029-0020!53!0-a booster pumps - operation & maintenance manual for ap, cbp, 2cbp

Operation andMaintenance Manual for

Hale Booster PumpsAP

CBP2CBP

Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation. Hale Products is responsible only to the limits stated in the product warranty. Product specifications contained in this material are subject to change without notice.

HALE PRODUCTS, INC. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 TEL: 610-825-6300 FAX: 610-825-6440 MANUAL P/N 029-0020-69-0, REV B, 2002 HALE PRODUCTS, INC., MANUAL P/N 029-0020-53-0, REV A

ECO NO REV CHANGED FROM BY DATE APVD 02-0301 A RELEASED SAG 10/15/02 MAL

HALE PRODUCTS, INC

A Unit of IDEX Corporation Conshohocken, PA 19428 USA

DRAWN BY: SAG ISSUE DATE: CHECKED BY: PRW 10/15/02

COPYRIGHT NOT TO BE REPRODUCED OR USED TO

MAKE OTHER DRAWINGS OR MACHINERY

9615

Booster

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ContentsSECTION I: INTRODUCTION .................................................................... I-1Overview............................................................................................................................................................. I-1

Principals Of Operation ......................................................................................................................... I-1Centrifugal Force .................................................................................................................................. I-1Pump Stages ........................................................................................................................................ I-2Two-Stage Booster Pump ..................................................................................................................... I-3

Components of a Booster Pump ........................................................................................................................ I-3Pump Body........................................................................................................................................... I-3Impeller and Shaft Assembly ................................................................................................................ I-3 Mechanical Seal .................................................................................................................................. I-4Gearbox ................................................................................................................................................ I-4Pump Drives ......................................................................................................................................... I-4

Accessories ....................................................................................................................................................... I-5Auxiliary Cooling (Overheat Protection) ................................................................................................ I-5Priming Systems .................................................................................................................................. I-5Priming the Pump ................................................................................................................................. I-5Priming Valves ...................................................................................................................................... I-6 Pressure Control .................................................................................................................................. I-6Thermal Relief Valveb (TRV) .................................................................................................................. I-7Anodes ................................................................................................................................................. I-7

Explanation of Terms ......................................................................................................................................... I-8

SECTION II OPERATING PROCEDURES................................................2-1Stationary Pumping Operations ........................................................................................................................ 2-1

Pumping From a Hydrant(General Operation) ....................................................................................................................... 2-1

Draft limiting factors ............................................................................................................................. 2-2Pumping from Draft .............................................................................................................................. 2-2

Pump and Roll Operation .................................................................................................................................. 2-4Relief Valve Procedures .................................................................................................................................... 2-4

TPM /P35 Relief Valve Procedures .................................................................................................... 2-4Process of Cavitation ........................................................................................................................................ 2-5

Warning Signs of Cavitation: Discharge and Gauges .......................................................................... 2-6Discharge Pressure ............................................................................................................................. 2-6Vacuum Compound Gauge .................................................................................................................. 2-6How to Prevent Cavitation .................................................................................................................... 2-6During Operations: ............................................................................................................................... 2-6Preventive Measures: ........................................................................................................................... 2-6

Post Operation procedure ................................................................................................................................. 2-8

SECTION III PREVENTIVE MAINTENANCE ............................................3-1Overview............................................................................................................................................................ 3-1Post-Operation Maintenance Procedures ......................................................................................................... 3-1Weekly Maintenance ........................................................................................................................................ 3-1

Relief Valve Testing .............................................................................................................................. 3-1Valve Maintenance ............................................................................................................................... 3-2Verify all Gauges are in Working Order. ............................................................................................... 3-2Inspect Water and Foam Tanks. .......................................................................................................... 3-2

Monthly Maintenance ....................................................................................................................................... 3-3Gearbox Lubrication ............................................................................................................................. 3-3Priming System Test (Dry Vacuum Test)

(Refer to NFPA 1901 or NFPA 1911) .............................................................................................. 3-3Annual Pump Maintenance ............................................................................................................................... 3-4

Booster

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Replace Gearbox Oil ........................................................................................................................... 3-4Tank to Pump Flow Rate Test .............................................................................................................. 3-4Performance Testing Overview ............................................................................................................. 3-5Worn Clearance Rings and Impeller Hubs ........................................................................................... 3-8

Extreme Conditions Maintenance Guidelines ................................................................................................... 3-8

SECTION IV: TROUBLESHOOTING .......................................................4-1SECTION V MAINTENANCE AND REPAIR...............................................5-1Overview............................................................................................................................................................ 5-1General Repair Guidelines ................................................................................................................................ 5-1

Cleaning and Inspection Guidelines ..................................................................................................... 5-1Recommended Cleaners...................................................................................................................... 5-3

Pump Components ........................................................................................................................................... 5-3Pump and Gearbox Assembly ............................................................................................................. 5-3Remove the Pump from the Apparatus ................................................................................................. 5-3AP Pump Disassembly ....................................................................................................................... 5-5AP Pump Body.................................................................................................................................... 5-5Remove AP Pump Body ...................................................................................................................... 5-5Install the Pump body .......................................................................................................................... 5-5AP IMPELLER AND MECHANICAL SEAL .......................................................................................... 5-5Remove AP Impeller ............................................................................................................................. 5-5Remove AP Mechanical Seal .............................................................................................................. 5-6Reinstall AP Mechanical Seal .............................................................................................................. 5-6Reinstall the AP Impeller ...................................................................................................................... 5-6REMOVE AP PUMP HEAD................................................................................................................. 5-6REINSTALL AP PUMP HEAD.............................................................................................................. 5-7AP Gearbox ......................................................................................................................................... 5-8Disassemble AP Gearbox .................................................................................................................... 5-8Reassemble and Reinstall AP Gearbox ............................................................................................... 5-8

CBP Pump Repair ........................................................................................................................................... 5-11CBP Pump Body ................................................................................................................................ 5-11Remove CBP Pump Body................................................................................................................... 5-11 Reinstall CBP Pump Body ................................................................................................................ 5-11CBP IMPELLER AND MECHANICAL SEAL ....................................................................................... 5-11Remove CBP Impeller ......................................................................................................................... 5-11Reinstall CBP Impeller ....................................................................................................................... 5-12REMOVE CBP MECHANICAL SEAL ................................................................................................ 5-12Reinstall CBP Mechanical Seal ........................................................................................................ 5-12CBP PUMP HEAD ............................................................................................................................ 5-12REMOVE CBP PUMP HEAD ............................................................................................................ 5-12Reinstall CBP Pump Head................................................................................................................. 5-13CBP GEARBOX................................................................................................................................. 5-13Remove and Disassemble CBP Gearbox........................................................................................... 5-13Reassemble and Reinstall CBP Gearbox .......................................................................................... 5-14

2CBP Pump Repair ........................................................................................................................................ 5-16Disassemble the 2CBP Pump from the Gearbox Assembly ............................................................ 5-16Reassemble Pump to Gearbox .......................................................................................................... 5-16Disassemble the 2CBP Gearbox ....................................................................................................... 5-18Reassemble and Reinstall 2CBP Gearbox ........................................................................................ 5-19

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SECTION VI: PARTS LISTS ......................................................................6-1AP Pump ............................................................................................................................................. 6-2CBP Pump ........................................................................................................................................... 6-52CBP Pump ......................................................................................................................................... 6-8Hydraulic Adapter ........................................................................................................................................... 6-12Tachometer Option.......................................................................................................................................... 6-13

Introduction Sec I-1

Booster Pumps

SECTION I:INTRODUCTIONOVERVIEW

Hale Products currently has 3 models of boosterpumps in production:

o APo CBPo 2CBP

Unless otherwise indicated, these procedureswill apply to all models of Hale booster pumps:Any variations in operations and maintenance ofthe different models will be addressed within thecontext of this manual.

Hale booster pumps are the favorite of firefighters throughout the world. Booster pumpscan be used as initial attack pumps or asauxiliary pumps in conjunction with theapparatus main pump. Covering a range ofcapacities from 20 Gallons Per Minute (GPM)(76 Liters per Minute, LPM) to 500 GPM (1,893LPM), Hale booster pumps offer the versatility,dependability, reliability, and ease of operationso necessary to effective fire fighting.

Hale Booster Pumps are of a compact size andlightweight design for easy mounting on theapparatus chassis. The pump is coupled to thegearbox and the apparatus builder need onlysupply the transmission PTO (power takeoff)and connecting shaft.

Principles Of Operation

This section reviews the principles of operationof Hale booster pumps and provides adescription of the pump components.

Centrifugal Force

Hale booster pumps are centrifugal pumps thatoperate on the principle that centrifugal force iscreated by a rapidly spinning disk. Figure 1-1

shows an amount of water has been placed atthe center of a disk. The disk is rotated andthe water is thrown outward from the center tothe edge of the disk. The velocity at which thewater travels from the center directly relates tothe diameter of the disk and the speed ofrotation. When water is confined in a closedcontainer (such as the pump body), the velocityis converted to pressure; pressure is therefore,dependant on the speed of rotation.

There are three inter-related factors thatregulate the performance of a centrifugal pump:

o Speed (RPM): If the speed of rotationincreases with the flow held constant, the waterpressure increases.

o Pressure: Pressure is usually measuredin pounds per square inch (PSI) or (BAR). Ifpressure changes and speed is constant, theflow will change inversely. That is, if pressureincreases, flow decreases.

o Flow: Flow is usually measured in thenumber of gallons of water per minute (GPM)or liters per minute (LPM) that a pump candeliver when supplied from draft. If thepressure is held constant, the flow will increasewith an increase in the speed of rotation.

Figure 1-1: Centrifugal forcefrom a rotating disk

Sec I- 2 Introduction

Booster Pumps

The centrifugal pump is preferred by the fireprotection service due to its ability to fully utilizeany positive inlet pressure, reducing the strainon the pump.

For example, if the required discharge pressureis 120 PSI (8 BAR), and the inlet pressure is 45PSI (3 BAR), the pump must only produce thedifference in pressure of 75 PSI (5 BAR). Thiscontributes to low engine and pump speedswhich reduces wear on the pump. Anotherimportant benefit is the centrifugal pump hasbasically only two moving parts; the impellerand the shaft.

Pump Stages

The number of impellers on a common shaftdetermines the number of pump stages. Halesingle-stage booster pumps use a singleimpeller to develop the required volume andpressure. Two stage pumps have two impellers

on a common shaft.

During operation water enters the suction eye ofthe impeller. The rotating impeller vanesdevelop discharge pressure and direct the waterto the discharge opening. The cutwater is awedge that divides the water between the volute(pump body) and the pump discharge.

There are three models of Hale booster pumps.(The anticipated use determines which model isselected.) The AP and CBP booster pumps aresingle stage and provide initial attack pumpperformance per NFPA 1901 standards. The2CBP is a two-stage series operation pump, isused as a high-pressure booster pump.

The available Booster Pump Models and theirflow capacities are shown in Table 1-1.Figure 1-2: Pump Stages

Figure 1-3: Single-stage Water Flow

Model Type Capacity Pressure

AP Single-Stage High Volume Attack Pump

100 to 700 GPM (379 to 2650 LPM) NFPA1901 Rated

@250 to 500 GPM (946 to 1893 LPM)

100 to 350 PSI (7 to 24 BAR)

CBP Single-Stage High

Volume Attack/Booster Pump

50 to 400 GPM (189 to 1514 LPM) NFPA1901 Rated @250 GPM (946 LPM)

100 to 400 PSI (7 to 28 BAR)

2CBP Two-Stage High Pressure Booster

Pump

20 to 100 GPM (76 to 379 LPM)

300 to 1000 PSI (21 to 69 BAR)

Table 1-1: Booster Pump Models and Capacities


Booster Pumps

Two-Stage Booster Pump

The Hale Two-Stage Booster Pump (2CBP)has two impellers connected in series for high-pressure operation. The output of the firstimpeller is supplied to the intake of the secondimpeller. This second impeller adds additionalpressure and directs the water to the discharge.Since the two-stage booster pump onlyoperates in series, the final water pressure isthe inlet pressure plus the pressure added byboth impellers. The volume of water deliveredat the discharge, however, is the same. Figure1-4 shows the flow of water through a Hale2CBP booster pump.

COMPONENTS OF A BOOSTER

PUMP

Booster pumps are made up of:

o Pump Bodyo Impeller and Shaft Assemblyo Mechanical Sealo Gearbox

Figure 1-5 shows these basic parts of a Hale

booster pump. These parts are brieflydescribed in the following section.

Pump Body

The Hale single-stage booster pump body is asingle-piece casting. Service of the impeller,clearance rings, and mechanical seal isaccomplished by removing the pump body fromthe pump head and gearbox.

The pump body is constructed from fine graincast iron. For areas where salt water iscommonly used, a bronze version of the boosterpump is available.

Impeller and Shaft Assembly

The impeller provides velocity to the water. Theimpeller is made of high quality bronze and ismounted on a stainless steel shaft that isrotated by the gearbox. Water enters therotating impeller at the intake (or eye). Thevanes guide water from the inlet to thedischarge. Vanes curve away from the directionof rotation so water moves toward the outeredge (see Figure 1-2). The shrouds form thesides of the impeller and keep the water

Figure 1-4: 2-Stage waterflow (Top half of 2CBP shown only.)

Figure 1-5: Parts of the Hale Booster Pump


Booster Pumps

confined to increase acceleration and pressure.

The discharging tube is widest at the pumpoutlet. The increasing discharge path, knownas the volute, collects the fast moving water andconverts the water's velocity into pressure.

Mechanical Seal

The mechanical seal is common to all Halebooster pumps. Shown in figure 1-6, astationary seat is in constant contact with arotating seal ring to prevent leakage. Thesealing diaphragm is made of a rubberelastomer specifically designed for high-temperature operations.

If a pump is operated without water forextended periods, or without discharging water,it may overheat. This may damage themechanical seal or the drive mechanism.

Gearbox

The gearbox is typically constructed of finegrain alloy cast iron. Inside the gearbox (Figure1-5) a gear set and input drive shaft made ofheat-treated nickel steel, transfers engine powerto the impeller. Hale offers a variety of pumpgear ratios to accommodate a wide range ofend-user and apparatus manufacturerrequirements based on the pump's intendeduse, horsepower and speed rating of the

engine, and the torque rating of thetransmission PTO.

Pump Drives

There are four common types of booster pumpdrives used on fire fighting apparatus:

1. The most common drive is the PTO mountedon the truck transmission or four-wheel drivetransfer case which allows for pump and rolloperation.

2. A stand-alone drive with separate engine(auxiliary engine).

3. The truck chassis engine crankshaft (front-engine PTO).

4. Hydraulic Motor

Hale booster pumps are built to produce thevolumes and pressures shown on theirrespective performance curves. However, thevolumes and pressures safely obtainable aredependent on the torque capacity of theapparatus transmission or transfer case, powertakeoff and the pump drive line. In most cases,the torque rating of the PTO determinesmaximum pump performance.

The apparatus builder can give various pumpperformance spots that will define the torquelimit of the PTO in terms of GPM and PSI.When pumping continuously, care should betaken not to overheat the apparatus' PTO,transmission or transfer case.

HALE Power Takeoff Pumps

Hale booster pumps are available for eitherengine rotation or opposite engine rotation PTOoperation. Additionally, the pump can beconfigured to discharge in a variety of positions.Since some PTOs match engine rotation andsome turn opposite of the engine rotation, eachpump model can be built to match the rotationof the PTO.

Figure 1-6: Mechanical Seal


Booster Pumps

NOTE: Please refer to Hale Bulletin #886 forfurther assistance in selecting the correctbooster pump PTO.

ACCESSORIES

In addition to the basic parts of Hale boosterpumps described above, the following items areavailable to enhance operation:

o Cooling Systemso Priming Systemso Pressure Control Deviceso Anodes

Auxiliary Cooling (Overheat Protection)

A cooler is available to protect the gearbox, theapparatus engine, and the pump.

The gearbox cooler (see Figure 1-7), circulatespump water to transfer heat from the gearbox oilto the pump discharge. It is standard equipmenton pumps with a capacity of 750 GPM or greaterand optional equipment on all other pumps.

Priming Systems

Priming the Pump

Priming pumps are used to evacuate air in thesuction hose and the pump. The vacuumcreated allows atmospheric pressure to pushwater from the static source through the suctionhose and into the pump. Hale booster pumpsuse Rotary Vane Positive Displacement typepumps for priming.

A priming pump draws air out of the pump bodyand discharge piping allowing water to enter.Shown in figure 1-8, the priming pump has arotor mounted off-center (eccentric) to thepump body housing. The vanes in the rotorslide in grooves and are held against the bodyhousing by centrifugal force. As a vane turnstoward the discharge, it recedes into the rotorcompressing the air. As the rotor continuespast the discharge, the vane advances outwardfrom the groove and against the body housing.During this cycle, the space between the rotorand housing case fills with air. The vanes,acting as wipers, force air out of the discharge,creating a vacuum inthe main pumpallowing atmosphericpressure to pushwater into the hoseand suction side ofthe pump. ESP Priming

Pump

Figure 1-8: Rotary Vane Priming Pump

Figue 1-7. This AP pump showsthe optional gearbox cooler (Thisoption available on CBP, and2CBP too.)


Booster Pumps

The Hale ESP-seriespriming pump is anenvironmentallyfriendly primer thatdoes not require aseparate lubricantreservoir. The vanesand pump body areself lubricating formaintenance free operation.

A Hale priming pump has a single control toopen the priming valve between the boosterpump and the priming pump, and start thepriming motor.

Priming Valves

Hale priming valves open when the primingpump is operated to allow the air to escape fromthe pump. There are two priming valvesavailable:

1. Hale Semi-Automatic Priming Valve forRemote Mounting (SPVR) A hose isconnected from the SPVR to the priming tapon the booster pump body. When the SPVRis installed, a single push-button on theoperators panel starts the priming pumpmotor. When a vacuum is created, theSPVR opens. Releasing the push-buttonstops the priming pump and the SPVRcloses. Figure 1-9

2. The Hale PVG Priming Valve (Figure 1 -10) is mounted on the pump operatorspanel. The PVG is a combination valve andswitch. When the handle on the PVG ispulled out, the valve opens and the switchenergizes the primer motor. Pushing thehandle de-energizes the motor and closesthe valve.

Pressure Control

The P Series relief valve system is a bronze,variable-pressure setting relief valve thatprevents undue pressure per the requirementsof NFPA Standard 1901. An indicator light onthe operator control panel signals when thevalve is open.

The P Relief Valve System

The P relief valve system consists of a panelmounted control valve (PM) and, depending onthe pressure rating of the pump, a P30, or P35relief valve mounted in the discharge piping andplumbed back to the pump suction. Valveconnections are either flanged or Victaulic tm.Both are shown in figure 1-12.

How the Relief System Works:

A bleeder line mounted in the pump dischargepressure tap provides pressure to thediaphragm in the PM control valve. Thehandwheel on the PM control either increasesor decreases the spring tension on thediaphragm. The seat of the P-series relief valveis kept closed by pump discharge pressure.

As pump pressure increases, more pressure is

Figure 1 -10: PVG Priming Valve

Figure 1 -9 : SPVR Priming Valve


Booster Pumps

applied to the diaphragm in the PM Controlvalve. As the pressure on the diaphragmincreases beyond the set point, the stem willmove off its seat, allowing pump pressure topush on the piston in the relief valve. Thepressure on the piston will cause the relief valveseat to liftallowingexcesspressure todump back tothe pumpsuction. Afterthe pressureequalizes, thepiston returnsto the closedposition.

The amberindicator light on the PM control illuminateswhen the relief valve is open.

Thermal Relief Valveb (TRV)

The Thermal Relief Valve (see Figure 1-11)protects the pump from overheating. Theoptional TRV unit can be attached to thedischarge piping either by flange mounting or 1-1/4" NPT threaded connection (38 mm for theTRVM). The valve monitors the temperature ofthe water in the pump. When the temperature

exceeds 120o F (48.9o C), the valveautomatically opens and depending on theinstallation, discharges a small amount of watereither to the ground or into the water tankallowing cooler water to enter. After thetemperature returns to a safe level, the valvecloses. The TRV will flow up to 1-2 GPM (3-7LPM).

TRV-L Kit

The TRV-L kit includes a chrome panel placardwith a warning lamp, lamp test button, and apreassembled wiring harness. The lightilluminates whenever the TRV is open anddischarging water. An optional buzzer providesaudible warning. The buzzer mounts on theoperator panel.

Anodes

The Hale Anode Systemhelps prevent damagecaused by galvanic corrosionin the pump. Galvanic actionpits the pump and pumpshaft material. The popularityof non-corrosive water tanksand piping has increased thistype of corrosion in todaysfire pumps. The Hale AnodeSystem is a sacrificial metal, which helpsprevent corrosion. The anode will fit on anyHale truck mounted pump, regardless of age ormodel. It is designed to be easily installedrequiring four bolts and a gasket. Total time toinstall is just fifteen minutes, yet it will provideyears of protection for the pump. The Anode kitis designed for installation in the standard Hale115 series flange opening. On fabricatedmanifolds and similar applications, the installeris to provide 1-1/4 NPT openings and installanodes directly. It is recommended that oneanode be installed on the suction side and oneon the discharge side.

Figure 1-11: TRV-L

Figure 1-13:Hale Anode

Figure 1-12:


Booster Pumps

EXPLANATION OF TERMS

Atmospheric Pressure

Static air pressure. Air pressure is 14 poundsper square inch at sea level. Pressure increasesbelow sea level and decreases above sea level.The weather also effects air pressure. Air in ahigh pressure area compresses and warms as itdescends. The warming inhibits the formation ofclouds, meaning the sky is normally sunny inhigh-pressure areas. But haze and fog stillmight form. Just the opposite occurs within anarea of low atmospheric pressure. Atmosphericpressure effects a pumps ability to pump fromdraft. Higher pressures will increase a pumpsperformance, while lower pressures can causea noticeable decrease in lift.

Cavitation

The sudden formation and collapse of low-pressure bubbles in liquids by means ofmechanical forces, such as those resulting fromrotation of a pump impeller.

Dead Heading

Operating a pump without any discharge. Lackof flow causes temperatures to rise inside thepump.

Impeller

The working part of centrifugal pumps whichimparts energy (motion) to the water.Essentially, an impeller consists of two discsseparated by curved vanes. The vanes forcethe water to rotate between the discs and isthrown outward at high velocity. The water fromthe impeller discharges into a divergingpassage known as a volute, converting the highvelocity energy of the water into pressure.

Priming Pump

An auxiliary positive displacement pump whichpumps air out of the booster pump creating avacuum in order to prime the pump. Thepriming pump is a rotary vane type, electricmotor driven. Once the main pump is primedand pumping, the priming pump is shut off.

Relief Valve

An automatic valve which, when activated bythe relief valve control will hold the pumppressure to no more than 30 PSI when thepump discharge is gated or closed. The valvemaintains a set pressure by diverting the pumpdischarge flow into the pump suction.

Relief Valve Control (PM)

A hand adjustment valve. When set to thedesired pressure, the relief valve will maintainthe desired pump discharge pressure and limita pressure increase to no more than 30 PSI (2BAR).

Volute

The increasing discharge path of the pump, itsfunction is to collect the water from the impellerand depending on its design can either increasepressure and decrease velocity or increasevelocity and decrease pressure.

Operating Procedures Sec II- 1

Booster Pumps

SECTION II OPERATINGPROCEDURES

This section supplies information andprocedures for the operation of Hale boosterpumps. Included in this section are proceduresfor pumping from an on-board tank, a hydrant,from draft, and post-operation procedures.

Unless otherwise indicated, these instructionsapply to all Hale booster pumps.

THE PROCEDURES IN THIS SECTION AREGENERAL OPERATING PROCEDURES. THEYDO NOT REPLACE LOCAL PROCEDURES ORPOLICIES, NOR DO THEY REPLACE THERECOMMENDATIONS AND PROCEDURESPROVIDED IN THE TRUCK MANUAL.

STATIONARY PUMPING OPERATIONS

Pumping From a Hydrant(General Operation)

1. Position the truck for the best hydrant hookupand discharge hose layout.

REFER TO DEPARTMENT PROCEDURESFOR SETTING WHEEL CHOCKS AND LAYINGOUT SUCTION AND DISCHARGE HOSES.

ALL VALVES, DRAIN COCKS, AND CAPSSHOULD BE CLOSED.

2. Bring the truck to a complete stop beforeattempting to shift from "road" to "pump".

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRALposition.

5. Engage the pump PTO switch.

DO NOT LEAVE THE CAB OR ATTEMPT TOPUMP UNTIL ALL "OK TO PUMP" LIGHTS INTHE CAB ARE ILLUMINATED. (Figure 2-1).

6. Exit the driving compartment only after all theabove steps are completed.

DO NOT OPEN THE THROTTLE UNLESSTHE GREEN INDICATOR LIGHT IS ON(Figure 2-2).

7. Verify the pump panel shift indicator light ison and that all hose connections are com-plete.

8. Open the hydrant. Bleed off the air from thesuction hose.

9. Open the suction valve.

10. If necessary to eliminate air pockets, primethe pump; see Pumping From Draft forinstructions.

Figure 2-1: Driver's CompartmentIndicator Lights

Sec II- 2 Operating Procedures

Booster Pumps

11. Advance the engine throttle gradually untilthe master discharge gauge indicates thedesired pressure.

DO NOT REDUCE THE PRESSURE ONTHE INTAKE GAUGE BELOW ZERO;SERIOUS DAMAGE TO THE WATER MAINCOULD RESULT.

The master intake gauge reading must bemaintained at 5 PSI (.3 BAR), minimum. If thegauge shows a vacuum the pump is attemptingto draw more water than the hydrant cansupply. When this occurs, reduce the pump flowto increase the pressure.

As the throttle is opened, the pressure gaugereading increases with the engine speed. If theengine speed increases without an increase inpressure, the pump is beginning to cavitate.Close the throttle slowly until the pressurebegins to drop, and the engine returns to an idle.

12. Set the automatic relief valve according todepartment policy. If no department policyexists, refer to the Relief Valve Procedureslater in this section.

13. If the pump overheats and it is not equippedwith a Hale TRV valve, open the valve toaccess the bypass line, if it is furnished, oropen the valve to the booster tank (bothsuction and discharge sides) to circulatewater.

14. After completion of pumping operations,gradually reduce the pump pressure until theengine is at idle speed. Disengage the PTO.

DRAFT LIMITING FACTORS

The effect of raised water temperatures whenpumping from a positive pressure source(hydrant) is negligible on fire pumpperformance. But when pumping from draft,elevated water temperature does have a limitingeffect. Water temperatures above 95o F (35o C)will cause a noticeable decrease in lift whendrafting. Another factor that can limit lift whendrafting is barometric pressures below 29 In ofHg. It is important to be aware of environmentalconditions when drafting.

PUMPING FROM DRAFT

1. Get as close to the water source as possible.The pump can draw 100% of its rated capac-ity with less than a 10 foot vertical lift. As thelift increases to above 10 feet, the pump

Water TemperatureFo (C)

Lift LossHead Ft (Meters)

60 (16) NFPA Baseline

70 (21) .3 (.09)

80 (27) .6 (.18)

90 (32) 1.1 (.335)

100 (38) 1.7 (.52)

110 (43) 2.5 (.76)

Table 2-1 : Additional Losses BeyondBaseline NFPA Rating

Figure 2-2: Pump Operator's Panel


Booster Pumps

Running the engine at speeds higher than1200 RPM during priming is not recom-mended since it will not improve primingoperation and may cause damage to thepump.

IF THE DISCHARGE GAUGE READING DOESNOT INCREASE, THE INTAKE GAUGEREADING DOES NOT FALL BELOW ZERO,OR THE PRIMING PUMP DOES NOTDISCHARGE WATER TO THE GROUND IN 30TO 45 SECONDS, DO NOT CONTINUE TORUN THE PRIMING PUMP. STOP THE PUMPAND CHECK FOR AIR LEAKS OR POSSIBLEPUMP TROUBLE.

10. Gradually open the discharge valve untilwater emerges in a steady stream. Thenopen the other discharge valves to thedesired setting.

11. Open the engine throttle gradually until thedesired pressure or flow is reached.

As the throttle is opened, increase the pressuregauge reading with engine speed. If the enginespeed increases without an increase inpressure, the pump is nearing cavitation.Cavitation will be discussed in detail later.Reduce the flow from the pump to maintainpressure or reduce the pressure (throttle) tomaintain flow.

13. If a pump shutdown is desired while pumpingfrom draft, reduce the engine speed to idle,and close the discharge valves. To resumepumping, open the throttle and dischargevalves.

14. Set the automatic relief valve according todepartment policy. Refer to the Relief ValveProcedures later in this section.

15. If the pump overheats and is not equippedwith the Hale TRV valve, open the valve toaccess the pump auxiliary cooling system, or

capacity will be reduced.

2. Bring the truck to a complete stop.

3. Apply the truck parking brake.

4. Shift the truck transmission to the NEUTRALposition.

REFER TO DEPARTMENT PROCEDURESON SETTING WHEEL CHOCKS AND HOSES.ALL VALVES, DRAIN COCKS, AND CAPSSHOULD BE CLOSED.

5. Engage pump PTO.

DO NOT LEAVE THE CAB OR ATTEMPTTO PUMP UNTIL ALL THE INDICATORLIGHTS IN THE CAB ARE ON.

6. Exit the driving compartment only after all theabove steps are completed and the indicatorlights in the cab and on the panel are on.

DO NOT ADVANCE THE THROTTLEUNLESS THE "OK TO PUMP" INDICATORLIGHT IS ON.

7. Verify the pump panel shift indicator light ison.

8. Activate the priming pump by pulling thecontrol handle located on the pump panel.

9. Monitor the intake and discharge mastergauges. The pump is primed when theintake indication reading falls below zero,and the discharge pressure starts to in-crease. Water may also be heard discharg-ing to the ground.


Booster Pumps

slightly open the drain line.

16. After completing pumping procedures,gradually reduce the engine RPM to idlespeed and disengage the PTO.

PUMP AND ROLL OPERATION

Hale booster pumps are primarily driven by atransmission mounted Power-Take-Off (PTO)unit.

During pump and roll operation, it is necessaryto slow the forward motion of the apparatus tothe PTO manufacturer's recommendedengagement speed.

The following outlines a general pump and rollprocedure:

1. Slow the apparatus to safe PTO engagementspeed as recommended by the PTO manu-facturer.

Note: Most PTOs must be engaged while theapparatus is stopped. Only a "Hot Shift" PTOcan be engaged while the apparatus is rolling.

2. Engage the PTO.

3. Verify the PUMP ENGAGED light is illumi-nated.

4. Open the valve between the tank and pumpsuction.

5. Observe pump discharge pressure and verifythe pump pressure increases.

6. Prime the pump if necessary.

7. Open the discharge valves and commenceoperations.

RELIEF VALVE PROCEDURES

TPM /P35 Relief Valve Procedures

These procedures cover the Hale TPM ReliefValve System. Be sure to select the correctprocedure, for the equipment on the truck.

1. Set the pressure indicator on the PMDcontrol valve to a position slightly above thenormal operating pressure (even beforewater starts to flow).

2. After normal operating pressure has beenachieved (as indicated on the master pres-sure gauge while the pump is dischargingwater), slowly move the adjusting handwheel counterclockwise until the relief valveopens, and the amber indicator light comeson.

3. Turn the hand wheel slowly clockwise untilthe indicator light goes out. The relief valvewill operate at the set pressure.

4. When the pump is not in operation, turn thehand wheel clockwise back to a positionslightly above the normal operating pressure.

Figure 2-3 PMD ReliefValve Control


Booster Pumps

More complete and detailed information canbe found in the relief valve manual.

THE PRESSURE INDICATOR ON THEPANEL IS ONLY A ROUGH INDICATIONOF TPM SETTING. ALWAYS USE THEABOVE PROCEDURE TO PROPERLY SETTHE TPM RELIEF VALVE SYSTEM.

CAVITATION

Cavitation can occur while pumping from draft,in relay, or from a hydrant. The operator must beaware of the warning signs and correct thesituation, or serious damage to the pump andimpeller will occur.

Cavitation can damage the impeller and othersensitive components, impair pumpperformance, and reduce flow capacity. Thedamage done during any one period ofcavitation is not great, but the effects arecumulative. Implosions occurring duringcavitation break away or erode tiny pieces ofmetal from the internal parts and the pumpcasing. When enough metal has been chippedaway, the impeller becomes unbalancedcausing a strain and vibration on bearings,bushings and shafts.

The way to eliminate cavitation is to increase theflow to the pump, decrease the amount of waterbeing discharged from the pump, or reduce thepressure in the pump by decreasing enginespeed.

Cavitation

Cavitation occurs when a centrifugal pump isattempting to discharge more water than it isreceiving. It is often referred to as the pumprunning away from the supply."

Process of Cavitation

1. When increased discharge demand exceedsthe intake, bubbles form in the low-pressureregion (eye) of the impeller.

2. The pressure of the water in the pump dropsas it flows from the suction flange throughthe suction nozzle and into the impeller.

3. As flow from the pump increases, thevacuum at the impeller increases. As thevacuum increases, the boiling point of waterin that vacuum decreases until it reaches apoint near the impeller eye where it boils andvaporizes.

4. Once the vapor pockets, or bubbles, enterthe impeller, the process begins to reverseitself. As the vapor reaches the dischargeside of the pump, it is subjected to a highpositive pressure and condenses back to aliquid.

5. The sudden change from vapor to liquidgenerates a shock effect that damages theimpeller and pump housing. Usually thereare thousands of tiny vapor pockets(bubbles) rather than a few large ones. It isthe collapsing (or implosion) of thesebubbles that causes the characteristic soundof cavitation that has been described asrocks tumbling in the pump.

Figure 2-4 Low Pressure Regions


Booster Pumps

Warning Signs of Cavitation: Dischargeand Gauges

Discharge Pressure

In a properly functioning pump, an increase inRPM will increase the discharge pressure andvolume. An increase in engine RPM that doesnot cause an increase in the pump dischargepressure, is the most reliable indication that apump is approaching cavitation.

Vacuum Compound Gauge

The operator should not depend entirely on thevacuum (compound) gauge to indicate when apump is nearing cavitation: The vacuum gaugeis usually tapped into the intake chamberseveral inches away from the leading edge ofthe impeller eye where the greatest amount ofvacuum occurs. The vacuum gauge does nottake into account ambient temperature noratmospheric pressure and is not accurate nearzero on the vacuum scale.

How to Prevent Cavitation

A soft sleeve has an advantage over a hardsleeve when pumping from a hydrant because itwill partially collapse providing an immediateindication to the operator that cavitation isimminent. A hard sleeve indicates problems onlyat the intake gauge which is not the best or mostreliable indicator.

Monitoring current operating conditions,knowing the capabilities of the equipment, andregular inspection are the best protectionagainst cavitation.

During Operations:

o Do not increase the pump speed beyond thespeed at which the pressure ceases to rise.

o Monitor the water temperature baseline perNFPA standards is 60 F (16 C). Table 2-1

illustrates the amount of lift loss astemperatures rise. If there is a marked lossof suction capacity, the pump may be nearcavitation.

NOTE: When water reaches 95 F( 35 C),the operator is likely to notice a markeddecrease in lift.

o Monitor barometric pressure. NFPAstandards sets a baseline of 29.9Hg. SeeTable 2-2.

o Location: The higher the elevation abovesea level, the lower the atmosphericpressure and less lift. See Table 2-3.

o Open the throttle gradually and watch the

pressure gauge and the tachometer, ifequipped. An increase in engine RPMwithout a corresponding increase inpressure indicates cavitation.

o Use a hard suction hose when pumping fromdraft and soft suction hose when pumpingfrom hydrant.

Preventive Measures:

o Regularly inspect discharge and suctionhoses to check for air leaks: these can also

Barometric Readingin (mb)

Lift-loss in Head Feet(meters)

29.9 (1012.53) NFPA Baselines

29.7 (1005.76) .2 (.06)

29.5 (999) .5 (.15)

29.3 (992.21) .7 (.21)

29.1 (985.444) .9 (.27)

28.9 (978.67) 1.1 (.33)

28.7 (971.89) 1.4 (.43)

Table 2-2 : Lift-Loss from Barometric Pressure


Booster Pumps

cause cavitation.

o Consider the size of the suction hose: Table2-4 shows the NFPA pre-selected hosesizes for each pump-rating capacity. Usingthe appropriate-sized hose will minimize theoccurrence of cavitation.

o Consider the piping within the truck: Furthersuction losses may result from additionalsuction piping added to the fire pump duringassembly by the manufacturer.

o Follow the maintenance and inspectionprocedures.

o Cavitation can occur with large nozzle tips.Solve this problem by reducing flow.

o Cavitation can also occur when air enters thepump. The pump may be primed, however,air leaks can cause rough operation and anincrease of engine speed without an in-crease in pressure or flow. If an air leak issuspected, discontinue pumping and refer toSection IV.

ElevationFeet (Meters)

Lift-Loss in Feet(Meters)

2,000 (609) NFPA Baseline

3,000 (914) 1.1 (0.33)

4,000 (1219) 2.2 (0.67)

5,000 (1524) 3.3 (1)

6,000 (1828) 4.4 (1.34)

7,000 (2133) 5.5 (1.67)

8,000 (2438) 6.6 (2.01)

9,000 (2743) 7.7 (2.35)

10,000 (3048) 8.8 (2.68)

Table 2-3: Lift Loss from Elevation

HoseDiameters

(mm)

3"(76)

4"(102)

4 "(114)

5"(127)

6"(152)

Dual6"

FLOWS GPM(LPM) Lift Loss

250 5.2(19.7)

350 2.5(9.5)

500 5.0(19)3.6

(51.5)

750 11.4(43)8.0(30)

4.7(17.8)

1.9(7.2)

1000 14.5(55)

8.5(32)

3.4(12.9)

1250 13(49)5.2

(19.6)

1500 7.6(28.7)1.9

(7.2)

175010.4

(39.4)2.6

(9.8)

2000 3.4(12.9)

2500 5.2(19.6)

Table 2-4: Hose Sizes for Pump-Rating Capacity


Booster Pumps

POST OPERATION PROCEDURE

o Return the engine to idle.

o Slowly close all valves.

o Place the transmission in neutral or park.

o Slowly shift from "pump" to "road" to disen-gage the pump.

o Drain the pump (especially important infreezing weather):

a. Open the discharge valves, removesuction tube caps, and discharge valve caps.

b. Open the pump body drain cocks or Halemultiple drain valve. If a multiple drain valveis used, all pump drain lines should beconnected to this valve.

c. After the pump is completely drained,replace all caps and close all valves,

o If sea water, dirty water, alkaline wateror foam solution, has been used, flush the pumpwith clean water.

o Remove the wheel chocks only whenpreparing to leave the scene.

o Fill out the pump run log, indicating totalpumping time and total out-of-station time.

o Report all pump, vehicle and equipmentmalfunctions, and irregularities to the properauthority.

o Know and follow all local procedures.

Preventive Maintenance

Booster Pumps

Sec III- 1

SECTION III PREVENTIVEMAINTENANCE

OVERVIEW

Hale Booster Pumps require very little care andmaintenance. However, the little required isimportant. Preventive maintenance tasks takelittle time to accomplish and consist of leaktesting, lubrication and cleaning. Theprocedures supplied in this section are fornormal use and conditions.

This section provides recommended actions tobe completed after each use, weekly, monthlyand annually basis.

Post-Operation Maintenance Procedures

Flush Pump

1. Inspect the suction hose and rubber washersas well as the washers in the suction tubecaps. Remove any foreign matter from thehose and coupling. Replace worn, dam-aged, or dry washers.

2. Verify all discharge valves, drain valves anddrain cocks are closed.

3. Tighten the suction caps.

Weekly Maintenance

Weekly maintenance consists of:

o Testing the relief valve system

o Testing the priming system

o Testing the pump shift warning indicatorlights

o Valve Maintenance

o Checking and cleaning the intake strainers

o Checking any auxiliary engine.

o Verifying all gauges are in working order.

o Operating pump controls.

o Inspecting water and foam tanks.

o Checking roof and bumper turrets

o Checking auxiliary fire suppression equip-ment

Relief Valve Testing

When the relief valve is not in operation, keepthe hand wheel set above the normal operatingpressure.

1. Set up to pump from theonboard water tank withthe discharge flow back tothe water tank.

2. Turn the relief valve handwheel clockwise to thestop to prevent the reliefvalve from operating.Figure 3-1

3. Bring the pump pressureup to 150 PSI (10 BAR) asindicated on the masterpressure gauge pernormal operating procedures.

4. Turn the relief valve hand wheel counter-clockwise until the relief valve opens. Therelief valve is open when the amber indicatorlight is lit and the pressure begins to drop.

5. Turn the relief valve hand wheel clockwisethen counterclockwise a few times to ensurethat the hand wheel turns freely. Observethe pressure gauge and indicator light for

Figure 3-1PM Valve Control

Booster Pumps

Sec III- 2 Preventive Maintenance

proper valve operation.

6. Return the relief valve hand wheel and theapparatus to normal operational condition.

Pump Shift Warning Indicator Lights

VERIFY THE PARKING BRAKE IS SET ANDTHE WHEELS ARE CHOCKED TO PREVENTANY MOVEMENT OF THE APPARATUS.

1. Follow the operating procedures in Section IIto engage the pump if no local proceduresexist.

2. Verify the warning indicators in the cab andthe pump control panel function properly.

3. Verify the indicator lights on the control panelfunction properly and agree with the indica-tors in the cab. Repair or replace any mal-functioning indicators.

Valve Maintenance

Properly functioning valves are integral to theproper operation of the pump. Refer to the valvemanual for proper valve maintenanceprocedures.

1. Lubricate all suction and discharge valvesusing an approved lubricant.

2. Verify each valve operates easily and closescompletely.

3. Inspect and lubricate all of the valve link-ages. Repair or replace any damaged ornonfunctional linkages.

4. The relief valve operator should be lubri-cated every 5 months.

Check and Clean the Intake Strainers

Remove the strainers. Clean any debris out ofthe intake. Flush the pump if required bydepartment procedures. Repair or replace anydamaged strainers.

Check Auxiliary Engine

If the pump is powered by a separate engine,check the engine, fuel tanks and drive for wearand proper operation.

Verify all Gauges are in Working Order.

Any gauge that is repeated in the cab or anotherpanel, must agree with the gauge on theoperator's panel. Gauges not reading within10% of the calibrated test gauge must beremoved from service and recalibrated.

Operate Pump Controls.

Operate the pump drive controls to verify thepump can be engaged. Verify the indicator lightswork properly.

Inspect Water and Foam Tanks.

Visually inspect water and foam tanks for properlevel and gauge readings. If any debris ispresent, flush the tanks to protect the pump fromwear caused by dirty water or foam concentrate.

Check Roof and Bumper Turrets

If the apparatus is so equipped, verify the turretsfunction properly, and no leaks are present.

Check Auxiliary Fire Suppression Equipment

Visually inspect all piping and valves on thepump and auxiliary equipment for corrosion ordamage.


Booster Pumps

Sec III- 3

Monthly Maintenance

o Check the Gearbox Oil

o Perform the dry vacuum test

o Check the drive line bolts.

Gearbox Lubrication

Too much oil or the wrong type of oil will resultin unnecessary loss of power and high oiltemperature. Change the oil every 12 months,depending on pump usage. Recommended oilfor Hale booster pumps is SAE EP-90, 80W-90,or synthetic 75W-80 gear oilthat meets service rating of APIGL-5 requirements. Gearboxcapacity is one to two quarts.

1. Remove the gearbox oil fillplug, and check the level ofthe oil in the gearbox. Thelevel should be up to theplug hole. Figure 3-2

2. If the oil appears white or "milky," a waterleak is indicated. Remove the drain plug(figure 3-3) and drain the oil into a suitablecontainer. Examine the oil for metal flakes orother contamination. Either of these condi-tions indicate maintenance is required on theunit.

Priming System Test (Dry Vacuum Test)(Refer to NFPA 1901 or NFPA 1911)

1. Close all valves and drains. Cap all suctionopenings and the outlet of the suction siderelief valve (if equipped).

2. Connect a test vacuumgauge or manometer to theintake test gauge connectionon the pump panel.

3. Engage the priming pump

until the gauge indicates at least 22 IN-ngvacuum.

4. Compare the readings of the test gauge andthe apparatus gauge. Note any difference.

5. Stop the priming pump and observe thegauge. If the vacuum falls more than 10 in ofHg in 5 minutes, it is a certain indication of atleast one air leak. Vacuum leaks may oftenbe detected by ear if the apparatus engine isturned off. Correct leaks immediately toreturn the pump to service.

6. Test the suction hose as follows:

a. Attach the suction hose to the pump.

b. Place a suction tube cap on the end ofthe hose in place of a strainer.

c. Close all valves and drains. Cap allsuction openings and the outlet of the suc-tion side relief valve (if so equipped).

d. Connect a calibrated vacuum gauge ormanometer to the intake test gauge connec-tion on the pump panel.

e. Engage the priming pump until the gaugeindicates at least 22 IN-ng vacuum.

f. Watch the gauge. If the vacuum fallsmore than 10 inches in 5 minutes, it is acertain indication of at least one air leak.

g. Verify the test gauge and the apparatusgauge display the same readings. Repair orreplace any gauges that do not display thecorrect pressure.

IF LEAKS CANNOT BE DETECTED BYFOLLOWING THE PROCEDURE , IT ISADVISABLE TO TEST THE PUMPHYDROSTATICALLY.

o Open all the valves.

Figure 3-2

Figure 3-3

Booster Pumps


o Place caps on all valves

o Connect a positive pressuresource

o Inspect the pump for leaks.

Drive Line and Flange Bolts

Check all drive line and flange bolts to ensure:

1. No bolts are missing.

2. All bolts are tight. Use a torque wrench totorque bolts to the drive train manufacturer'srecommended specifications.

3. Bolts used are Grade 8 strength.

Annual Pump Maintenance

o Replace the pump gearbox oil. Use SAE EP-90, 80W-90, or synthetic 75W-80 gear oilthat meets service rating of API GL-5 re-quirements.

o Check individual drain lines from the pump tothe multi-drain to ensure proper drainageand protection from freezing.

o Tank to pump flow ratetest.

o Clean ESP Primer if in-stalled.

o Perform the yearly pumptest to check performancelevels. (See NFPA Stan-dard 1911 for more details.)

Replace Gearbox Oil

1. Remove the magnetic drain plug from thegearbox.

2. Drain the oil from the gearbox.

3. Inspect the magnetic drain plug. If of metalfilings are present on the drain plug, removethe cooler or coverplate to visually inspectand clean the internal components. Repair orreplace as necessary.

4. Replace the cooler or cover, if necessary.Remove the oil fill plug, and replace the drainplug.

5. Fill the gearbox with an approved gear oiluntil the oil level is at the fill plug opening(approximately 1 to 2 quarts).

6. Replace the fill plug.

Check Drain Lines to Multi-Drain

Drains are supplied on the pump and piping atthe lowest points where water could collect andfreeze rendering the pump useless. Most ofthese drains are piped together to a multi-drainto allow the entire system to be drained by onevalve.

It is necessary to inspect each line to the multi-drain to ensure the entire system is drainingwhen the valve is operated.

Inspect each connection and verify the individuallines to the multi-drain are free of debris. Repairor replace any lines that are damaged, kinked,or corroded.

Tank to Pump Flow Rate Test

Note: This procedure is written for informationonly. It does not supercede any local proce-dure.

1. Fill the water tank until it overflows.

2. Close the tank fill line, bypass the coolingline, and all the pump intakes.

3. Attach sufficient hoselines and nozzles toflow the desired discharge rate.

Grade 8Bolt headFigure 3-4

Figure 3-5


Booster Pumps

Sec III- 5

4. With the pump in gear, open the discharge towhich the hose is attached and begin flowingwater.

5. Increase the engine throttle until the maxi-mum consistent pressure is obtained on thedischarge gauge.

6. Close the discharge valve without changingthe throttle setting. Refill the tank through thetop fill opening or a direct tank line. Thebypass valve may be opened during this timeto prevent pump overheating.

7. Reopen the discharge valve, and check theflow through the nozzle using a Pitot tube orflowmeter. Adjust the engine throttle to bringthe pressure to the amount previouslydetermined.

8. Compare the flow rate measured to theNFPA minimum or the designed rate of thepump. If the flow rate is lower, a problemexists in the tank to pump line. The minimumflow rate should be continuously dischargeduntil 80% of the tank is discharged.

The pump should experience no mechanicalproblems, powerloss, or overheat during thetest.

Performance Testing Overview

The yearly standard performance test consistsof checking the pump (according to the rating) atthree capacities and comparing the results towhen the pump first placed in service. Thisprovides some measure of any performancedeterioration. Table 3-1

A pump must be able to pump full capacity at150 PSI, 70% capacity at 200 PSI and 50%capacity at 250 PSI.

Performance Testing Equipment andMaterials

Testing is appropriately accomplished with adead weight gauge tester, which is usuallyavailable at the local water works.

To accurately test pumper performance,requires a Pitot gauge, a calibrated pressuregauge, and a vacuum gauge or manometer.

Use smooth bore test nozzles of accurate sizewith the Pitot gauge. The volume pumped isthen determined by referring to the dischargetables for smooth nozzles. Preferably, nozzleswill be used on a Siamese deluge gun forgreatest accuracy. A stream straightener, justupstream of the nozzle is advisable.

Example PUMP RATING GPM (LPM)

CAPACITY PRESSUREPSI (BAR)

250(946)

350(1325)

450(1703)

500(1893)

750(2839)

1000(3785)

FULL 150 (10) 250(946)

350(1325)

450(1703)

500(1893)

750(2839)

1000(3785)

70% 200 (13) 175(662)

245(927)

315(1192)

350(1325)

525(1987)

700(2650)

50% 250 (17) 125(473)

175(662)

225(852)

250(946)

375(1419)

500(1893)

Table 3-1

Booster Pumps


Refer to local procedures for pump testingprocedures and practices.

For Pitot gauge accuracy, the nozzle pressuresshould be between 30 and 85 PSIG. See thechart on the facing page for nozzle flow andpressures. Table 3-3 provides GPM for variousnozzle sizes.

Because NFPA standards specify both GPMand pressure, it is usually necessary to restrictthe flow somewhat to build up the pumppressure. In normal pumping, this restrictionwould be caused by the friction loss in the lines.However, depending on line loss alone wouldrequire a large amount of hose for some tests.It is common practice to use 50 to 100 feet ofhose and gate the discharge valves as requiredto maintain pressure.

Performance Testing Procedure

Note: The NFPA standards require a 10 percentreserve in pressure at the capacity run when theapparatus is delivered.

1. Check the relief valve according to the ReliefValve Testing procedure under WeeklyMaintenance.

2. Perform steps 2 and 3 of the Post-OperationMaintenance procedures in this section.

3. Run the standard pump test in accordancewith NFPA standards to check pump perfor-mance.

4. Pumps rated below 750 GPM are tested foran hour per NFPA 1901, 14-13.2.3.2. Runthe engine for 20 to 30 minutes to stabilizethe engine temperature. Then run the pumpfor 20 minutes at capacity, 10 minutes at 70percent capacity, and 10 minutes at 50percent capacity.

5. If the apparatus does not reach performancelevels, refer to the Diagnostic/Service chartin Section IV.

6. Compare the results of this test to those fromwhen the apparatus was delivered. It maybe that the apparatus did not show the 10percent reserve at delivery. If the apparatus

Pump ModelClearance Ring Inner Diameter (pressed

into pump body or pump head)IN (MM)

Impeller Hub OuterDiameter

PermissibleClearance

CBP 3.6312-3.6326(92.232-92.268)3.620-3.622

(91.948-91.999).009-.013

(.227-.330)

AP 4.770-4.777(121.158-121.336)4.760-4.758

(120.904-120.853).012-.017

(.305-.432)

Table 3-2: Impeller and Clearance Ring Diameters and Clearance Values


Booster Pumps

Sec III- 7

GPM AT VARIOUS NOZZLE SIZESNOZZLE Nozzle SizePRESS 5/8 7/8 1" 1 1/8" 1 1 3/8

30 41 64 92 125 163 206 254 30835 44 69 99 135 176 222 275 33240 47 73 106 144 188 238 294 35545 50 78 112 153 199 252 311 37750 53 82 118 161 210 266 328 39755 55 86 124 169 220 279 344 41760 58 90 130 176 230 291 360 43562 58 91 132 179 234 296 366 44264 59 93 134 182 238 301 371 44966 60 94 136 185 241 305 377 45668 61 96 138 188 245 310 383 46370 62 97 140 190 248 315 388 47072 63 99 142 193 252 319 394 47774 64 100 144 196 255 323 399 48376 65 101 146 198 259 328 405 49078 66 103 148 201 262 332 410 49680 66 104 150 203 266 36 415 50285 68 107 154 210 274 347 428 51890 70 110 159 216 282 357 440 53395 72 113 163 222 289 366 452 547

100 74 116 167 228 297 376 464 562105 76 119 171 233 304 385 476 575110 78 122 175 239 311 394 487 589115 80 125 179 244 319 403 498 602120 81 127 183 249 325 412 509 615

GPM AT VARIOUS NOZZLE SIZESNOZZLE Nozzle SizePRESS 1 1 5/8 1 1 7/8 2 2 1/4" 2 " 3"

30 366 430 498 572 651 824 1017 146435 395 464 538 618 703 890 1098 158140 423 496 575 660 751 951 1174 169145 448 525 610 700 797 1009 1245 179350 473 555 643 738 840 1063 1313 189055 496 582 675 774 881 1115 1377 198260 518 608 705 809 920 1165 1438 207162 526 618 716 822 935 1184 1462 210564 535 628 728 835 950 1203 1485 213866 543 637 739 848 965 1222 1508 217268 551 647 750 861 980 1240 1531 220470 559 656 761 874 994 1258 1553 223672 567 666 772 886 1008 1276 1575 226874 575 675 783 898 1022 1293 1597 229976 583 684 793 910 1036 1311 1618 233078 590 693 803 922 1049 1328 1639 236180 598 702 814 934 1063 1345 1660 239185 616 723 839 963 1095 1386 1711 246590 634 744 863 991 1127 1427 1761 253695 651 765 887 1018 1158 1466 1809 2605

100 668 784 910 1044 1188 1504 1856 2673105 685 804 932 1070 1217 1541 1902 2739110 701 823 954 1095 1246 1577 1947 2803115 717 841 976 1120 1274 1613 1991 2867120 732 859 997 1144 1301 1647 2034 2928

Table 3-3

Booster Pumps


performance has dropped appreciablycompared to its original performance, itneeds to be serviced. (Apparatus testresults should be on file with the deliverydocuments. If not, they may be obtainedfrom the apparatus manufacturer or from theoriginal certifying authority.)

Worn Clearance Rings and Impeller Hubs

Because clearance ring replacement requirespump disassembly, it is advisable to thoroughlycheck other possible causes of low performancebefore assuming that clearance ring wear is atfault.

Clearance rings limit the internal bypass ofwater from the discharge side of the pump backto the suction. The radial clearance betweenthe impeller hub and the clearance rings is onlya few thousandths of an inch when new. In clearwater, the clearance rings continue to effectivelyseal for hundreds of hours of pumping. In dirtyor sandy water, the impeller hub and clearancerings will wear faster. The more wear, thegreater the bypass and lower pumpperformance.

When new, the radial clearance between theimpeller hubs and the clearance ring is from0.005 to 0.007 inch per side. Any increase willallow more bypass and result in lowerperformance. It should not be necessary toreplace clearance rings and impellers until theaverage radial clearance reaches 0.015 to 0.020inch or more per side, as measured withcalipers. Refer to Table 3-2.

If the clearance rings on the CBP pump showsignificant wear but the impeller itself is withinthe size tolerance, "undersized " clearance ringscan be installed to delay a complete rebuild.Contact Customer Service at Hale Products andrefer to part 321-0070-01-0 for CBP

Often, replacement of the clearance rings willreduce the bypass and restore the pump to nearoriginal performance. A complete restoration

requires that the impellers also be replaced. SeeSection V for maintenance and repairinformation if pump disassembly is required.

EXTREME CONDITIONS

MAINTENANCE GUIDELINES

Freezing Weather

Drain the pump body and discharge valves. Ifthe gearbox is equipped with a water coolingline, drain this line also. There should be drainsfor the gauge lines, the cooling line to theengine, and to the relief valve (if equipped). Allof these should be opened until all water isdrained out, then close the drain valves.

In freezing weather, drain the pump as follows:

1. Open the discharge and suction valves,remove suction tube caps and dischargevalve caps.

2. Open the pump body drain cocks and drainvalves

3. After the pump is completely drained replaceall caps and close all valves.

Contaminated Water

After pumping salt water, contaminated water orfoam solution, or if water containing sand orother foreign matter has been used, connect thepump to a fresh water hydrant or other source offresh clean water and flush the contaminantsout of the pump.

Troubleshooting Sec IV- 1

PUMP LOSES PRIME ORWILL NOT PRIME

NOTE: Weekly primingpump operation isrecommended to ensureproper operation.

Electric Priming System No recommended enginespeed is required to operatethe electric primer. However,1,000 engine RPM will maintainthe electrical system whileproviding enough speed forinitial pumping operation.

Defective Priming System Check the priming system byperforming a Dry VacuumTest per NFPA standards. Ifthe pump holds vacuum, butprimer pulls less than 22inches of vacuum, it couldindicate excessive wear in theprimer.

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

SECTION IV: TROUBLESHOOTING

Table 4-1 lists the symptoms of some common problems and possiblecorrective measures. Before calling Hale or a Hale authorized partsservice center for assistance, eliminate problem causes using this guide.If the problem cannot be corrected, please have the following informationready prior to calling the Hale Customer Service Technician Departmentfor assistance. Customer Service Number: 1-800-720-3473.

o Pump Model and Serial Numbero Observed symptoms and conditions under which the symptoms occur.

NOTE: The location of the serial number will vary depending on the pump model but it is generallydisplayed on the pump operator's panel and/or the side of the gearbox.

PTO WILL NOT ENGAGE

TABLE 4-1. HALE PUMP TROUBLE ANALYSIS

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

Consult PTO Manufacturer'sInstructions.

Faulty Wiring Verify the indicators areproperly functioning.

PUMP WILL NOT ENGAGE

Figure 4-1: Serial Plate

Sec IV- 2 Troubleshooting


Suction lift too high Do not attempt lifts exceeding22 feet.

Restricted suction strainer Remove obstruction fromsuction hose strainer.

Clean and tighten all suctionconnections. Check suctionhose and hose gaskets forpossible defects.

Primer not operated longenough.

Proper priming proceduresshould be followed. Do notrelease the primer controlbefore assuring a completeprime.

Suction Connections

PUMP LOSES PRIME ORWILL NOT PRIME (cont'd.)

Air Leaks Attempt to locate and correctair leaks using the followingprocedure:

1. Perform dry vacuum test onpump per NFPA standards with22 inches minimum vacuumrequired with loss not toexceed 10 inches of vacuum in5 minutes.

2. If a minimum of 22 inches ofvacuum cannot be achieved,the priming device or systemmay be defective, or the leak istoo big for the primer toovercome (such as an openvalve).

NOTICE: Do not run the primer over 45 seconds. If prime is not achieved in 45 seconds, stop andlook for causes (air leaks or blocked suction hose).


5. The suction side relief valvecan leak. Plug the valve outletconnection and retest.

INSUFFICIENT PUMPCAPACITY

Insufficient engine power Engine power check or tune upmay be required for peakengine and pump performance.

Refer to rotation symptomslater in this section.


PUMP LOSES PRIME ORWILL NOT PRIME (Cont'd.)

3. After priming, shut off theengine. Audible detection of aleak is often possible.

4. Connect the suction hosefrom the hydrant or thedischarge of another pumper topressurize the pump withwater, and look for visibleleakage and correct. Apressure of 100 PSI (6.9 BAR)should be sufficient. Do notexceed pressure limitations ofpump, accessories, or pipingconnections.

Air Leaks (cont'd.)

Suction hose diameter is toosmall for the volume beingdischarged

Use a larger suction hose.

Shorten total length byremoval of one length.

Reduce volume ofdischarge

Restriction in the suctionline at the strainer

Remove any debrisrestricting entrance ofwater at the strainer.

Partial collapse of the liningin the suction hose

Damage to the outer lining mayallow air in between the outerand inner linings causing apartial collapse. Replace thehose and retest.


Clean suction hose strainer ofobstruction and followrecommended practices forlaying suction hose.

Blockage of suction hose entry


Relief Valve improperly set If the relief valve control is settoo low the relief valve willopen and bypass water. Resetthe relief valve control per theprocedures in Section III. Otherbypass lines (such as foamsystem or in-line valves) mayreduce pump capacity orpressure.

INSUFFICIENT PUMPCAPACITY (cont'd.)

ENGINE SPEEDS TOO HIGHFOR REQUIRED CAPACITYOR PRESSURE

Truck transmission in wrongrange or gear

Verify the transmission is in thecorrect gear.

Lift too high, suction hose toosmall

Higher than normal lift (10 feet)will cause higher enginespeeds, high vacuum andrough operation. Use largersuction hose. Bring the pumpcloser to the water source.

Inner line of suction hose maycollapse when drafting and isusually undetectable. Changethe suction hose on the pump;test for comparison againstoriginal hose.

Defective suction hose

Pump is approachingcavitation.

Gate the discharge valves toallow pressure to increase.This will reduce flow.Reduce the throttle openingto the original pressuresetting.


RELIEF VALVE DOES NOTRELIEVE PRESSURE WHENVALVES ARE CLOSED

Incorrect setting of Control(PMD) Valve

Check and repeat properprocedures for setting reliefvalve system. (See Section 3)

Relief Valve inoperative Refer to the relief valvemanual.

RELIEF VALVE DOES NOTRECOVER AND RETURN TOORIGINAL PRESSURESETTING AFTER OPENINGVALVES

Dirt in system causingsticky or slow reaction

Refer to the relief valvemanual.

Clean the valve with a smallwire or straightened paper clip.Refer to the relief valvemanual.


Worn pump impeller(s) and / orclearance rings

Installation of new partsrequired.

Impeller blockage Blockage in the impeller canprevent loss of both capacityand pressure. Back flushingthe pump from discharge tosuction may free blockage.Removal of the pump headmay be required (this isconsidered a major repair).

Blocked relief valve.

WATER IN PUMP GEARBOX Leak coming from above pump Check all piping connectionsand tank overflow for possiblespillage falling directly on tothe pump gearbox.

If mechanical seal is installed,there should be no leaks.Inspect the oil seal andreplace if necessary.

Leaking Mechanical Seal



DISCHARGE VALVESDIFFICULT TO OPERATE

Lack of lubrication Recommended weeklylubrication of discharge andsuction valve, use anapproved lubricant. Refer tothe valve manual for moreinformation.

Cavitation Troubleshooting

Water temperature too high. Reduce volume discharged bylowering RPM or gating thedischarge valves.

Locate a source of coolerwater.

Pump is beginning tocavitate

Discharging more water thanthe pump is taking in.

Gate the discharge valves toreduce flow and maintainpressure.

Increase the flow into the pumpwith more and/or larger intakelines.

Air Leak

Locate and eliminate all airleaks during maintenance.

Verify air bleeder on thesuction tube is notopen.

Drafting too high

Locate the pump closer to thewater source.

Verify lift loss, hose friction,water temperature and otherlift limiting factors are reducedor eliminated.


Figure 4-2 Impellers as installedon the 2CBP


Rotation SymptomsIt is possible to reassemble the pump incorrectly or withthe wrong parts. Always compare the replacement partswith the original hardware. Contact customer service atHale Products to answer questions or concerns.

Reduced pressure 60-100 psi.and reduced flow.

Wrong impeller installed Verify the new impeller vanesare oriented the same as theold impeller before installing.See figure 4-3.

Impellers installed backwards(2CBP)

Verify the impellers are in thecorrect order. P/N 016-0280-00-0 is installed closest to thegearbox in an engine rotationapplication and closest to thefront in an Opposite enginerotation application.

Wrong Application The pump was installed on anapplication for which it was notintended i.e. front mount vs.rear mount.

Figure 4-3 Engine rotation

Maintenance and Repair

Booster Pumps

Sec V- 1

SECTION V MAINTENANCEAND REPAIR

OVERVIEW

This section describes the removal, inspection,and re-installation (as required for maintenanceand repair) of all booster pump components. Tocompletely disassemble the pump and gearbox,follow the disassembly instructions in the orderwhich they appear in this text. At any point in thedisassembly process, the pump may bereassembled by following the instructionsbackwards through this manual.

NOTE: Unless otherwise indicated, theseinstructions apply to all Hale booster pumps.

General Repair Guidelines

1. Match mark or note the orientation ofcomponents before disconnecting orremoving them.

2. Where grease is called for, use a LithiumBased Grease with 1 to 3% MolybdenumDisulfate. The following are examples ofapproved greases:

o Dow Corning BR2-PLUSo Lubriplate Fiske #3000o Shell Super Duty Greaseo Imperial #777o Mobil Grease Specialo Sunoco Moly #2EP

3. In the gearbox, use only oil with an API GL-5rating. Use SAE EP-90, 80W-90 orsynthetic 75W-80 oil. (See Table 5-1 forgearbox oil capacities.)

4. Before installing the mechanical seal, usethe alcohol swabs provided by HaleProducts Inc. to clean all grease or oil fromthe pump shaft and bearing housing.

5. Use only PAC-EASE Rubber LubricantEmulsion (or equal) on the rubbermechanical seal parts to ease installation.

USE OF ANY OTHER LUBRICANT CANDAMAGE THE MECHANICAL SEAL ANDSEAT.

6. Replacement steel fasteners, must be grade5, 360O nylon patchlock fasteners. ApplyLoctite 242 (or equal) to all threads.

7. Before working on the pump, disconnect thesuction and discharge piping and drain thepump body. Disconnect cooling tubes fromthe water manifold and pump as required.

8. Label and disconnect all wiring from thepump.

Cleaning and Inspection Guidelines

Wherever the procedures call for cleaning andinspection, these guidelines should be followed:

1. Inspect all components for excessive orabnormal wear.

2. Wherever a requirement for new parts isindicated, obtain new components from HaleProducts Inc.

3. Wherever procedures call for the removal ofgaskets, the gasket should be replaced.Clean all gasket mating surfaces beforeinstalling new gaskets.

4. Bearings and other components should becleaned using only recommended solvents.

5. Bearings and seals should be inspectedwhenever the parts are disassembled. Lookfor signs of excessive wear.

Sec V- 2 Maintenance and Repair

Booster Pumps

Bolt Size Material Maximum Torqueft-lb (n-m)

5/16-18 zinc-plated steel 17 (23)

5/16-18 zinc-plated steelw/360o nylon lock

19 (26)

5/16-18 silicon bronze 10.3 (14 )

3/8-16 zinc-plated steel 30 (41)

3/8-16zinc-plated steel

w/360o nylon lock 33 (45)

3/8-16 silicon bronze 18 (24 )

7/16-14 zinc-plated steel 50 (68 )

7/16-14zinc-plated steel

w/360o nylon lock 53 (72)

7/16-14 silicon bronze 29 (39)

Table 5-2: Torque Values

Pump ModelClearance Ring Inner Diameter (pressed into pump

body or pump head)In (mm)

Impeller Hub OuterDiameter

PermissibleClearance

CBP 3.6312-3.6326(92.232-92.268)3.620-3.622

(91.948-91.999).009-.013

(.227-.330)

AP 4.770-4.777(121.158-121.336)4.760-4.758

(120.904-120.853).012-.017

(.305-.432)

Table 5-3: Impeller and Clearance Ring Diameters and Clearance Values

Model Gearbox Oil Capacity

AP 1 QTS. (1.66L)

CBP CBP2 & 3 = 1 QTS. (1.66L)CBP4 & 5 = 1 QT. (.95L)

2CBP2CBP2 & 3 = 1 QTS. (1.66L)

2CBP4 & 5 = 1 QT. (.95L)

Table 5-1: Oil Capacity Table

Figure 5-1 Measuring the Impellerand Clearance Ring


Booster Pumps

Sec V- 3

6. Replace any hardware that shows signs ofexcessive wear.

7. When inspecting the impellers and clear-ance rings for wear, measure the impellerhub diameter and the inner diameter of theclearance ring. Compare these measure-ments to data in Table 5-3. If measure-ments indicate, obtain replacement clear-ance rings and impeller.

NOTE: If either the impeller hub or clearancerings are out of tolerance, both rings and theimpeller must be replaced as well as themechanical seal.

Recommended Cleaners

Hale recommends:

o Safety Kleen

o Stoddard Solvent

Tools Required

Lifting gear-lever hoist or chain hoist, andshort choker

Ball peen hammer Center punch Drift punch Allen wrenches Strap wrench Snap Ring Pliers Pry bars (2) Ratchets and wrenches for disassembly Torque wrench, capable of 40, 65, and 135

ft-lb (54, 88, and 183 N-m) Pan (to catch drip oil) Disposable-rags Oil dry Wood Wedges Bearing Puller Pusher tube (a small section of PVC tubing

to fit over the shaft)

PUMP COMPONENTS

Pump and Gearbox Assembly

Read all the instructions before beginning anyrepair.

THE PUMP AND GEARBOX ASSEMBLIESWEIGH APPROXIMATELY 250 LBS (113 KG).USE PROPER LIFTING DEVICE WHENREMOVING OR INSTALLING PUMP ANDGEARBOX ASSEMBLY.

NOTE: These procedures refer to Figures 5-2and 5-3. Please review the General Repair andCleaning and Inspection Guidelines on page 37before beginning these procedures.

Remove the Pump from the Apparatus

1. Park the vehicle on a level surface. Set theparking brake and chock the front and rearwheels.

2. Place apparatus out of service inaccordance with departmental procedures.

3. Obtain access to the pump and gearbox.Match mark or tag all connections beforeremoval.

4. Remove drain plugs and drain the pump andpiping. Disconnect suction and dischargepiping from the pump.

5. Remove the magnetic oil-drain plug (seeFigure 5-2). Drain the gearbox oil into asuitable container. Examine the oil forincluded water (water turns the oil a milkycolor or settles in the bottom of the oil) andproperly dispose of the oil.

6. Disconnect the drive shaft from the gearbox.

Sec V- 4 Maintenance and Repair

Booster Pumps

7. Disconnect airlines, electrical switches, andthe tachometer cable as required.

8. Attach a proper lifting device beforeloosening or removing mounting brackets.

9. Disconnect mounting brackets to removethe pump and gearbox assembly.

10. Place the pump and gearbox assembly on astable work stand. The air vent and gearboxcover are exposed. This will provide easyand safe access to the internal components.

REINSTALL PUMP ON APPARATUS

After completing repairs and /or maintenance,reinstall the pump and gearbox assembly.

1. Place the pump and gearbox assembly on astable platform. Attach a proper liftingdevice.

2. Lift the pump and gearbox assembly intoposition on the equipment. Connect the

mounting brackets using the properfasteners. Torque the fasteners to valuesprovided in Table 5-3.

3. Connect the drive shaft to the gearbox.Apply Loctite to the fasteners and torqueto PTO manufacturer's specifications.

4. Connect any electrical switches, airlines andtachometer cable if appropriate.

5. Install the magnetic oil-drain plug.

6. Fill the gearbox to the level of the oil plug.Use only oil with an API GL-5 rating. UseSAE EP-90, 80W-90 or synthetic 75W-80oil. See Table 5-1 for approximate gearboxoil capacity.

7. Reconnect the suction and discharge pipingto the pump.

8. Test the pump for proper operation, note anyleaks.

9. Return the apparatus to normal operation.

Figure 5-3: CBP Pump and GearboxAssembly with Gearbox CoverFigure 5-2: AP Pump and Gearbox

Assembly with Optional Cooler


Booster Pumps

Sec V- 5

AP PUMP DISASSEMBLY

AP Pump Body

The pump body can be removed from thegearbox assembly providing access to theinternal parts without disconnecting the driveunit.

Remove AP Pump Body

1. Disconnect the suction, discharge, coolinglines, and any electrical wiring. Disconnectmounting brackets as required. Match markthe pump body and pump head to ensureproper alignment during reassembly.

2. Remove the 7/16 - 14 X 1" cap screws thathold the pump body assembly to the pumphead.

3. Remove the pump body from the pumphead, do not damage the brass clearancerings or impeller.

Figure 5-4: AP Pump andGearbox Assembly

4. Remove all remaining gasket material fromthe mating surfaces of the pump body andpump head.

Install the Pump body

1. Use a press to install the clearance ring inthe pump body.

2. Apply a small amount of grease to thegasket and align on the pump body.

3. Install the pump body onto the pump head,do not damage the clearance rings orimpeller.

4. Apply Loctite 242 (or equal) to the threadsand install the 7/16-14 UNC x 1 cap screwsthat hold the pump body to the pump head.Refer to Table 5-2 for recommended torquevalues for fastener size and material.

5. Reconnect all piping and tubing.

6. Return the apparatus to service.

AP IMPELLER AND MECHANICAL SEAL

Remove AP Impeller

1. Remove the pump body as described above.

2. Remove the cotter pin that secures theimpeller nut.

3. Hold the impeller with a strap wrench, andremove the impeller nut.

4. To avoid warping the impeller, use wedgesand a proper puller t

029-0020!53!0-a booster pumps - operation & maintenance manual for ap, cbp, 2cbp

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