through the side) in the suction side on the front of the Qtwo
cover plate, the transfer indicator pump body. The following procedure is used for
guide, and the support and transfer both check valves.
bracket.
2. Remove the four 1/2-13UNC X 1-1/4 inch
e. Insert the stem drive gear into place in long cap screws from the check valve
the transfer bracket, and then slide the cover on the front side of the pump body.
adjustment stem through the stem Note position of check valve for
drive gear. reassembly.

f. Insert the stem drive gear lock pin 3. Remove the check valve.
into place, locking the stem drive
gear onto the adjustment stem. 4. Clean the gasket surfaces, and inspect the
check valve pivots and pivot sockets.
g. Apply Loctite 242 to the transfer
indicator guide set screws and install. 5. Install the check valve.
Do not tighten.
6. Install the new gasket in the pump body.
h. Turn the adjustment handwheel
counter clockwise until it stops. Make 7. Apply Loctite to the four cap screws and
sure the transfer indic ator is at the top secure the check valve cover to the pump
of the slotted guide toward the body with the cap screws, being careful to
transfer indic ator, making certain that align the check valve pivot with the pivot
the transfer indicator engages the socket in the check valve cover. Tighten
transfer indicator guide in the top to 53 ft-lb (75 Nm).
groove. Then, tighten the inside
setscrew in the transfer guide 8. Fill the pump and test the valve for proper
indicator. operation and leaks.

i. Rotate the adjustment handwheel

from stop to stop. The transfer
indicator should move freely from the
top to the bottom of the slotted guide
in the cover plate.

j. Tighten the outside setscrew in the

operation indicator guide, and recheck
the movement of the transfer
indicator.

k. Fill the pump and test the valve for

proper operation and leaks.

5-28
 Muscle Pumps

L. Tank to Pump Check Valve 10. Install a new gasket.

1. Drain the water tank and the pump. 11. Apply Loctite 242 to the eight 7/16-
14UNC X 1-1/2 inch long cap screws and
2. Disconnect the control linkage at the attach the tank-to-pump valve to the pump
Tank-to-Pump Valve. body. Tighten to 53 ft-lb (72 Nm).

3. Disconnect both ends of the flexible hose 12. Slide the flexible connection hose so it is
connecting the water tank to the Tank-to- evenly spaced and secured on the water
Pump valve. Then, slide the flexible hose tank outlet and the tank-to-pump valve
toward the water tank outlet or the Tank- plumbing.
to-Pump valve plumbing.
13. Attach the tank-to-pump valve controls
NOTE: If the tank-to-pump valve is air-operated, and linkage.
drain the vehicle’s air system and disconnect the
supply and the return line on the valve actuator, but 14. Fill the pump and test the valve for proper
do not remove the actuator from the valve. Also, operation and leaks.
the tank-to-pump valve may be connected to the
pump body by cap screws or studs with nuts. If M. Suction Extension and Suction Tube
studs are used, it may be necessary to remove some
or all of the studs to remove the valve. If so, 1. Place apparatus out of service.
remove only the studs necessary to remove the
valve, as any studs left will assist in realigning the 2. Open and drain pump body.
valve during installation.
3. Remove twelve 7/16-14UNC X 1-1/4 inch
4. Remove the eight 7/16-14UNC X 1-1/2 long cap screws from suction tube flange.
inch long cap screws retaining the tank-to-
pump valve to the pump body. 4. Clean suction tube and all components.

5. Remove the tank-to-pump valve and 5. Remove fourteen 1/2-13UNC X 1-1/4

associated plumbing. inch long cap screws from the suction tube
extension.
NOTE: The back flow valve is a flat butterfly
plate with two pivots attached at the top. These 6. Clean the suction tube extension and all
pivots fit into two open pivot sockets in the pump components.
body. When the gasket is removed, the back flow
valve may fall out. 7. Clean seating surfaces of pump body,
housing, suction tube extension and
6. Remove the old gasket from the pump suction tube.
body.
8. Place a new gasket on the seating surface
7. Remove the back flow valve. of the pump body. Apply a light coat of
grease to the gasket to hold it in place.
8. To install the back flow valve, first clean
all of the gasket surfaces on the pump 9. Reinstall suction tube extension, insert
body and the tank-to-pump flange. fourteen 1/2-13UNC X 1-1/4 inch cap
long screws, torque to 65 ft-lb (88N-m).
9. Install the back flow valve. Using two
fingers, hold the pivots in the pivot
sockets and check the valve for freedom
of movement.

5-29
 Muscle Pumps

10. Place a new gasket on the seating surface e. Disconnect the pump gearbox cooling
of the suction tube extension. Apply a lines.
light coat of grease to the gasket to hold it
in place. f. Disconnect the electrical switches and
the airlines.
11. Reinstall the suction tube, insert twelve
7/16-14UNC X 1-1/4 inch long cap g. Remove the fire pump gearbox. See
screws. Using a criss-cross pattern, torque paragraph B.1, this section.
to 40 ft-lb (54 N-m).
h. Secure the pump gearbox into a
12. Fill the pump and test for leaks. holding fixture.

N. Gearbox Disassembly and i. Remove and disassemble the

Assembly intermediate shaft assembly (refer to
figure 5-7).
G-Series 1) Remove the 7/16-14UNC X 1
1. Removal and Disassembly inch long cap screw holding the
intermediate shaft washer, remove
a. Park the vehicle on a level surface. Shut the washer.
down the engine. Set the parking brake
and chock the front and rear tires. 2) Carefully press the intermediate
gear shaft out of the gearbox
b. Drain the water from the pump. housing from the rear to the front.

c. Drain the gearbox lubricant. 3) Reach into the top of the gearbox
housing and remove the
d. Disconnect the drive shafts from the intermediate gear spacer and the
gearbox. intermediate gear.

5-30
 Muscle Pumps

4) Remove the intermediate gear 1) Loosen the 3/8-16UNC inch hex

bearing from the intermediate gear. nut locking the gearshift rod end
to the gear shaft. Remove the
5) Remove the two different size gearshift rod end with the hex nut.
intermediate shaft seal rings from
the intermediate gear shaft. 2) Remove the 1/2-20 UNF X 1/2
inch long nylon loc king set
6) Clean and inspect each screw, gearshift lock spring and
component of the intermediate gearshift ball from the gearshift
shaft assembly. Inspect bearings shaft cap.
for wear, pitting, and damage.
Inspect the gear tooth surface for 3) Remove two 5/16-18 hex nuts and
wear da mage and pitting, replace two 5/616-18UNC X 1 inch long cap
all components that are worn, screws and remove the cylinder
damaged, or pitted. cover.
4) Remove the outer retaining ring
j. Remove and disassemble the tail shaft locking the cylinder piston to the
assembly (refer to figure 5-8). gearshift shaft

NOTE: If the tail shaft and sliding gear shaft 5) Remove the cylinder piston, then
require service it is not necessary to remove the remove the inner retaining ring.
gearbox from the apparatus.
6) Remove two 7/16-14UNC X 1 inch
NOTE: If only the tail shaft assembly needs to be long nylon locking cap screws and
removed, set the gearshift mechanism to engage remove the shifting cylinder.
the sliding gear with the sliding gear shaft (pump
position).

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 Muscle Pumps

NOTE: The gearshift fork cannot be removed NOTE: If only the sliding gear assembly needs to
from the sliding gear shaft until the sliding gear is be removed, set the gearshift mechanism to engage
removed. the sliding gear with the tail shaft (road position).

7) Remove four 7/16-14UNC X 1 1) Remove four 7/16-14UNC X 1

inch long nylon locking cap inch long nylon locking cap
screws securing the rear bearing screws securing the front bearing
cap to the gearbox housing. cap to the gearbox housing.
8) Remove the tail shaft assembly 2) Remove the sliding gear assembly
from the gearbox housing. from the gearbox housing.
9) Remove the inner tail shaft
3) Remove the sliding gear bearing
bearing retaining ring from the tail
shaft. retaining ring from the sliding
gear shaft.
10) Remove the inner tail shaft
4) Remove the sliding gear bearing
bearing from the shaft and rear
from the sliding gear shaft and
bearing cap.
front bearing cap.
11) Remove the inner tail shaft outer
retaining ring from the tail shaft. 5) Remove the sliding gear shaft
from the front bearing cap.
12) Remove the outer tail shaft
6) Remove the drive shaft oil seal
bearing retaining ring.
from the front bearing cap.
13) Remove the tail shaft from the
7) Reaching through the top of the
rear bearing cap.
gearbox housing, carefully
14) Remove the outer tail shaft remove the sliding gear.
bearing from the rear bearing cap.
NOTE: Make a note of the location of the gearshift
15) Remove the drive shaft oil seal fork in relation to the gearshift shaft before
from the rear bearing cap. removing.

16) Clean and inspect each 8) Loosen the 7/16-14UNC X 1-3/4

component of the tail shaft inch long cap screw attaching the
assembly. Inspect bearings for gearshift fork to the gearshift
wear, pitting, and damage. Inspect shaft, and then pull the shaft from
gear tooth surface for wear, out of the gearbox housing.
damage, and pitting. Replace all
components that are worn, 9) Reaching through the top of the
damaged, or pitted. gearbox housing, carefully
remove the gearshift fork with the
k. Remove and disassemble the sliding cap screw attached.
gear assembly (refer to figure 5-7).
10) Clean and inspect each component
NOTE: If the tail shaft and sliding gear shaft of the sliding gear assembly,
require service it is not necessary to remove the inspect bearing for wear, pitting,
gearbox from the apparatus. and damage, inspect gear tooth
surface for wear, damage, and
pitting, replace all components
that are worn, damaged, or pitted.
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 Muscle Pumps

l. Inspect the Cooling Tube for Damage 2) Apply Loctite 242 to the 7/16-
and Leaks. 14UNC X 1-3/4 inch long cap
screw that attaches the gearshift
m. Remove and disassemble the fork onto the gearshift shaft.
remainder of the gearshift shaft cap. Tighten to 25 ft-lb (34 Nm).

1) Remove two 7/16-14UNC cap 3) Reaching through the top of the

screws, then remove the gearshift gearbox housing, place the sliding
shaft cap. See figure 6-5. gear into the shift fork. Make sure
the shift fork groove on the
2) Remove the gearshift switches sliding gear is oriented towards
from the gearshift shaft cap.. the front of the gearbox.

3) Clean and inspect each component 4) Install a new drive shaft oil seal in
of the gearshift shaft cap assembly. the front bearing cap.
Replace all components that are
worn, damaged or pitted. 5) Using a brass drift or a bearing
installation tool, install the sliding
2. Assembly and Installation gear bearing allowing the retaining
ring to contact the surface of the
a. Assemble and install the gearshift cap. front bearing cap.

1) Install new switch seal ring on the 6) Install the slinger on the sliding
gearshift switches. Thread gearshift gear shaft.
switch into the gear shift shaft cap.
7) Insert the sliding gear shaft into
2) Install a new gearshift cap gasket the front bearing cap by sliding it
on the gearbox housing. from the front to the rear. Be sure
to be careful when sliding shaft
3) Apply Loctite 242 to the two through the drive shaft oil seal
7/16-14UNC cap screws and and bearing.
install the gearshift shaft cap to
the gearbox housing. Secure cap 8) Install bearing retaining ring.
with two 7/16-14UNC cap screws.
9) Install a new front bearing cap
b. Assemble and install the sliding gear gasket onto the front bearing cap
assembly. (hold gasket in place using a
general purpose grease).
1) Reaching through the top of the
gearbox housing, hold the gearshift 10) Apply Loctite 242 to the four
fork in place, slide the gearshift 7/16-14UNC X 1 inch long cap
shaft through the opening in the screws. Then install the sliding
front of the gearbox housing, gear shaft and front bearing cap
through the gearshift fork. Insure and tighten to 40 ft-lb (54 Nm).
fork is in the proper position.
11) The sliding gear shaft will mesh
with the sliding gear. Insure the
gearshift fork is in its proper
position.

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 Muscle Pumps

c. Assemble and install the tail shaft 11) Apply Loctite 242 to the four
assembly. 7/16-14UNC X 1 inch long cap
screws. Then install the rear
1) Using a brass drift or a bearing bearing cap and tighten the cap
installation tool, install the outer screw to 40 ft-lb (54 Nm).
tail shaft bearing in the rear
bearing cap. 12) Install a new shifting cylinder
gasket.
2) Install a new drive shaft oil seal in
the rear bearing cap. 13) Install a new gearshift shaft seal
ring in the shifting cylinder.
3) Insert the tail shaft into the rear
bearing housing, be careful when 14) Install the shifting cylinder by
sliding the shaft through the drive sliding it over the gearshift shaft
shaft oil seal and tail shaft outer until it contacts the gearbox
bearing. housing. Apply Loctite 242 to the
two 7/16-14UNC X 1 inch long
4) Install the tail shaft retaining ring nylon locking cap screws and
to secure the outer tail shaft tighten.
bearing in its proper position on
the tail shaft. NOTE: Install piston retaining rings with flat side
(square corners) facing away from piston.
5) Install the inner tail shaft retaining
ring. 15) Install the inner piston-retaining
ring on the gearshift.
6) Using a brass drift or a bearing
installation tool, install the inner 16) Install a new piston inner seal ring
tail shaft bearing from the outside on the gearshift shaft.
inuntil the retaining ring contacts
the surface of the tail shaft 17) Install a new piston outer seal ring
housing. on the cylinder piston.

7) Install the tail shaft inner bearing 18) Install the cylinder piston on the
inner retaining ring. gearshif with the flat side of the
piston facing the interior of the
8) Install the sliding gear shaft cylinder.
needle bearing in the front end of
the tail shaft. 19) Install the outer piston-retaining
ring on the gearshift shaft.
9) Apply a light coating of grease
and apply new gasket to tail shaft 20) Install a new gearshift shaft seal
housing. on the cylinder cover.

10) Install the tail shaft and rear bearing 21) Install cylinder cover by sliding
cap. Be careful when sliding the tail over the gearshift shaft. Apply
shaft with the sliding gear needle Loctite 242 to the two 5/16-18UNC
bearing will slide over the male end X 1 inch long hex head screws and
of the sliding gear shaft. two 5/16-18UNC studs and
tighten.

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 Muscle Pumps

22) Install the gearshift rod end on the J-Series

end of the gearshift shaft. Tighten (Refer to figure 6-6)
the 3/8-16UNC locking hex nut.
1. Removal and Disassembly
d. Assemble and install the intermediate
shaft assembly. a. Park the vehicle on a level surface.
Shut down the engine. Set the
1) Press a new intermediate gear parking brake and chock the front and
bearing into the intermediate gear. rear tires.
2) Install new intermediate shaft seal b. Drain the water from the pump.
rings on the ends of the
intermediate shaft. c. Drain the gearbox lubricant. Remove
magnetic plug, level plug and sight
3) Reaching through the top of the gauge plug.
gearbox place the intermediate
gear in position towards the front d. Disconnect the drive shaft from the
of gearbox housing. gearbox.
4) On the XG gearbox, hold the e. Remove the fire pump gearbox. See
intermediate gear spacer in paragraph B.1, this section.
position towards the rear of the
gearbox housing. Install the f. Secure the pump gearbox into a
intermediate shaft (front cutout holding fixture.
facing down) through the front
opening in the gearbox housing. g. Remove and disassemble the idler
shaft assembly (refer to figure 6-6).
5) Press the intermediate shaft
through the intermediate gear and 1) Remove the locknut and washer
the intermediate gear spacer until from the idler shaft.
the cut out on the front of the
shaft is flush with the surface of 2) Carefully press the idler shaft out
the gearbox housing. of the gearbox housing.
6) Apply Loctite to the 7/16-14UNC 3) Reach into the top of the gearbox
X 1 inch long cap screw, install housing and remove the idler
the intermediate shaft washer and gear.
tighten cap screw.
4) Remove the idler gear bearing
7) Rotate the sliding gear shaft and from the gear.
manually shift the gearshift shaft
to check for proper operation. 5) Remove the two different size
idler shaft seal rings from the idler
8) Using a lifting device remove the gear shaft.
gearbox from the holding fixture.
6) Clean and inspect each component
9) Install the fire pump gearbox; see of the idler shaft assembly. Inspect
paragraph B.2, this section. bearings for wear, pitting and
damage. Inspect the geartooth
surface for wear, damage and

5-35
 Muscle Pumps

pitting, replace all components 3) Place input gear into gearbox

that are worn, damaged or pitted. housing in proper orientation.

h. Remove and disassemble the input 4) Install .500 x 2.063 long key in the
shaft assembly. input shaft. Holding input gear in
place, start to ni sert input shaft.
1) Remove the 1/2-13UNC X 1-1/4 Make sure key in shaft aligns with
inches long cap screw and washer. slot in gear. Make sure shaft
aligns with bearing.
2) Using an appropriate pulle r,
remove the companion flange 5) Install a new spherical roller
from the input shaft. bearing over input shaft. Align
the shaft and bearing with housing
3) Remove the .375x1.563 long and carefully press bearing into
square key from the input shaft. place.

4) Remove the oil seal from the 6) Install new split ring into gearbox
companion flange end of the drive housing.
shaft, then remove the bearing
retaining ring. 7) Press new oil seals into both sides
of gearbox housing.
5) Remove oil seal from other sides
of gearbox and remove the 8) Install .375 x 1.563 key on input
bearing retainer ring. shaft, then install companion
flange.
6) Using proper press, carefully
press input shaft from gearbox 9) Apply Loctite 242 to 1/2-13UNC
housing. X 1-1/2 inches long cap screws,
then install washer and cap screw.
7) Remove bearings and .500 x
2.063 long square key from input b. Assemble and install the intermediate
shaft. shaft assembly.

8) Note orientation of gear, then 1) Press new idler gear bearings into
reach into top of gearbox housing the idler gear.
and remove input gear from
gearbox housing. 2) Install new shaft seal rings on the
ends of the intermediate shaft.
9) Using bearing puller, remove
bearing from gearbox housing if 3) Reaching through the top of the
necessary. gearbox, place the intermediate
gear in position towards the front
2. Assembly and Installation of the gearbox housing.

a. Assemble and install the input shaft. 4) Press the idler shaft through the
idler gear until the shaft is seated
1) Obtain a new 309 bearing and in the gearbox housing.
install in non-drive side of
gearbox housing. 5) Apply Loctite to the idler shaft
threads, install the idler shaft
2) Install new split ring in non-dive washer and locknut. Tighten lock
side of housing. nut.
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 Muscle Pumps

6) Rotate the input gear shaft to g. Using a non-marring mallet carefully

check for proper operation. separate the pump head from the
pump body.
7) Using a lifting device, remove the
gearbox from the holding fixture. h. Remove the shaft and rotor assembly,
and the vanes from the pump body.
8) Install the gearbox; see paragraph
B.2 this section. i. Remove the seal from the pump head
assembly.
O. Primers
j. Inspect all components for corrosion
1. ESP Priming Pump and abnormal wear. Clean all
(Refer to figure 6-7) components. Obtain new components
as necessary.
The hale ESP primer is relatively maintenance
free. If after testing of the priming system the k. Carefully press new seal into the
primer fails to pull the required vacuum the primer pump head assembly.
vanes may be worn and require replacement.
l. Insert rotor and shaft assembly into
The following procedures should be used to pump body assembly. Slide new
replace the primer vanes. vanes into the slots in the rotor. Rotate
the rotor and shaft making sure the
a. Place apparatus out of service in vanes move freely in the slots.
accordance with departmental
procedures. m. If necessary install new pins into the
pump head assembly. Align the pins
b. De-energize apparatus electrical system. with the holes in the pump body
assembly and slide pump head over
NOTE: Before beginning disassembly make note rotor shaft. Once head is seated
of the position and locations of components to against the pump body make sure the
ensure correct re-assembly. rotor assembly turns freely in the
pump assembly.
c. Tag and disconnect wires from battery
connection, solenoid connection and n. Install motor on pump assembly and
ground connection point. secure in place using 3/8-16 UNC X2-
1/2 inch long cap screw and 3/8-16
d. Tag and disconnect hose from suction UNC nut on the stud. Tighten the nut
connection. and cap screw.

e. Loosen nuts on studs or bolts that o. Place primer assembly on the

hold primer assembly to mounting mounting point and tighten cap
pad. Remove primer to suitable work screws or nuts.
area.
p. Reconnect suction hose making sure
f. Remove the 3/8-16 UNC X2-1/2 inch the connection is tight.
long cap screw and remove the 3/8-16
UNC nut from stud. Carefully q. Reconnect ground wire, battery
separate pump assembly from motor. connection and solenoid connection.

r. Energize apparatus electrical system.

5-37
 Muscle Pumps

s. Tests operate the primer to ensure it is g. Install the valve spring and diaphragm
working correctly. washer onto the valve. Apply Loctite
242 to the diaphragm washer retaining
t. Return apparatus to normal operation. screw, compress the valve spring with
the diaphragm washer and install the
2. SPV Priming Valve valve.
(Refer to figure 6-8)
h. Align the diaphragm holes with the
a. Drain the pump. cap screw holes in the diaphragm
cover. Apply Loctite 242 to the eight
b. Disconnect the 3/4 inch (19 mm) 5/16-18UNC X3/4 inch long cap
vacuum hose connecting the priming screws and install the diaphragm
valve to the primer. Remove two 7/16- cover and diaphragm valve body.
14UNC nuts attaching the priming valve Tighten to 17 ft-lb (23 Nm).
to the studs in the pump body or
universal adapter if mounted. i. Install the valve strainer and O-ring
seal onto he pump side of the priming
NOTE: If the strainer and O-ring seal remains on valve.
the pump body, remove it carefully for cleaning
and installation. If the valve strainer is removed as j. Apply Loctite 242 on the two 7/16-
part of the priming valve, remove it from the body 14UNC priming valve-mounting
and set it aside. Use care as the valve strainer is nuts and install the priming valve
easily damaged. into the pump body. Tighten to 40
ft-lb (54 Nm).
c. Note the location of the drain hole in
the diaphragm cover, and then remove k. Connect the vacuum hose to the
the eight 5/16-18UNC X3/4 inch long primer.
cap screws securing the diaphragm
cover to the valve body. Remove the l. Fill the pump and test the valve for
diaphragm cover and the diaphragm. proper operation and leaks.

d. Hold pressure on the diaphragm 3. PVG Priming Valve.

washer to compress the valve spring, (Refer to figure 6-9)
then remove the diaphragm washer
retaining screw. Remove the a. Drain the pump.
diaphragm washer and valve spring.
From the opposite side of the valve b. Disconnect the 3/4 inch flexible hose
body, remove the valve. to the ESP priming pump and the
electrical connections.
e. Clean all components of the priming
valve and mating surfaces. Inspect the c. Remove two 7/16-14UNC X 1-1/4
valve seat, and replace, if worn or inch cap screws retaining the PVG
damaged. priming valve to the pump body.

f. Install the valve into the valve body d. Remove the PVG priming valve and
from the pump side of the body. discard.

e. Remove the old gasket from the pump

body.

5-38
 Muscle Pumps

f. Remove, clean and inspect the b. Service

priming valve strainer, replace if
required. 1) If the valve leaks, it is probably
due to the O-ring seal not pressing
g. Clean the pump body gasket surface. tightly enough against the seal. To
ensure the pressure of the O-ring
h. Reinstall the priming valve strainer. against the valve ball:

i. Install a new gasket. a) Remove the valve cover.

j. Apply Loctite 242 to the two 7/16- NOTE: The valve is usually assembled with two
14UNC X 1-1/4 inch long cap screws or three gaskets. Do not remove to many gaskets.
and install a new PVG priming valve. The valve should turn easily yet hold a vacuum
and pressure. Never remove the last gasket.
k. Reinstall the 3/4 inch flexible hose
from the ESP priming pump and b) Remove one valve cover
reconnect the electrical connections. gasket.

l. Fill the pump and test the valve for c) Reassemble and check for
proper operation and leaks. leaks.

P. Accessories d) If leaks persist, repeat steps A

through C.
1. Valves (General Procedure for maintenance
of valves). e) If valve still leaks, remove the
cover and turn the O-ring
a. Lubrication around and put the new side
against the ball. Reassemble
1) On a Hale ball valve, using a and test.
brush, lubricate the face of the
ball with waterproof grease once a f) If this fails, install a new O-
week. ring.

2) On a suction valve, squirt some NOTE: If the valve has high usage and wear, it
oil in the space next to the rubber might be necessary to install a new ball, pivot or
washer to lubricate the swivel stem.
balls. The remote control linkage
connecting the valves should be g) If valve leaks up through
lubricated monthly. the stem, install a new
stem O- ring.
3) If a drain valve is installed on a
discharge valve, insert an oil can c. Disassembly and Assembly
tip in the open end of the
discharge valve and allow some To disassemble valve, refer to proce-
oil to run down the connecting dures below. When disassembled,
pipe to the closed drain valve. clean and inspect all components for
excessive wear and damage. Replace
4) If the discharge valve has a built- O-rings and gaskets. Reassemble,
in drain valve, oil the passageway install and test for proper operation
that the drain valve piston slides and leaks.
in then move the piston back and
fourth to lubricate the seal rings.
5-39
 Muscle Pumps

2. 40BD Series Valve Maintenance b. To install the valve in the apparatus

(Refer to figures 6-19 and 6-20) do the following:

The Hale 40BD series valve requires a minimum 1) Make sure the connector mating
amount of maintenance. Most maintenance can be surfaces are clean and free from
performed with the valve in place on the apparatus. debris and dirt.
The only time the valve must be removed is when
there is not access to the valve or the valve requires 2) Make sure the V-clamps are on the
rebuilding. connectors and there is clearance
to allow insertion of the valve
a. To remove the valve from the body between the connectors.
apparatus do the following:
3) Apply a small amount of grease to
1) Place apparatus out of service in the O-ring grooves on the valve
accordance with departmental body to hold the O-rings in place
procedures. and install new O-rings in both
grooves.
2) Open all drains and release
pressure from pump system. 4) Making sure the O-rings do not
get pinched slide the valve body
3) Tag and disconnect electrical between the connectors.
wires from valve.
5) Once valve is in place and
4) Disconnect valve operator reach oriented slide the V-clamps into
rods and remove panel interference. place over the valve body groove
and connectors.
5) Disconnect drain lines from valve
6) Tighten the T-bolt nut to 20 ft-lb
(27 Nm) on each clamp. Install
jam nuts then install thread caps.

VALVE BODY IS HEAVY. MAKE SURE THE 7) Reconnect drain lines, operator
VALVE BODY IS PROPERLY SUPPORTED reach rods and electrical
BEFORE REMO VING FASTENING DEVICES. connections.

6) Remove thread cap from T-bolt 8) Test apparatus and check valve
on V-clamps. for leaks.

7) Remove jam nuts from clamps 9) Return apparatus to normal

then loosen T-bolt nuts. operation.

8) Slide the clamps towards the c. To lubricate valve ball and seat do the
connectors to clear valve. following:

9) Slide valve body from between 1) Place apparatus out of service in

both connectors. accordance with departmental
procedures.
10) Take valve to suitable work area
for disassembly and repair. 2) Open all drains and release
pressure from pump system.

5-40
 Muscle Pumps

d. On valves with 5 inch NST discharge k) Reconnect discharge piping.

fittings
5) Test operate apparatus and check
1) Remove cap from discharge for leaks.
connection
6) Return apparatus to service.
2) Reaching into discharge tube
apply a coating of grease to the 3. 40BD Valve Seat Replacement
valve ball surface.
a. Place apparatus out of service in
3) Making sure hands and fingers are accordance with departmental
clear manually operate valve procedures.
through a couple of complete
cycles to spread grease. b. Open all drains and release pressure
from pump system.
4) On valves mounted in line or tank
suction valves do the following: c. Gain access to the outlet side of valve.

a) Gain access to the outlet side d. Remove piping from discharge

of valve. connection.

b) Remove piping from discharge e. Remove thread cap from T-bolt on V-

connection. clamp.

c) Remove thread cap from T- f. Remove jam nut from clamp then
bolt on V-clamp. loosen T-bolt nut.

d) Remove jam nut from clamp g. Slide the clamp towards the
then loosen T-bolt nut. connectors to clear valve then remove
the connector and O-ring.
e) Slide the clamp towards the
connectors to clear valve then h. Carefully pry the seat housing out of
remove the connector and O- the valve using the ridge provided.
ring.
i. Push seat assembly out of housing.
f) Apply a coat of grease to the
valve ball. j. Clean and inspect all parts and mating
surfaces.
g) Make sure fingers are clear of
valve and manually operate k. Install new valve seat seal on seat
valve through a few complete then push seat and seal assembly into
cycles. housing.

h) Apply a light coat of grease to l. Apply a light coat of grease and

the O-ring groove and insert a install new seal in groove of seal
new O-ring into groove. housing.

i) Install discharge connector and m. With the seat oriented towards the
secure in place by tightening valve ba ll push seat and housing
T-bolt nuts to 20 ft-lb. assembly into discharge side of valve
body.
j) Install jam nut and thread cap.
5-41
 Muscle Pumps

n. Apply a light coat of grease to the O- j. Reattach any items that were removed
ring groove and insert a new O-ring from valve to gain access to the top
into groove. and bottom collars.

o. Install discharge connector and secure k. Test operate pump and check for
in place by tightening T-bolt nuts to leaks.
20 ft-lb (27 Nm).
l. Return apparatus to service.
p. Install jam nut and thread cap.
5. Drain Valve Repair Procedures
q. Reconnect discharge piping.
a. Type HD Drain Valve:
r. Test operate apparatus and check for (Refer to figure 6-21)
leaks.
If the type HD drain valve is leaking
s. Return apparatus to service. the seals must be replaced. Replace
the seals using the following
4. Valve Stem Seal Replacement procedures:

a. Place apparatus out of service in 1) Place apparatus out of service in

accordance with departmental accordance with department
procedures. procedures.

b. Open all drains and release pressure 2) Open all drain valves to make
from pump system. sure all pressure is relieved from
the pump.
c. Gain access to the valve.
3) Gain access to inlet fitting on the
d. Remove the 7/16-14 UNC X 1 inch valve and disconnect the hose or
long hex head cap screws that secure tube from the valve.
the top collar or bottom collar
assembly to the pump body. 4) Holding stem with a pair of pliers
if necessary and remove the knob
e. Remove collar assembly from valve from the valve stem.
body.
5) Loosen or remove screws that
f. Remove old seal ring from stem. hold valve body to the operator
Make sure stem and seal ring groove panel and remove valve assembly
are clean then install new seal ring on to suitable work area.
stem.
6) Remove the piston-retaining ring
g. Install new collar seal ring on collar from the valve body.
assembly then install collar assembly
in valve. 7) Slide the piston assembly out of
the valve body.
h. Install the 7/16-14 UNC X 1 inch long
hex head cap screws. 8) Remove the old seal rings from
the valve piston.
i. Tighten screws to 40 ft-lb.
9) Clean all parts and check for
excessive wear or pitting.

5-42
 Muscle Pumps

10) Apply a light coat of general- 4) Holding stem with a pair of pliers,
purpose grease to the new seal rings if necessary, and remove the knob
and install in grooves on valve from the valve stem
piston.
5) Loosen or remove screws that
11) Slide piston and seal ring hold valve body to the operator
assembly into the valve body panel and remove valve assembly
being careful that the seal rings do to suitable work area.
not bind or get cut.
6) Remove the piston stop plate from
12) Install piston-retaining ring into the valve body.
groove in valve body.
7) Slide the piston assembly out of
13) Make sure the piston moves freely the valve body.
back and forth in the valve body.
8) Remove the old seal ring from the
14) Install valve assembly into valve piston. Also remove the seal
operator panel and tighten ring that is cemented into the
mounting screws. valve body.

15) Screw operating knob onto valve 9) Clean all parts and check for
stem. excessive wear or pitting.

16) Attach hose or tubing to inlet 10) Apply a light coat of general-
fitting of the drain valve. purpose grease to the new seal
ring and install in groove on valve
17) Test operate apparatus and check piston
drain valve for leaks.
11) Apply a light coating of 3M
18) Return apparatus to normal EC847 (or equal) adhesive to the
operation. seal ring groove in the valve body
and install the seal ring into the
b. Type DV5 Drain Valve: groove. Make sure the adhesive is
(Refer to figure 6-22) dry before continuing installation.

If the type DV5 drain valve is leaking 12) Slide piston and seal ring
the seals must be replaced. Replace the assembly into the valve body
seals using the following procedures: being careful that the seal rings do
not bind or get cut.
1) Place apparatus out of service in
accordance with department 13) Install piston stop plate on valve
procedures. body.

2) Open all drain valves to make 14) Make sure the piston moves freely
sure all pressure is relieved from back and forth in the valve body.
the pump.
15) Install valve assembly into
3) Gain access to inlet fittings on the operator panel and tighten
valve and disconnect the hoses or mounting screws.
tubes from the valve.
16) Screw operating knob onto valve
stem.
5-43
 Muscle Pumps

17) Attach hoses or tubing to inlet 7) Remove the seat from the seat
fittings of the drain valve. retaining washer.

18) Test operate apparatus and check 8) Remove the knob from the stem
drain valve for leaks. by loosening the set screw in the
knob.
19) Return apparatus to normal
operation. 9) Clean all parts and check for
excessive wear or pitting. Check
c. Type DV7 Drain Valve: to make sure the sealing surfaces
(Refer to figure 6-23) of the inlet fittings are clean and
not pitted.
If the type DV7 drain valve is leaking
the seals must be replaced. Replace 10) Install a new seat in the seat
the seals using the following retaining washer.
procedures:
11) Install a thrust washer on the stem
1) Place apparatus out of service in then install the seat retaining
accordance with department washer and the other thrust
procedures. washer. Secure these parts to the
stem using the retaining ring.
2) Open all drain valves to make
sure all pressure is relieved from 12) Install the operating knob on the
the pump. stem and secure in place with the
setscrew.
3) Gain access to the backside of the
valve body where the grease 13) Carefully thread the stem assembly
fitting is located. Remove any into the valve body.
tubing or hoses that interfere with
valve disassembly. Remove the 14 Lock the stem assembly in the
retaining ring from the valve body using the retaining ring.
stem.
15) Attach hoses or tubing to inlet
4) Unscrew the valve stem fittings of the drain valve.
completely from the valve body.
16) Test operate apparatus and check
5) Remove the retaining ring that drain valve for leaks.
holds the seat and seat retaining
washer on the valve stem. 17) Return apparatus to normal
operation.
6) Remove the seat retaining washer
from the stem with the thrust
washers.

5-44
 Muscle Pumps

PARTS LIST HALE TYPE “G” SERIES GEARBOX

FIGURE 6-5
ITEM NO. PART NO QTY DESCRIPTION

1 007-0100-00-0 1 Tube-Drive Unit Cooling (LG & XG Gear Box) (Qmax/Qtwo)

007-0170-00-0 1 Tube-Drive Unit Cooling (SG Gear Box) (Qmax/Qtwo)
2 008-0053-02-0 1 Cap-Gearshift Shaft
3 008-0560-00-0 1 Cap-Rear Bearing
4 008-0570-00-0 1 Cap-Front Bearing
5 018-1810-07-0 12 Screw-7/16-14 x 1 Lg. Hex Hd. Zinc Pl. Stl. 3600 Nylon Locking Cap
6 018-1816-02-0 1 Screw-7/16-14 x 1-3/4 Lg. Hex Hd. Zinc Pl. Stl. Cap
7 018-1822-02-0 2 Screw-7/16-14 x 2-1/4 Lg. Hex Hd. Zinc Plated Stl. Cap (For Shipping
Only) (Not Shown)
8 018-2104-61-0 1 Screw-1/2-20 x ½ Lg. Flat Point Zinc Pl. Stl. 3600 Nylon Locking Cap
9 018-5002-00-0 4 Screw No. 4 x ¼ Lg. Rd. Hd. Zinc Pl. Drive
10 018-1810-190-0 2 Screw-7/16-14, Socket Head Cap Screw
11 028-0041-02-0 1 Fork-Gearshift (LG & SG Gearbox)
028-0400-00-0 1 Fork-Gearshift (XG Gearbox)
12 028-0050-00-0 1 Rod End-Gearshift Shaft
13 031-0970-00-0 1 Gear-Sliding (41 Teeth) (LG & SG GEARBOX)
031-1300-00-0 1 Gear-Sliding (51 Teeth) (XG Gearbox)
14 031-1310-00-0 1 Gear-Intermediate (59 Teeth) (XG Gearbox)
031-0980-00-0 1 Gear-Intermediate (51 Teeth) (LG Gearbox)
031-1040-00-0 1 Gear-Intermediate (40 Teeth) (SG Gearbox)
15 037-1341-00-0 1 Shaft-Gearshift
16 037-1530-00-0 1 Shaft-Intermediate Gear
17 039-0050-00-0 1 Ball-Gearshift Shaft
18 040-0140-00-0 2 Ring-Switch Seal Ring
19 040-2109-00-0 1 Ring-Gearshift Shaft Seal
20 040-2240-00-0 1 Ring-Intermediate Shaft Seal
21 040-2280-00-0 1 Ring-Intermediate Shaft Seal
22 042-0060-00-0 1 Spring-Gearshift Shaft Lock
23 044-0260-00-0 1 Vent-Air
24 046-5060-00-0 1 Gasket-Gearshift Cap
25 046-5130-00-0 2 Gasket-Front & Rear Bearing Cap
26 048-0070-00-0 1 Bushing-Speedcounter Drive
37 077-2750-01-0 4 Ring-Tailshaft & Sliding Gear Retaining
28 077-5000-00-0 1 Ring-Tailshaft Bearing Retaining
29 088-0040-00-0 2 Connector-Cooling Tube (Qmax/Qtwo)
217-0401-00-0 2 Plug-1/2 NPT MI (Qflo only)
30 097-1330-00-0 1 Washer-Intermediate Shaft
31 101-0082-00-0 1 Plate-Serial Number
32 101-0310-00-0 1 Tag-Oil Warning (Not Shown)
33 101-0941-00-0 1 Tag-Warning (Not Shown)
34 110-1600-02-0 1 Nut-3/8-16 Zinc Pl. Stl. Hex

6-18
 Muscle Pumps

PARTS LIST HALE TYPE “G” SERIES GEARBOX

FIGURE 6-5 (CONTINUED)
ITEM NO. PART NO QTY DESCRIPTION

35 115-0090-00-0 1 Cover-Gearshift Shaft Front

36 142-0160-00-0 1 Slinger
37 159-1460-00-0 1 Spacer-Intermediate Gear (XG Gearbox)
38 200-2450-00-0 2 Switch-Gearshift
39 217-0501-00-0 1 Plug-3/4 NPT Black MI (Oil Fill & Drain)
40 217-0501-08-0 1 Plug-3/4 NPT Magnetic (Oil Drain)
41 217-3007-00-0 1 Plug-Speedcounter
42 250-0214-00-0 1 Bearing-Tail Shaft
43 250-0214-06-0 2 Bearing-Sliding Gear & Tail Shaft
44 250-8010-00-0 1 Bearing-Sliding Gear Shaft Needle
45 250-8040-00-0 1 Bearing-Intermediate Gear
46 296-2540-00-0 2 Seal-Drive Shaft Oil
47 504-0380-00-0 1 Housing-Gearbox (Assembly)(SG Gearbox)
504-0340-00-0 1 Housing-Gearbox (Assembly) (LG Gearbox Optional)
504-0510-00-0 1 Housing-Gearbox (Assembly) (XG Gearbox Optional)
48 018-2014-07-0 6 Screw-1/2-13 x 1-1/2 Lg. Hex Zinc Pl. Stl. Nylon Locking Cap
49 046-6370-00-0 1 Gasket-Housing Cover (LG & SG Gearbox)
046-6370-01-0 1 Gasket-Housing Cover (XG Gearbox)
50 537-1740-00-0 1 Shaft-Sliding Gear (Assembly)
159-0610-00-0 8 Spacer
51 537-1750-00-0 1 Shaft-Tailshaft (Assembly)
52 101-1730-00-0 2 G-Flange Instruction Tag

OPTIONAL SPEEDCOUNTER ATTACHMENT

ADD THE FOLLOWING PARTS TO THE ‘G’ SERIES GEARBOX

53 007-0040-00-0 1 Adapter-Speedcounter
008-0070-00-0 1 Cap-Speedcounter Drive Sleeve (Not Shown, Panel Mounted
Component)
013-0010-00-0 1 Shaft-Speedcounter Flexible (Not Shown, Panel Mounted Component)
54 031-0170-00-0 1 Gear-Speedcounter Driven
048-0090-00-0 1 Sleeve-Speedcounter Drive (Not Shown, Panel Mounted Component)
55 040-0180-00-0 1 Ring-Speedcounter Adapter Seal

6-19
 Muscle Pumps

6-20
 Muscle Pumps

PARTS LIST HALE TYPE "J" SERIES GEARBOX

FIGURE 6-6

ITEM NO. PART NO. QTY. DESCRIPTION

1 004-0590-01-0 1 Housing - Lower J-Gearbox

2 004-0590-02-0 1 Housing - Upper J-Gearbox
3 018-2074-02-0 4 Screw - 1/2-13 UNC X 7.5 in. Lg. (1.63 (-16) J-Gearbox Ratio)
018-2070-02-0 4 Screw - 1/2-13 UNC X 7.0 in. Lg. (1.80 (-18) and 2.08 (-21)
J-Gearbox Ratios)
018-2064-02-0 4 Screw - 1/2-13 UNC X 6.5 in. Lg. (2.35 (-23) and 2.57 (-25)
J-Gearbox Ratios)
4 018-2036-02-0 4 Screw - 1/2-13 UNC X 3.75 in. Lg. (1.63 (-16) J-Gearbox Ratio)
018-2034-02-0 4 Screw - 1/2-13 UNC X 3.5 in. Lg. (1.80 (-18) and 2.08 (-21)
J-Gearbox Ratios)
018-2030-02-0 4 Screw - 1/2-13 UNC X 3.0 in. Lg. (2.35 (-23) and 2.57 (-25)
J-Gearbox Ratios
5 008-0810-00-0 1 Cap - End Upper Housing
6 018-2012-02-0 4 Screw - 1/2-13 UNC X 1-1/4 in.Lg. Upper Housing End Cap
7 044-0260-00-0 1 Vent - Breather Upper Housing End Cap
8 046-1650-00-0 1 Gasket - Upper Housing End Cap
9 064-6410-00-0 2 Pin - Dowel
10 046-1690-00-0 1 Gasket - Spacer
11 159-1600-03-0 1 Spacer - Gear (1.63 (-16) J-Gearbox Ratio)
159-1600-02-0 1 Spacer - Gear (1.80 (-18) J-Gearbox Ratio)
159-1600-01-0 1 Spacer - Gear (2.08 (-21) J-Gearbox Ratio)
159-1600-00-0 1 Spacer - Gear (2.35 (-23) J-Gearbox Ratio)
12 046-1690-00-0 1 Gasket - Spacer (Not used on 2.57 (-25) J-Gearbox Ratio)
13 110-3505-99-0 1 Nut - Locking, Idler Shaft
14 097-2170-00-0 1 Washer - Idler Shaft Nut
15 250-8220-00-0 2 Bearing - Tapered Roller, Idler Shaft
16 031-1600-00-0 1 Gear - Helical (57 teeth)
17 037-2250-00-0 1 Shaft - Idler
18 040-2210-00-0 1 O Ring -Idler Shaft
19 040-2280-00-0 1 O Ring - Idler Shaft
20 018-2012-02-0 1 Screw - 1/2-13 UNC X 1-1/4 in. Lg.
21 097-0890-01-0 1 Washer
22 115-1510-00-0 1 Flange - Companion
23 296-2100-00-0 2 Seal - Oil
24 077-3930-00-0 2 Ring - Retaining
25 250-8200-00-0 1 Bearing - Spherical Roller
26 037-2240-00-0 1 Shaft - Input
27 017-0300-02-0 1 Key - Companion Flange
28 017-0650-01-0 1 Key - Input Shaft Gear
29 031-1540-00-0 1 Gear - Helical (54 teeth)
30 250-0309-00-0 1 Bearing - Deep Groove Ball
31 217-3370-00-0 1 Gauge - View 1/2 NPT
32 217-0401-00-0 1 Plug - 1/2 NPT
33 217-0401-08-0 1 Plug - Magnetic 1/2 NPT

6-21
 Muscle Pumps

6-22
 Muscle Pumps

PARTS LIST HALE TYPE ESP PRIMING PUMP

FIGURE 6-7
ITEM NO. PART NO QTY DESCRIPTION

1 018-1624-02-0 1 Screw-3/8-16 x 2-1/2 Lg. Zinc Pl. Stl. Hex Hd Cap

2 018-8150-00-0 1 Stud-Terminal
3 064-6311-01-0 2 Pin-Locating
4 101-1580-00-0 1 Decal-ESP Model
5 101-1590-00-0 1 Tag-Instruction (Not Shown)
6 110-1600-02-0 2 Nut-3/8-16 Zinc Pl. Stl. Hex
7 130-0010-01-0 4 Vane-Rotor
200-0041-00-0 1 Motor-Priming Pump (12 Volt)
8 200-0062-00-0 1 Motor-Priming Pump (24 Volt)
9 217-0101-13-0 1 Plug-1/8 NPT Soc. Hd, Brass
10 296-2710-00-0 1 Seal-Head Shaft
11 501-1810-01-0 1 Body-Pump (Assembly)
12 001-0131-01-0 1 Body-Pump
13 250-9111-00-0 1 Bearing-Pump
14 502-0061-01-0 1 Head-Pump Mounting (Assembly)
15 002-0111-01-0 1 Head-Pump Mounting
16 250-9111-00-0 1 Bearing-Head
17 513-0190-00-0 1 Strap-Ground (Chassis Mount)
18 537-0281-01-0 1 Shaft-Pump (Assembly)
19 016-0171-01-0 1 Rotor
20 037-0271-00-0 1 Shaft-Pump

ADDITIONAL PARTS REQUIRED

WHEN THE PRIMING PUMP IS MOUNTED ON THE GEARBOX WITH PVG

018-1812-07-0 2 Screw-7/16-14 x ¼ Lg. Zinc Pl. Stl. Nylon Locking Hex Hd. Cap
097-0250-00-0 2 Washer-Mounting

ADDITIONAL PARTS REQUIRED

WHEN THE PRIMING PUMP IS MOUNTED ON THE GEARBOX WITH SPV

018-1812-07-0 2 Screw-7/16-14 x 1-1/4 Lg. Zinc Pl. Stl. Nylon Locking Hex Hd. Cap
097-0250-00-0 2 Washer-Mounting
082-4027-00-0 1 3/4 NPT Brass Street Elbow
082-0547-02-0 1 3/4 NPT x 3/4 Hose Barb Brass Fitting
340-0230-03-0 AR 3/4 Inch Inside Diameter Vacuum Hose (H03912)

6-23
 Muscle Pumps

6-24
 Muscle Pumps

PARTS LIST HALE TYPE SPV PRIMING VALVE

SEMI-AUTOMATIC
FIGURE 6-8
ITEM NO. PART NO QTY DESCRIPTION

1 340-0640-00-1 AR 3/4 ID Hose (Aeroquip 2556-12 or Equal)

2 110-1800-02-0 2 Nut, 7/16-14 Zinc Plated
3 018-8040-00-0 2 Stud, 7/16-14 x 1-3/4 In. Lg. Zinc Plated
4 010-0040-00-0 1 ZMQ-329H PRM Valve Strainer
5 040-2260-00-0 1 40-4N200 Ring Seal
6 018-1406-07-0 8 Screw, 5/16-18 x 3/4 In. Lg.
7 044-0231-00-0 1 Diaphragm Cover (Painted)
8 046-0121-00-0 1 Diaphragm, 5-3/8 In. Dia.
9 018-1004-32-0 1 Screw, #10-24 x 1/2 In. Lg.
10 005-0021-00-0 1 SPV Diaphragm Plate
11 042-0081-00-0 1 Valve Return Spring, Stainless
12 038-0151-00-0 1 SPV Priming Valve Valve
13 082-4027-00-0 1 Street Elbow, 3/4 Male NPT x 3/4 Female NPT
14 082-4027-01-0 1 Connection, 3/4 Male NPT x 3/4 Hose Barb
15 038-0141-00-0 1 SPV Priming Valve Body
16 101-0050-01-0 1 SPV Prime Placard
17 200-0120-04-0 1 Starter Switch, Momentary Push
18 082-0501-02-0 1 3/4 NPT Brass Close Nipple
19 038-1630-03-0 1 3/4 NPT Inline Check Valve
20 007-3370-00-0 1 Universal Mounting Adapter

6-25
 Muscle Pumps

6-26
 Muscle Pumps

PARTS LIST HALE TYPE PVG PRIMING VALVE

FIGURE 6-9
ITEM NO. PART NO QTY DESCRIPTION

1 012-0160-00-0 1 Handle
2 018-1104-02-0 2 Screw-#10-32 x 1/2 Lg. Hex Hd. Zinc Pl. Stl. Cap
3 018-1205-44-0 2 Screw-1/4-20 x 5/8 Lg. P.H. Rd. Hd. SST. Mach
4 018-1612-54-0 1 Screw-3/8-16 x 1-1/4 Lg. Soc. Hd. Stl. Knurled Pt. Set.
5 038-0171-00-0 1 Body-Valve
6 040-1139-03-0 1 Ring-Body Seal
7 040-2090-03-0 1 Ring-Piston Seal
8 040-2140-03-0 1 Ring-Body Seal
9 042-0091-00-0 1 Spring
10 073-0041-00-0 1 Piston-Valve
11 097-0160-01-0 2 Washer-Lock
12 097-0170-00-0 1 Washer-Valve Piston
13 101-0050-00-0 1 Plate-Instruction
14 200-0020-00-0 1 Switch-Priming Valve

6-27
 Muscle Pumps

PARTS LIST HALE TYPE K HEAT EXCHANGER

FIGURE 6-10
ITEM NO. PART NO QTY DESCRIPTION

1 018-1406-02-0 8 Screw – 5/16-18 X 3/4 Lg. Cad. Pl. Stl. Hex Cap
2 018-1412-02-0 1 Screw – 5/16-18 X 1-1/4 Lg. Cad. Pl. Stl. Hex Cap
3 044-0670-00-0 1 Header – Heat Exchanger
4 046-5970-00-0 1 Gasket – Header
5 046-5980-00-0 2 Gasket – Connector
6 048-0510-00-0 2 Sleeve – 5/16 In. O.D. Tubing
7 082-3004-00-0 2 Connector-1/4 In. NPT Female x 5/16 O.D. Tube
8 108-0180-00-0 1 Body – Heat Exchanger
9 115-0800-01-0 * Connector – 1-1/4 "B" Cooler
115-0800-02-0 * Connector – 1-1/2 "C" Cooler
115-0800-03-0 * Connector – 1-3/4 "D" Cooler
115-0800-04-0 * Connector – 2 "E" Cooler
115-0800-05-0 * Connector – 2-1/4 "F" Cooler
115-0800-06-0 * Connector – 2-1/2 "G" Cooler
10 217-0201-00-0 1 Plug – 1/4 NPT M.I.
11 507-0150-00-0 1 Coil – Heat Exchanger Cooler

*NOTE: (2) CONNECTORS REQUIRED PER ASSEMBLY IN ANY COMBINATION

6-28
Muscle Pumps

6-29
 Muscle Pumps

PARTS LIST HALE TYPE TRV/TRVM SERIES RELIEF VALVE

FIGURE 6-11
ITEM NO. PART NO QTY DESCRIPTION

1 010-0580-00-0 1 Strainer – Inlet

2 018-1607-58-0 1 Screw – Adjusting
3 038-1251-00-0 1 Element – Temperature (120o F/49o C)
038-1251-01-0 1 Element – Temperature (170o F/77o C)
4 038-1280-00-0 1 Body – (TRV 120) (1-1/4 NPT)
038-1280-03-0 1 Body – (TRV170) (1-1/4 NPT)
038-1280-01-0 1 Body – (TRVM) (ISO 228/1-G 1-1/4)
5 040-0250-07-0 2 Ring – Piston Seal
6 042-0540-00-0 1 Spring – Piston
7 064-0322-02-0 1 Pin – Spring (TRV170 Only)
8 073-0100-00-0 1 Piston
9 077-1180-20-0 1 Ring – Spring Retaining
10 077-9024-20-0 1 Ring – Element Retaining
11 217-0101-13-0 1 Plug – 1/8 NPT Soc. Hd. Brass (not used when TRV-L Kit installed)

PARTS LIST TRV-L KIT

12 082-0145-02-0 1 Elbow – 1/8 NPT x 1/4 FNPT Reducing Street

13 082-0146-02-0 1 Fitting – 1/8 NPT x 1/8 FNPT
14 101-1720-00-0 1 Nameplate – Test Switch and Light
15 200-0120-04-0 1 Switch – Push Button
16 200-0540-02-0 1 Bulb – Only
17 200-0540-13-0 1 Lens – Red
18 200-0540-16-0 1 Body – Indicator Light
19 200-2560-00-0 1 Switch – Foammaster
20 513-0360-01-0 1 Wire Harness

OPTIONAL AUDIBLE ALRM FOR TRV-L KIT

21 200-1310-00-0 1 Alarm – Audible

OPTIONAL FLANGE FOR MOUNTING TRV ON MIDSHIP PUMP (NOT SHOWN)

018-1812-02-0 4 Screw – 7/16-14 x 1-1/4 Lg. Hex Hd. Zinc Pl. Stl. Cap
046-0050-00-0 1 Gasket – Flange
115-1260-00-0 1 Flange – 1-1/4 NPT

6-30
Muscle Pumps

6-31
 Muscle Pumps

PARTS LIST HALE TYPE PG30 RELIEF VALVE

FIGURE 6-12
ITEM NO. PART NO QTY DESCRIPTION

1 018-1104-02-0 1 Screw-#10-32 x 1/2 Lg. Hex Hd. Zinc Pl. Stl. Mach.
2 018-1110-02-0 1 Screw-#10-32 x 1 Lg. Hex Hd. Zinc Pl. Stl. Mach.
3 018-1814-02-0 8 Screw-7/16-14 x 1-1/2 Lg. Hex Hd. Zinc Pl. Stl. Cap
4 018-1816-02-0 4 Screw-7/16-14 x 1-3/4 Lg. Hex Hd. Zinc Pl. Stl. Cap
5 019-0110-00-0 1 Guard-Switch
6 038-0281-00-0 1 Body-Relief Valve
7 038-1010-01-0 1 Valve
8 040-1149-00-0 1 Ring-Cover Seal
9 040-1160-03-0 1 Ring-Valve Seal
10 040-2340-00-0 1 Ring-Piston Seal
11 042-0020-00-0 1 Spring-Valve
12 046-0050-00-0 2 Gasket-Flange
13 046-6250-00-0 1 Gasket-Cover
14 073-0190-01-0 1 Piston-Relief Valve
15 077-0620-44-0 1 Ring-Spring Retaining
16 077-0750-21-0 1 Ring-Piston Retaining
17 082-0107-02-0 1 Connector-1/8 NPT to 3/8 Tubing Compression
18 097-0160-01-0 2 Washer-#10 Zinc Pl. Stl. Lock
19 097-0250-00-0 4 Washer-Flat Zinc Pl. Stl.
20 097-0440-00-0 2 Washer-Valve Mounting
21 097-0990-00-0 1 Washer-Spring Zinc Pl. Stl.
22 110-7610-00-0 1 Nut - 9/16-18 Stamped Stl
23 110-1100-02-0 2 Nut-#10-32 Hex Zinc Pl. Stl.
24 115-0080-00-0 1 Flange-3 NPT
25 513-0421-00-0 1 Flasher Assembly
26 200-2271-00-0 1 Switch-Pilot Light
27 242-0081-00-0 1 Strap-Switch
28 544-0100-00-0 1 Cover-Relief Valve
29 242-0510-14-0 1 Strap - Flasher

6-32
Muscle Pumps

6-33
 Muscle Pumps

PARTS LIST HALE TYPE SV SENSING VALVE

FIGURE 6-13
ITEM NO. PART NO QTY DESCRIPTION

1 010-0080-01-0 1 Strainer-Relief Valve Control

2 018-1412-02-0 4 Screw-5/16-18 x 1-1/4 Lg. Hex Hd Zinc Pl. Stl. Cap
3 018-1820-02-0 1 Screw-7/16-14 x 2 Lg. Hex Hd. Zinc Pl. Stl. Cap
4 038-1290-00-0 1 Valve-Sensing Needle
5 038-1550-00-0 1 Valve-Check
6 042-0560-00-0 1 Spring-Sensing Valve
7 044-1220-00-0 1 Cover-Sensing Valve
8 046-0130-00-0 1 Diaphragm-Control Body
9 082-0210-02-0 1 Nipple-1/4 NPT Brass Close
10 097-0220-00-0 1 Washer-Diaphragm Support
11 242-0750-00-0 1 Clamp-Sensing Valve
12 538-1431-00-0 1 Body-Sensing Valve

6-34
 Muscle Pumps

PARTS LIST HALE TYPE PM/PMD CONTROL VALVE

FIGURE 6-14
ITEM NO. PART NO QTY DESCRIPTION

562-0800-00-0 - PM CONTROL VALVE (Used with QD & QG Relief Valve Systems)

562-0081-00-0 - PMD CONTROL VALVE (Used with TPM Relief Valve System)
1 018-1422-02-0 4 Screw-5/16-18 X 2-1/4 Lg. Hex Hd. Zinc Pl. Stl. Cap
2 038-0191-00-0 1 Valve-Control
3 041-0241-00-0 1 Stem-Adjusting
4 042-0100-00-0 1 Spring-Inside
5 042-0110-00-0 1 Spring-Outside
6 046-0130-00-0 1 Diaphragm-Control Body
7 062-0090-00-0 1 Housing-Spring
8 064-6310-00-0 1 Pin-Indicator
9 077-1120-40-0 1 Ring-Bearing Washer Retaining
10 082-0107-02-0 1 Connector-Compression 1/8 NPT To 3/8 Tubing
11 082-0206-02-0 1 Connector-Compression 1/4 NPT To 3/8 Tubing
12 097-0180-00-0 1 Washer-Bearing
13 097-0220-00-0 1 Washer-Diaphragm Support
14 097-1150-00-0 1 Washer-Sealing
15 101-0010-00-0 1 Tag-Instruction (Not Shown)
16 110-7011-00-0 1 Nut-Adjusting
17 242-0050-00-0 1 Clamp-Diaphragm
18 250-8002-00-0 1 Bearing-Thrust
512-0070-00-0 1 Wheel-Adjusting (Assembly)
19 012-0170-00-0 1 Wheel-Adjusting
20 012-0180-00-0 1 Handle-Wheel
21 018-1214-45-0 1 Screw-1/4-20 X 1-1/2 Slotted Rd. Hd Zinc Pl. Steel Mach.
22 064-1016-01-0 1 Pin-Spring
23 110-1205-11-0 1 Nut-1/4-20 Esna Nylon Lock 300 Series Stainless
24 538-0790-00-0 1 Body-Control (Assembly)
038-0181-00-0 1 Body-Control (Included in 538-0790-00-0)
250-9140-00-0 1 Bearing-Pm Control (Included in 538-0790-00-0)
519-0071-10-0 1 Indicator-PMD Control (Used on PMD Control in TPM Relief Valve System)
25 519-0071-00-0 1 Bracket-Control Valve Indicator
26 048-1121-00-0 1 Slide-Control Valve Indicator
27 097-0750-01-0 1 Washer
28 110-1008-06-0 1 Nut-Lock
29 010-0080-01-0 1 Strainer-Relief Valve Control
30 018-1205-44-0 4 Screw-1/4-20 X 5/8 Lg. Rd. Hd. Sst. Philips Head Mach.
31 101-0062-00-0 1 Plate-Instruction
101-0062-01-0 1 Plate-Instruction (Used on PM Control in QD & QG Relief Valve Systems)
32 200-0540-03-0 1 Light-Indicator (Assembly) (Amber)
200-0540-02-0 1 Bulb-14V, 0.24AMP, 3.4W, 2CP
200-0540-12-0 1 Body-Indicator Light
200-0540-15-0 1 Lens-Yellow (Amber)

6-35
 Muscle Pumps

6-36
 Muscle Pumps

PARTS LIST HALE TYPE QD RELIEF VALVE

FIGURE 6-15
ITEM NO. PART NO QTY DESCRIPTION

1 018-1104-02-0 2 Screw-#10-32 X 1/2 Lg. Hex Hd. Zinc Pl. Stl. Mach.
2 018-1822-02-0 4 Screw-7/16-14 X 2-1/4 Lg. Hex Hd. Zinc Pl. Stl. Cap
3 038-0090-00-0 1 Valve-Relief Valve
4 038-0100-00-0 1 Body-Relief Valve
5 040-1149-00-0 1 Ring-Cover Seal
6 040-1160-03-0 1 Ring-Piston Seal (Small)
7 040-1570-00-0 1 Ring-Valve Body Seal
8 040-2390-00-0 1 Ring-Piston Seal (Large)
9 040-2420-00-0 1 Ring-Valve Body Seal
10 042-0020-00-0 1 Spring-Valve
11 073-0010-00-0 1 Piston-Relief Valve
12 077-0620-44-0 1 Ring-Spring Retaining
13 077-0750-21-0 1 Ring-Piston Retaining
14 082-0206-02-0 1 Connector-Compression 1/4 NPT to 3/8 Tubing
15 097-0160-01-0 2 Washer-#10 Zinc Pl. Stl. Lock
16 097-0990-00-0 1 Washer
17 110-1100-02-0 2 Nut-#10-32 Zinc Pl. Stl. Hex
18 200-2450-00-0 1 Switch-Indicator Light
19 242-0011-00-0 1 Bracket-Switch
20 242-0081-00-0 1 Strap-Switch
21 544-0010-00-0 1 Valve-Relief Valve (Assembly)
044-0120-00-0 1 Cover-Relief Valve
048-0050-00-0 1 Sleeve-Relief Valve Cover
22 110-7610-00-0 1 Nut - 9/16-18 Stamped Stl.
23 064-1040-02-0 1 Pin

6-37
 Muscle Pumps

6-38
 Muscle Pumps

PARTS LIST HALE TYPE QG RELIEF VALVE

FIGURE 6-16
ITEM NO. PART NO QTY DESCRIPTION

1 018-1812-02-0 4 Screw-7/16-14 x 1-1/4 Lg. Hex Hd. Zinc. Pl. Stl. Cap
2 038-0101-00-0 1 Body-Relief Valve
3 040-1130-03-0 1 Ring-Piston Seal
4 040-2130-03-0 2 Ring-Relief Valve Seal
5 040-2390-00-0 2 Ring-Piston & Cover Seal
6 040-2420-00-0 1 Ring-Valve Body Seal
7 042-0550-00-0 1 Spring-Valve
8 044-0122-00-0 1 Cover-Relief Valve
9 073-0011-00-0 1 Piston-Relief Valve
10 077-0750-21-0 1 Ring-Piston Retaining
11 077-3930-00-0 1 Ring-Cover Retaining
12 082-0107-02-0 1 Connector-Compression 1/8 NPT to 3/8 Tubing
13 200-2262-00-0 1 Switch-Proximity
14 200-2650-00-0 1 Collet Fitting
15 538-1400-00-0 1 Valve-Relief Valve
16 038-1550-00-0 1 Valve-Check
17 082-0137-02-0 1 Nipple-1/8 NPT Hex
18 082-0206-02-0 1 Fitting-1/4 NPT x 3/8 Tube
19 082-0207-02-0 1 Tee-1/4 NPT x 1/4 FNPT x 3/8 tube compression
20 082-0214-02-0 1 Bushing-1/4 NPT x 1/8 NPT Brass
21 082-0230-02-0 1 Tee-1/4 x 1/4 x 1/8 NPT Brass
22 082-0257-02-0 1 Elbow-1/4 NPT Brass Service
23 082-3051-00-0 1 Orifice-QG Relief Valve
24 046-0080-00-0 1 Gasket-Relief Valve Body

6-39
 Muscle Pumps

PARTS LIST HALE ANTI-CORROSION ANODE

FIGURE 6-17
ITEM NO. PART NO QTY DESCRIPTION

1 529-0080-00-0 1 Kit-Anode
2 029-0510-00-0 1 Anode-Zinc (Assembly)
3 115-1260-00-0 1 Flange-Hale 115
4 046-0050-00-0 1 Gasket-Hale 115 Series
5 018-1812-02-0 4 Screw-7/16-14UNC x 1-1/4 Hex Hd. Cap

6-40
 Muscle Pumps

PARTS LIST HALE TYPE 30BPF TANK SUCTION VALVE

(LESS CHECK VALVE)
FIGURE 6-18
(ASSEMBLY PART NO. 538-0132-00-0)
ITEM NO. PART NO QTY DESCRIPTION

1 012-0080-00-0 1 Handle-Valve
2 018-1204-61-0 1 Screw-1/4-20 x 1/2 Flt Pt. Nylon Lock Zinc Pl. Stl. Set
3 018-1810-02-0 6 Screw-7/16-14 x 1 Lg. Hex Hd. Zinc Pl. Stl. Cap
4 018-2012-02-0 4 Screw-1/2-13 x 1-1/4 Lg. Hex Hd. Stl. Zinc Pl. Cap
5 018-8040-00-0 2 Stud-Body
6 039-0030-00-0 1 Ball-Valve
7 040-2109-00-0 2 Ring-Stem Seal
8 040-3390-01-0 1 Ring-Seat Seal
9 046-0060-00-0 1 Gasket-Body
10 064-1032-11-0 1 Pin-Handle
11 101-0480-00-0 1 Tag-Instruction
12 110-1800-02-0 1 Nut-7/16-14 Zinc Pl. Steel Hex
13 142-0530-00-0 1 Ring-Cover Seal
14 276-0020-00-0 1 Seat-Valve
15 538-1070-00-0 1 Body-Valve (Assembly)
16 038-0050-01-0 1 Body-Valve
17 040-0240-00-0 1 Ring-Seal
18 250-9400-00-0 1 Bearing-Valve Body
19 544-0110-00-0 1 Cover-Valve (Assembly)
20 044-0060-01-0 1 Cover-Valve
21 250-9400-00-0 1 Bearing-Valve Cover

TANK SUCTION CHECK VALVE

22 038-0120-00-0 1 Valve-Check (Bronze) (Optional)

When the 038-0120-00-0 check valve is used with a 3” or 4” NPT tank connection flange, furnish (1)
115-0130-00-0 check valve flange and (1) 046-0060-00-0 additional gasket.
A 4” NPT flange is not available on the Q series pump.

6-41
 Muscle Pumps

6-42
 Muscle Pumps

PARTS LIST HALE TYPE 40BD SERIES VALVE LINE

40BD MANUAL CONTROL VALVE
40BD HANDLE CONTROL VALVE
40BD ELECTRIC CONTROL VALVE
STANDARD PARTS
FIGURE 6-19

ITEM NO. PART NO QTY DESCRIPTION

538-1680-01-0 1 Valve-40BD Electric Control

538-1680-00-0 1 Valve-40BDS Manual Control
538-1680-02-0 1 Valve-40BDS Handle Control

1 018-1810-02-0 8 Screw-7/16-14 X 1 In Lg. Hex. Hd.

2 038-1900-00-0 1 Body-Valve
♦3 039-0280-00-0 1 Valve-Ball
•4 040-1500-00-0 2 Seal-Collar
•5 040-2140-03-0 2 Seal-Stem
•6 040-3480-01-0 1 Seal-Valve Seat
•7 040-3620-00-0 1 Seal-Spacer
•8 276-0270-00-0 1 Seat-Valve
9 159-1530-00-0 1 Seat-Spacer
♦10 548-0040-00-0 1 Collar-Bottom (Assembly)
♦11 548-0050-00-0 1 Collar-Top (Assembly)
048-1360-00-0 1 Collar-Top
040-0290-00-0 1 Seal-Bearing
250-9560-00-0 1 Bearing

• Items Included in Valve Seal Kit (546-1940-01-0) and Valve Rebuild Kit (546-1940-02-0).
♦ Additional Items included in Valve Rebuild Kit (546-1940-02-0).

40BD VALVE SEAL KIT (546-1940-01-0) 40BD VALVE REBUILD KIT (546-1940-02-0)

040-1500-00-0 2 Seal-Collar 039-0280-00-0 1 Valve-Ball

040-2140-00-0 2 Seal-Stem 040-1500-00-0 2 Seal-Collar
040-3480-01-0 1 Seal-Valve Seat 040-2140-03-0 2 Seal-Stem
040-3620-00-0 1 Seal-Spacer 040-3480-01-0 1 Seal-Valve Seat
276-0270-00-0 1 Seal-Valve 040-3620-00-0 1 Seal-Spacer
046-0060-00-0 1 Gasket 276-0270-00-0 1 Seat-Valve
040-2620-00-0 2 Seal-Connection 046-0060-00-0 1 Gasket
046-0050-00-0 2 Gasket 040-2620-00-0 2 Seal-Connection
046-0050-00-0 2 Gasket
548-0040-00-0 1 Assembly-Bottom Collar
548-0050-00-0 1 Assembly-Top Collar

6-43
 Muscle Pumps

6-44
 Muscle Pumps

PARTS LIST HALE TYPE 40BDS SERIES VALVE LINE

40BD MANUAL CONTROL VALVE
40BD HANDLE CONTROL VALVE
40BD ELECTRIC CONTROL VALVE
OPTIONAL PARTS
FIGURE 6-20
ITEM NO. PART NO QTY DESCRIPTION

MANUAL GEAR OPERATOR ASSEMBLY

1 531-0190-00-0 1 Operator-40BD Manual Gear with Remote Placard

531-0160-00-0 1 Actuator-Manual Gear
008-0790-00-0 2 Switch-Cap
097-0140-01-0 2 Washer-3/8 Lock
200-2450-00-0 2 Switch-Shift
064-6600-00-0 2 Pin
018-1607-02-0 4 Screw-3/8-16 x 7/8 Lg.
097-0680-01-0 4 Washer-3/8
018-0803-29-0 4 Screw-#8-32 x 3/8 Lg.

ELECTRIC GEAR OPERATOR ASSEMBLY

2 531-0180-00-0 1 Operator-40BD Electric Gear

531-0150-00-0 1 Actuator-Electric Gear
200-2450-00-0 2 Switch-Shift
008-0790-00-0 2 Switch-Cap
064-6600-00-0 2 Pin
110-1601-02-0 2 Nut-3/8-16
044-1480-00-0 1 Cover-Motor
018-0604-45-0 4 Screw-#6-32 x 1/2 Lg.
200-1240-00-0 1 Breaker-Circuit
048-1080-01-0 1 Pad-Breaker Mounting
013-1360-00-0 1 Wire-White
200-1250-00-0 1 Motor-Gear
018-0604-08-0 4 Screw-#6-32 x 1/2 Lg. Soc. Hd.
218-0608-08-0 4 Screw-M6-1 x 16 Soc. Hd.
064-6350-00-0 1 Pin-Drive
007-3330-00-0 1 Adapter-Motor
018-1607-02-0 4 Screw-3/8-16 x 7/8 Lg.
097-0680-01-0 4 Washer-3/8
018-0803-29-0 4 Screw-#8-32 x 3/8 Lg.
513-0270-05-0 1 Harness-Gearmotor Wiring

6-45
 Muscle Pumps

PARTS LIST HALE TYPE 40BDS SERIES VALVE LINE

40BD MANUAL CONTROL VALVE
40BD HANDLE CONTROL VALVE
40BD ELECTRIC CONTROL VALVE
OPTIONAL PARTS (CONTINUED)
FIGURE 6-20
ITEM NO. PART NO QTY DESCRIPTION

HANDLE ASSEMBLY

3 512-0480-00-0 1 Assembly-40BDS Handle

005-1230-00-0 1 Plate-Stop
012-1470-00-0 1 Handle-Valve
018-1404-02-0 1 Screw-5/16-18 X 1/2 Lg. Hex Hd. Zinc Pl. Stl. Cap
018-2010-02-0 3 Screw-1/2-13 X 1 Lg. Hex Hd. Zinc Pl. Stl. Cap
097-0580-00-0 3 Washer-1/2 Lock
097-1850-00-0 1 Washer-Handle
077-0870-04-0 1 E-Ring-Handle

CONNECTOR ASSEMBLIES

4 544-0250-00-0 1 Assembly-5” NST Valve With RV

044-1700-00-0 1 Connector-5” NST Valve With RV (Short)
044-1700-10-0 1 Connector-5” NST Valve With RV (Long)
018-1812-02-0 4 Screw-7/16-14 X 1-1/4 Lg.
538-1550-00-0 1 Valve-Relief
101-1560-00-0 1 Tag-Relief Valve Caution
046-0060-00-0 1 Gasket

5 544-0250-01-0 1 Assembly-5” NST Valve Connector

044-1700-01-0 1 Connector-5” NST Valve (Short)
044-1700-11-0 1 Connector-5” NST Valve (Long)

6 544-0250-02-0 1 Assembly-5” Vic/4” NPT Connector

044-1680-00-0 1 Connector-5” Vic/4” NPT

7 544-0250-03-0 1 Assembly-4” Vic Connector

044-1690-00-0 1 Connector-4” Vic

Each of the above connector assemblies include the following:

8 040-2620-00-0 1 Seal-Connection
9 217-4010-00-0 1 Cap-Thread
10 242-1000-00-0 1 Clamp-V-Band

6-46
 Muscle Pumps

PARTS LIST HALE TYPE 40BDS SERIES VALVE LINE

40BD MANUAL CONTROL VALVE
40BD HANDLE CONTROL VALVE
40BD ELECTRIC CONTROL VALVE
OPTIONAL PARTS (CONTINUED)
FIGURE 6-20
ITEM NO. PART NO QTY DESCRIPTION

MOUNT ASSEMBLIES

11 544-0260-00-0 1 Assembly-Straight 8-Bolt Mount

044-1650-00-0 1 8-Bolt Mount-Straight

12 544-0260-01-0 1 Assembly-3.5° 8-Bolt Mount

044-1660-00-0 1 8-Bolt Mount-3.5°
018-1810-91-0 8 Screw-7/16-14 X 1 Lg.
046-0060-00-0 1 Gasket

13 544-0260-02-0 1 Assembly-Straight 4-Bolt Mount

044-1670-00-0 1 4-Bolt Mount-Straight
018-1810-91-0 4 Screw-7/16-14 X 1 Lg.
046-0050-00-0 1 Gasket

Each of the above connector assemblies include the following:

6-47
 Muscle Pumps

PARTS LIST HALE TYPE 40BD SERIES VALVE

LOOSE PART KITS
FIGURE 6-20
ITEM NO. PART NO QTY DESCRIPTION

MANUAL 40BD VALVE LOOSE PARTS KIT (546-1930-00-0)

14 513-0410-01-0 1 Assembly- Remote Bushing Placard

037-2180-00-0 1 Shaft-Remote Pla card
250-9570-00-0 1 Bearing-Placard
040-0220-00-0 1 O-Ring-Placard
048-1380-00-0 1 Sleeve-Placard Bushing
088-0270-00-0 1 Joint-Universal
018-1014-29-0 1 Screw-#10-24 X 1-1/2 In. Lg. Hex. Hd.
097-1350-00-0 1 Washer-#10 External Tooth
110-1000-02-0 1 Nut-#10-24 Hex
15 512-0070-00-0 1 Assembly-Handwheel
16 513-0410-00-0 1 Assembly-Manual Valve Panel Placard Harness
101-1770-00-0 1 Placard-Manual Valve
513-0370-00-0 1 Placard-Side Wire Harness (Manual Valve)
200-0540-02-0 3 Bulb
200-0540-13-0 1 Lens-Red
200-0540-14-0 1 Lens-Green
200-0540-15-0 1 Lens-Amber
200-0540-16-0 3 Body-Indicator Light
018-1205-44-0 4 Screw-1/4-20 x 5/8 Lg.
110-1200-02-0 4 Nut-1/4-20
17 513-0430-00-0 1 Assembly-Manual Relay Harness
513-0370-01-0 1 Harness-Gear Actuator Side (Manual Valve)
200-2640-00-0 2 Relay
18 513-0270-04-0 1 Harness-Power
088-0270-00-0 1 Joint-Universal
018-1014-29-0 3 Screw-#10-24 X 1-1/2 In. Lg. Hex. Hd.
110-1004-06-0 3 Nut-#10-24 Lock
101-0850-54-0 1 Instructions-Installation

ELECTRIC 40BD VALVE LOOSE PARTS KIT (546-1930-01-0)

19 513-0390-00-0 1 Assembly- Electric Placard

101-1770-01-0 1 Placard-Electrical
513-0370-02-0 1 Harness-Placard Side (Electric Valve)
200-0540-02-0 3 Bulb
200-0540-13-0 1 Lens-Red
200-0540-14-0 1 Lens-Green
200-0540-15-0 1 Lens-Amber
200-0540-16-0 3 Body-Indicator Light
200-1220-00-0 1 Switch-Momentary Toggle
018-1205-44-0 4 Screw-1/4-20 x 5/8 Lg.

6-48
 Muscle Pumps

PARTS LIST HALE TYPE 40BDS SERIES VALVE LINE

LOOSE PART KITS FIGURE 6-20 (CONTINUED)
ITEM NO. PART NO QTY DESCRIPTION

ELECTRIC 40BD VALVE LOOSE PARTS KIT (546-1930-01-0) (CONTINUED)

110-1200-02-0 4 Nut-1/4-20
20 513-0430-01-0 1 Harness-Electrical Relay (Assembly)
513-0370-03-0 1 Harness-Gear Actuator Side (Electric Valve)
200-2640-00-0 2 Relay
18 513-0270-04-0 1 Harness-Power
19 012-1420-00-0 1 Handle-Override
018-1212-61-0 1 Screw-1/4-20 x 1-1/4 In. Lg.
101-0850-54-0 1 Instructions-Installation

VALVE OVERRIDE EXTENSION KIT (546-1950-00-0)

101-1770-02-0 1 Placard-Manual Override

018-1205-44-0 4 Screw-1/4-20 x 5/8 Lg.
110-1200-02-0 4 Nut-1/4-20
041-0570-00-0 1 Shaft-Valve Gear Operator Extension
018-1212-02-0 1 Screw-1/4-20 x 5/8 In. Lg. Hex Hd.
110-1206-02-0 1 Nut-1/4-20 Lock

40BD REMOTE OVERRIDE PLACARD KIT (546-1950-01-0)

513-0400-00-0 1 Assembly-Electric Override Placard Remote Bushing

088-0270-00-0 1 Joint-Universal
018-1014-27-0 3 Screw-#10-24 X 1-1/2 In. Lg. Hex. Hd.
110-0114-06-0 3 Nut-#10-24 Lock
101-0850-54-0 1 Instructions-Installation

6-49
 Muscle Pumps

6-50
 Muscle Pumps

PARTS LIST HALE TYPE HD DRAIN VALVE

FIGURE 6-21
ITEM NO. PART NO QTY DESCRIPTION

1 012-0010-00-0 1 Knob-Valve
2 038-0380-00-0 1 Body-Valve
3 040-1140-03-0 2 Ring-Piston Seal
4 073-0180-00-0 1 Piston-Valve
5 077-0810-10-0 1 Ring-Piston Retaining

6-51
 Muscle Pumps

PARTS LIST HALE TYPE DV5 DRAIN VALVE

FIGURE 6-22
ITEM NO. PART NO QTY DESCRIPTION

1 005-0260-00-0 1 Plate-Piston Stop

2 012-0010-00-0 1 Knob-Valve Piston
3 018-1205-44-0 2 Screw-1/4-20 x 5/8 Lg. Rd. Hd. SST P.H. Mach.
4 038-1110-00-0 1 Body-Drain Valve (Assembly)
5 038-1110-01-0 1 Body-Drain Valve
6 040-2180-00-0 1 Ring-Body Seal
7 040-2130-03-0 1 Ring-Piston Seal
8 073-0200-00-0 1 Piston-Valve Handle

6-52
 Muscle Pumps

PARTS LIST HALE TYPE DV7 DRAIN VALVE

FIGURE 6-23
ITEM NO. PART NO QTY DESCRIPTION

1 021-5000-00-0 1 Universal Joint

2 038-5031-00-0 1 Body-Drain Valve
3 046-7020-00-0 1 Seat-Drain Valve
4 064-0414-02-0 2 Pin-1/8 Dia. X 7/8 Lg. SST
5 077-9020-20-0 2 Ring-Retaining
6 082-5030-00-0 1 Fitting-Grease
7 097-5051-00-0 1 Washer-Seat Retaining
8 097-5060-00-0 2 Washer-Thrust
9 012-5071-00-0 1 Knob-Drain Valve (With 10-32NF X 3/8 Lg. Dog Point SST Setscrew)
10 041-5001-00-0 1 Stem-Drain Valve

538-1650-00-0 - Assembly-Hale Type DV7 Drain Valve (Without Knob, Item No. 9)
538-1650-01-0 - Assembly-Hale Type DV7 Drain Valve (With Universal Joint, Item
No.1, and Knob, Item No. 9)
538-1650-02-0 - Assembly-Hale Type DV7 Drain Valve (With Knob, Item No. 9)

6-53
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6-54
 Muscle Pumps

PARTS LIST HALE TYPE VPS CONTROL VALVE

FIGURE 6-24
ITEM NO. PART NO QTY DESCRIPTION

1 007-0080-01-0 1 Cylinder-Shift
2 018-1410-02-0 2 Screw-5/16-18 x 1 Lg. Hex Hd. Stl. Zinc Pl. Cap
3 018-1412-63-0 2 Screw-5/16-18 x 1-1/4 Lg. Soc. Hd. Stl. Flt. Pt. Zinc Pl. Set
4 018-1810-23-0 2 Screw-7/16-14 x 1 Lg. Counter-Bore 360° Nylon Lkg. Stl. Zinc Pl. Cap
5 037-1341-00-0 1 Shaft-Gearshift
6 040-0410-01-0 1 Ring-Cylinder Cover Seal
7 040-1139-03-0 1 Ring-Piston Inner Seal
8 040-2109-00-0 2 Ring-Gearshift Shaft Seal
9 040-3349-00-0 1 Ring-Piston Outer Seal
10 044-0210-01-0 1 Cover-Cylinder
11 046-5060-00-0 1 Gasket-Shifting Cylinder
12 073-0020-01-0 1 Piston-Cylinder
13 077-0750-05-0 2 Ring-Piston Retaining
14 110-1400-02-0 2 Nut-5/16-18 Zinc Pl. Stl. Hex
15 296-0020-00-0 1 Scraper-Gearshift Shaft

14 11
4
9
3
10

7
8

15 13
5
8
6

2 1

12

Figure 6-24. VPS Power Shift

6-55
 Glossary

Atmospheric Pressure caused by the elevation of air above the earth.

Pressure

Auxiliary Permits water from a pump to cool the radiator water through a heat exchange.
Cooling Valve

Capacity Pump flow rating.

Cavitation Caused by the pump attempting to deliver more water than is being supplied. This causes the
formation of water vapor, and liquid water, under pressure, rushes in to fill the empty space.
This damages the pump.

Centrifugal Force that tends to make rotating bodies move away from the center of rotation.
Force

Centrifugal A pump that uses a rapidly spinning disk to create the pressure for water movement.
Pump

Certification Pumper test in accordance with NFPA standards to determine if a pump can deliver its rated
volume and pressure.

Check valve In two stage pumps, there are two swing check or flap valves in the suction passage of the
second stage. They are located in each side of the pump between the suction tube and the
pump body. These valves swing open when pumping in parallel for volume. They are
closed by first stage pressure when pumping in series for pressure.

Clearance Prevent discharge water from returning to the eye of the impeller.
Rings

Compound A compound gauge is graduated to read pressure in pounds per square inch and vacuum in
Gauge inches of mercury.

Double Water enters on both sides of the impeller.

Suction
Impeller

Dry prime Provides information on the ability of a pump to evacuate air and draft water.
Test

Eye, Impeller Point where water enters the impeller.

Flow Meter Measures the volume of water flowing.

Friction Loss of pressure in hose, fittings, standpipes, and other appliances because of the
Loss resistance between the water molecules and the inside surfaces of hoses, fittings,
standpipes, and other appliances.

Front-mount Pump mounted ahead of the engine.

Pump

G- 1
 Glossary

Gauge Pressure read from a gauge (PSIG).

Pressure

Governor Minimizes pressure changes by controllin g engine speed.

Horsepower A measure of mechanical work.

Impeller The working part of a centrifugal pump that, when rotating, imparts energy to water.
Essentially, an impeller consists of two disks separated by curved vanes. The vanes force the
water to move outward between the disks so that it is thrown outward at high velocity by
centrifugal force.

Net Pump The difference in pressure between discharge and suction pressure.
Pressure

Packing Material that maintains an airtight seal at point where the impeller shaft enters and exits
the pump body.

Parallel Capacity position in which each impeller on a two-stage pump works independently into
the discharge.

Pitot Gauge Measures velocity head at the discharge of a nozzle.

Positive A pump with a fixed flow delivered to the discharge with each revolution.
Displacement
Pump

Positive Pressure above atmospheric.

Pressure

Power Valve A valve that uses hydraulic pressure to transfer pump operation from volume to transfer
pressure and vice area.

Pressure Force per unit area.

Pressure The pressure gauge is usually graduated in pounds per square inch only. It is connected
Gauge to the pump discharge manifold, thus indicating pump discharge pressure.

Priming Priming evacuates the air from the main pump and suction hose, thus creating a vacuum.
This allows atmospheric pressure on the source of water to push the water up into the
suction hose and pump.

Priming A positive displacement pump that creates a vacuum to prime the main pump.
Pump

Priming A valve located in the priming line between the priming pump and the main pump. It
Valve remains closed at all times except when priming. The control is located on the
pump panel.

G- 2
 Glossary

Pump Shift A midship pump is usually mounted with a split gearbox installed in the drive shaft.
The pump shift moves a sliding gear in the gearbox that transmits power either to the
pump or the rear axle. In road position, power is transmitted to the rear axle for driving; in
pump position, the rear axle is disconnected, and power is transmitted to the pump shaft.

Relay Movement of water from apparatus at a water source to additional apparatus until water
Reaches the fire ground.

Relief Valve An automatic valve which, when activated by the relief valve control, will hold pump
pressure steady when discharge valves or shutoff nozzles are closed. The valve maintains
its given pressure by dumping the pump discharge flow into the pump suction.

Relief Valve A handwheel adjustment valve which, set to control the desired pressure, will control the
Control relief valve to maintain the working pressure.

Series Pressure position in which the first impeller’s discharge is fed to the eye of the second
Impeller in a two-stage pump which then discharges the water from the pump.

Service Test Pump test performed to determine if the apparatus can deliver its rated volume and pressure.

Shrouds Sides of an impeller that confine the water.

Slinger Ring Prevents water from continuing to travel down a shaft to the gears and ball bearings.

Stages The number of impellers in a pump that are used in series; that is, one following another
in terms of flow. Each impeller develops part of the total pump pressure.

Tachometer Indicates the speed of the engine crankshaft in revolutions per minute.

Torque The force that acts to produce rotation.

Transfer A two-position valve in a pump that changes the operation from parallel (volume) to series
Valve (pressure) operation and vice versa (not used on single stage pumps).

Vanes Guides inside an impeller that direct water to the volute.

Volute Gradually increasing discharge waterway.

Water Amount of work that a pump can perform.

Horsepower

Wear Rings See Clearance rings.

G- 3
 Data for Practical Use

APPENDIX A
WATER HORSE POWER=GALLONS PER MINUTE X TOTAL HEAD IN POUNDS PER SQUARE INCH

ONE GALLON OF WATER WEIGHS 8.33 POUNDS

ONE GALLON = 231 CUBIC INCHES

ONE CUBIC FOOT = 7.48 GALLONS

ONE POUND PER SQUARE INCH OF HEAD = 2.31 FEET OF WATER

ONE INCH OF MERCURY = 1.132 FEET OF WATER

ONE POUND PER SQUARE INCH = 2.0178 INCHES OF MERCURY = 27.68 INCHES OF WATER

POUNDS PER SQUARE INCH = FEET HEAD X .433

FEET HEAD = POUNDS PRESSURE X .231

ONE GALLON PER MINUTE X 3.785 = ONE LITER PER MINUTE

ONE CUBIC METER = 1000 LITER

ONE IMPERIAL GALLON = 1.2 GALLONS

ONE POUND PER SQUARE INCH X .0690 = ONE BAR = .001 KPA

CONVERSIONS:

TO CONVERT TO MULTIPLY BY

GALLONS LITERS 3.785

PSI BARS 0.06895

BARS PSI 14.504

Ft-Lb (Torque) N-m 1.3558

HP KW 0.7457

A
 Limited Warranty
EXPRESS WARRANTY: Hale Products Inc. (“Hale”) hereby warrants to the original buyer that products manu-
factured by it are free of defects in material and workmanship for two (2) years or 2000 hours usage whichever
shall first occur. The “Warranty Period” commences on the date the original buyer takes delivery of the product
from the manufacturer.

LIMITATIONS: HALE’S obligation is expressly conditioned on the Product being:

• Subjected to normal use and service.

• Properly maintained in accordance with HALE’S Instruction Manual as to recommended services and
procedures.
• Not damaged due to abuse, misuse, negligence or accidental causes.
• Not altered, modified, serviced (non-routine) or repaired other than by an Authorized Service Facility.
• Manufactured per design and specifications submitted by the original Buyer.

THE ABOVE EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS WARRANTIES ARE
MADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED WARRANTIES INCLUDING, WITHOUT
LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR
PURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; OR PATENT INFRINGEMENT
FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER’S DESIGN AND SPECIFICATIONS.

EXCLUSIVE REMEDIES: If Buyer promptly notifies HALE upon discovery of any such defect (within the War-
ranty Period), the following terms shall apply:

• Any notice to HALE must be in writing, identifying the Product (or component) claimed defective
and circumstances surrounding its failure.
• HALE reserves the right to physically inspect the Product and require Buyer to return same to
HALE’S plant or other Authorized Service Facility.
• In such event, Buyer must notify HALE for a Returned Goods Authorization number and Buyer
must return the Product F.O.B. within (30) days thereof.
• If determined defective, HALE shall, at its option, repair or replace the Product, or refund the
purchase price (less allowance for depreciation).
• Absent proper notice within the Warranty Period, HALE shall have no further liability or obligation
to Buyer therefore.

THE REMEDIES PROVIDED ARE THE SOLE AND EXCLUSIVE REMEDIES AVAILABLE. IN NO EVENT
SHALL HALE BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE’ INCLUDING, WITHOUT
LIMITATION, LOSS OF LIFE; PERSONAL INJURY; DAMAGE TO REAL OR PERSONAL PROPERTY DUE TO
WATER OR FIRE; TRADE OR OTHER COMMERCIAL LOSSES ARISING, DIRECTLY OR INDIRECTLY, OUT
OF PRODUCT FAILURE.

Hale Products Inc. • A Unit of IDEX Corporation

700 Spring Mill Avenue • Conshohocken, PA. 19428
Phone: 610-825-6300 • Fax: 610-825-6440
IDEX CORPORATION www.haleproducts.com
 Hale Products Factory Authorized Service Centers
Haleís Factory Authorized Service Centers are ready to service your pump with
factory trained mechanics and a stock of parts to ensure that your apparatus is
ready for action. Contact a dealer near you for quick, dependable service.
____ ALABAMA ____ GEORGIA Southland Fire & Safety
Harless Fire Equipment Fireline Inc. 1918 S. Southland Avenue
P O Box 671 385A Framer Court Gonzales, LA 70737
1166 Faimund Muscoda Lawrenceville, GA 30045 504-621-3473
Bessemer, AL 35020 770-682-4446
205-425-1160
____ MASSACHUSETTS
Fouts Bros. Fire Equipment Greenwood Fire Apparatus !
North American Fire ! 2158 Atlanta Street
1515 West Moulton Street Smyrna, GA 30080 530 John Dietsch Blvd.
Decatur, AL 35601 770-433-0112 North Attleboro, MA 02763-1080
256-353-7100 508-695-7138
Southern Fire
____ ARIZONA P O Box 512 ____ MAINE
United Fire Equipment ! Jasper, GA 30143 Reliance Equipment
335 N. 4 th Avenue 706-692-7319 RR1, Box 211
Tucson, AZ 85705 Box 6622B
520-622-3639 _______ ILLINOIS Vaassalboro, ME 04989
Alexis Fire Apparatus 207-626-0075
____ CALIFORNIA 109 East Broadway
Burtonís Fire Apparatus Alexis, IL 61412 ____ MICHIGAN
1301 Doker Drive, Building B 309-482-6121
Modesto, CA 95351 Apollo Fire !
209-544-3161 12584 Lakeshore Dr.
Mid America Truck & Equip. Romeo, MI 48065
625 South Route 83 810-752-1800
Hi-Tech E.V.S. Inc. ! Elmurst, IL 60126
444 W. Greger Street 630-834-7300
Oakdale, CA 95361 Front Line Services
209-847-3042 8588 Carter Road
Towers Fire Apparatus Freeland, MI 48623
502 S. Richland St. 517-695-6633
KME West Freeburg, IL 62243
2831 E. Philadelphia 618-539-3863
Ontario, CA 91761 West Shore Services Inc.
909-937-3326 620 Lake Michigan Drive
Banner Fire Equipment P. O. Box 188
4601 Hedge Road
Los Angeles Freightliner East Alton, IL 62024 Allendale, MI 49401
1049A South Vineyard Ave. 618-251-4200 616-895-4347
Ontario, CA 91761
909-606-9100 _____ INDIANA ____ NEW JERSEY
Hoosier Fire Equipment Tasc Fire Apparatus
____ CONNETICUT 5012 Industrial Road
4009 Montdale Park Drive
American LaFrance of N.E. Farmingdale, NJ 07727
Valparaiso, IN 46383
199 Roberts St. 732-938-3393
219-462-1707
East Hartford, CT 06108
(860) 610-6202 Fire & Safety Services
WSF Emergency Vehicle 50 Shelton Road
Repair and Maintenance Piscataway, NJ 08854
____ DELAWARE 10677 Old Boon Highway
Delmarva American LaFrance 732-752-2400
Chandler, IN 47610
335 Strauss Ave ! 812-925-7595
Marydel, DE 19964 ____ NEW MEXICO
302-492-1245 Artesia Fire Equipment
____ IOWA 1014 South First Street
____ FLORIDA Toynes Fire Truck ! P. O. Box 1367
Elite Fire & Safety Equipment! East Main, Box 16 Artesia, NM 88210
3573 Enterprise Ave. #64 Breda, IA 51436 505-746-2426
Naples, FL 33942 712-673-2328
800-432-3626
KANSAS
Conrad Fire Equipment
Municipal Equipment ! 887 North Jan-Mar Court
1124 S. Woods Avenue Olathe, KS 66061
Orlando, FL 32805 913-780-5521
407-843-3071

Ten-8 Fire Equipment ! ____ LOUISIANA

2904 - 59 Avenue Drive E Casco Industries
Bradenton, FL 34203 P O Box 8007
941-756-7779 Shreveport, LA 71148
318-865-5107

Hale Products, A Unit of IDEX Corp, 700 Spring Mill Avenue, Conshohocken, PA 19428
TEL: 610/825-6300 FAX: 610/825-9615 Rev 10/02. Visit our Internet site at: www.haleproducts.com
!= 24 Hour Emergency Paging Service
 Hale Products Factory Authorized Service Centers
Haleís Factory Authorized Service Centers are ready to service your pump with
factory trained mechanics and a stock of parts to ensure that your apparatus is
ready for action. Contact a dealer near you for quick, dependable service.
____ NEW YORK Sutphen Corporation Jack L. Slagle Fire
Churchville Fire Equipment! 7000 Marysville Road Equip. & Supply Co.!
340 Sanford Road Amlin, OH 43002 1100 Bill Tuck Highway
Churchville, NY 14428 614-889-1005 South Boston, VA 24592
716-293-1688 434-575-7905
____ OKLAHOMA
Firematic Supply Co.! Chief Fire & Safety Vestís Sales and Service Inc.
10 Ramsay Road 927 South 4th Street 1185 Stonwall Road NE
Shirley, NY 11967 Chickasha, OK 73018 Check, VA 24072
631-924-3181 405-224-2596 540-651-8452

Garrison Fire & Safety! ____ PENNSYLVANIA ____ WASHINGTON

Route 23A, Main St. East Penn Fire & Emergency ! United Fire Service !
Palenville NY 12463 P. O. Box 299 1500 19th Ave NW
518-678-2281 Pottsville, PA 17901 Issaquah, WA 98027
570-429-1016 425-392-1622
Har-Rob Fire Apparatus!
519 Liberty Street Glick Fire Equipment ! _____ WEST VIRGINIA
Syracuse, NY 13204 307 Airport Drive
315-422-0730 Smoketown, PA 17576 All-American Fire Equipment !
717-299-4120 3253 US Route 60 East
Hendrickson Truck Center P. O. Box 146
1026 E. Jericho Turnpike Guardian Fire Equipment ! Ona, WV 25545
Huntington Station, NY 11788 215 E. Hancock St. 304-733-3581
631-424-8354 Lansdale, PA 19446
215-855-2000 ____ WISCONSIN
Nassau Fire Apparatus Service! Rennerts Fire Equipment !
67 Albany Avenue Halo Srevice Company 615 East John St.
Amityville, NY 11701 9 Jackson Avenue Marksean, WI 53946
631-789-2205 Colllingdale, PA 19023 920-398-1033
610-237-0619
Nichols Fire Apparatus !
P. O. Box 651 Honesdale Fire Equipment !
Hyde Park, NY 12538 140 Grandview Avenue CANADA
845-229-8181 Honesdale, PA 18431 Aero-Feu, Ltd
570-253-5037 615 Blvd. Guimond
____ NORTH CAROLINA Industrial Park
C.W. Williams Company Kaza Fire Equipment ! Longueuil, PQ
501 Instrument Drive 155 Lovell Avenue Canada J4G 1L9
P O Box 7757 Suite 1 450-651-2240
Rocky Mount, NC 27804 Ebensburg, PA 15931
919-977-9241 814-472-8650 Darch Fire
9-402 Harmony Road
Triad Transportation Sales ____ SOUTH CAROLINA R.R. #1
c/o West Carolina Freightliner Jack Slagle Fire Equipment Ayr, Ontario, Canada
6712 Freedom Drive P O Box 21984 N0B 1E0
Charlotte, NC 28214 Cayce, SC 29171 519-622-6110
877-815-1925 803-791-4555
Phoenix Emnergency Vehicles
____ OHIO ____ TENNESSEE #5 7870 - 48th Avenue
American National Fleet Service Fire Apparatus Services
Red Deer, AB, Canada
7714 Commerce Park Oval ! 115 Haywood Lane
Antioch, TN 37011 T4P 2B2
Independence, OH 44131 403-347-7045
866-353-3863 615-833-9031

____ TEXAS Profire Emergency Equipment

Cummins-Bridgeway LLC Fire Apparatus Specialist 30686-A South Fraser Way
2297 Southwest Blvd, Suite K 1215 Mississippi Abbotsford, BC, Canada
Grove City, OH 43123 South Houston, TX 77587 V2T 6L4
248-573-1600 713-941-0909 604-852-2510
Finley Fire Equipment ____ VIRGINIA
20 South 5th St. American Fire Equip.
McConnelsville, OH 43756 13720 Dabney Road
740-962-4328 Woodbridge, VA 22191
703-491-2990

Revised 7/17/03
Let Us Put Out A Few Fires For You.

IDEX CORPORATION
Fighting Fires Is Your Business.
Looking Out For Your Pump Is Ours.
Few things in life are more reliable than your new Hale
midship pump. We do our best to keep it that way, too, with
our standard two-year/2,000-hour warranty.
Now we’re going ourselves one better, with an extended
warranty that can keep your Hale midship pump covered for
up to five whole years.
We call it the Pro•Tech Maximum Warranty. It’s an
exceptional value in long-term protection and peace of mind.

Buy More, Pay Less.

With the Pro•Tech Maximum Warranty, you can choose your own coverage in one-year
increments. And the longer your coverage, the lower your annual cost.
You can buy one year for $350, two years for $675, or three years for $1,000.
Whichever term you choose, you’ll get the same coverage that makes our standard
warranty great — and lots more time to make the most of it. (For details, check the actual
Limited Warranty text on the next page.)

There’s A Sixty-Day
Deadline.
Strong as the Pro•Tech Maximum Warranty is, it’s only as good as
your commitment to maintaining and caring for your new Hale
Two Years/2,000 Hours
pump. So we must ask you to begin that process by committing to
an extended warranty within sixty days of placing your new pump
in service. One Year/1,000 Hours
Just complete the form on the opposite page, tear it off, fold it Two Years/2,000 Hours
as indicated, and return it to us with your check. Keep the upper
Three Years/3,000 Hours
portion for your records.
And if you have any questions, please feel free to call us at
610/825-6300 — and ask for our Warranty Department. Five Years/5,000 Hours
Keep This Portion For Your Records. extended warranty period commences two (2) years after the date the
Product is first placed in service — that is, upon the date on which the
Pump Model #:______________________________________________ standard warranty expires. The length of the extended warranty
period (one year/1,000 hours, two years/2,000 hours, or three
Pump Serial #: ______________________________________________ years/3,000 hours) shall be as selected and purchased by the original
buyer of the product.
Dealer Purchased From: ______________________________________
Limitations: Hale’s obligation is expressly conditioned on the Product being
Date: _______________________________________________________ • Subjected to normal use and service;
• Properly maintained in accordance with Hale’s Instruction Manual and
Apparatus Manufacturer: _____________________________________ the Hale Midship Recommended Maintenance List as to recommended
services and procedures (documentation may be required);
Date Placed In Service:________________________________________ • Not damaged due to abuse, misuse, negligence or accidental causes;
• Not altered, modified, serviced (non-routine) or repaired other
Express Warranty: In addition to the standard two-year/2,000-hour
than by an Authorized Service Facility;
limited warranty provided at no charge, Hale Products, Inc. (“Hale”)
• Manufactured per design and specifications submitted by the
hereby warrants to the original buyer that split-shaft midship type
original Buyer.
pumps manufactured by it are free of defects in material and
workmanship for the additional warranty period selected. The (Continued on other side.)

Midship Pump Registration Form

Complete and return (with your check payable to Hale Products, Inc.) to the address below.

Equipment Description Purchasing Company/Department

Pump Model #: ______________________________________ Name: ______________________________________________

Pump Serial #: _______________________________________ Street: ______________________________________________

Dealer Purchased From: _______________________________ City: ________________________ County: _______________

Dealer Salesman: _____________________________________ State: _______________________ Country: ______________

Date: _______________________________________________ Zip/Postal Code:______________________________________

Apparatus Manufacturer: _____________________________ Authorized Signature: ________________________________

Engine Model: _______________________________________ Today’s Date: ________________________________________

Transmission Model:__________________________________ Extended Warranty Period/Payment Enclosed (check one):

Date Placed In Service: ________________________________ ■ Two years/2,000 hours — No Charge

Vehicle Type (check one): ■ Additional One year/1,000 hours — $350

■ Pumper ■ Aerial ■ Tanker ■ Additional Two years/2,000 hours — $675

■ Tanker Pumper ■ Mini Pumper ■ Rescue Pumper ■ Additional Three years/3,000 hours — $1,000

HALE PRODUCTS, INC. • 700 Spring Mill Avenue • Conshohocken, PA 19428

(Continued from other side.) • If determined defective, Hale shall, at its option, repair or replace
the Product, or refund the purchase price (less allowance for
THIS EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS depreciation);
WARRANTIES ARE MADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED • Absent proper notice within the Warranty Period, Hale shall have
WARRANTIES, INCLUDING WITHOUT LIMITATION, THE IMPLIED no further liability or obligation to Buyer therefore.
WARRANTIES OF MERCHANTABILITY; FITNESS FOR A PARTICULAR
PURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; THE REMEDIES PROVIDED ARE THE SOLE AND EXCLUSIVE REMEDIES
OR PATENT INFRINGEMENT FOR A PRODUCT MANUFACTURED TO AVAILABLE. IN NO EVENT SHALL HALE BE LIABLE FOR INCIDENTAL OR
ORIGINAL BUYER’S DESIGN AND SPECIFICATIONS. CONSEQUENTIAL DAMAGES INCLUDING, WITHOUT LIMITATION, LOSS
OF LIFE; PERSONAL INJURY; DAMAGE TO REAL OR PERSONAL
Exclusive Remedies: If Buyer promptly notifies Hale upon discovery of PROPERTY DUE TO WATER OR FIRE; LOSS OF TIME OR USE OF THE
any such defect (within the Warranty Period), the following terms PRODUCT; INCONVENIENCE; TRADE OR OTHER COMMERCIAL LOSSES
shall apply: ARISING, DIRECTLY OR INDIRECTLY, OUT OF THE PRODUCT FAILURE.
• Any notice to Hale must be in writing, identifying the Product (or
component) claimed defective and circumstances surrounding its
failure;
• Hale reserves the right to physically inspect the Product and
require Buyer to return same to Hale’s plant or other Authorized
Service Facility;
Hale Products, Inc.
• In such event, Hale will provide a Returned Goods Authorization 700 Spring Mill Ave. TEL: (610) 825-6300
and Buyer must return the Product F.O.B. within thirty (30) days Conshohocken, PA 19428 FAX: (610) 825-6440
thereof;

HALE PRODUCTS INC. A Unit of Idex Corporation

700 Spring Mill Ave. • Conshohocken, PA • USA • 19428
TEL: (610) 825-6300 • FAX: (610) 825-6440

Printed in U.S.A. Bulletin #539 Rev. 3, 02/00

IDEX CORPORATION