3/15/2001

4D SERIES PUMPS
DESCRIPTION, OPERATION AND
MAINTENANCE

All Hale products are quality components: ruggedly designed, accurately machined, precision inspected, carefully assembled
and thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to
follow the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.

HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440

P/N 029-0020-66-0, REV A, © 2001 HALE PRODUCTS, INC., PRINTED IN U.S.A.

ECO NO REV CHANGED FROM BY DATE APVD
01-119 A RELEASE FOR PRODUCTION PRW 03/08/01 MAL

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.
 4D Series Pumps

Table of Contents
1. INTRODUCTION ...................................................................................................................................... 1
A. Overview ........................................................................................................................................... 1
B. Principles of Operation................................................................................................................... 1
4D Series Pump Operation.................................................................................................................. 2
C. Parts of Pump ................................................................................................................................... 3
2. OPERATING PROCEDURES ................................................................................................................ 5
Emergency Pump Shift Procedures.................................................................................................. 6
Post Operation Procedures ................................................................................................................ 7
3. PREVENTATIVE MAINTENANCE ........................................................................................................ 8
4. TROUBLESHOOTING ............................................................................................................................ 9
5. MAINTENANCE AND REPAIR PROCEEDURES ............................................................................13
GENERAL REPAIR GUIDELINES:..........................................................................................................13
GEARBOX AND PUMP REMOVAL .....................................................................................................13
GEARBOX AND PUMP INSTALLATION ..............................................................................................13
GEARBOX COVER................................................................................................................................14
SLIDING GEAR SHAFT ..........................................................................................................................14
TAIL SHAFT...............................................................................................................................................15
VPS ...........................................................................................................................................................15
4DG4 and 4D6G-35 SHIFT SWITCH...................................................................................................16
4DGK4-30 SHIFT SWITCH .....................................................................................................................17
INTERMEDIATE GEAR (4D6G-35) .......................................................................................................18
INTERMEDIATE GEAR (4DG4 and 4DGK4-30) ................................................................................18
PUMP BODY...........................................................................................................................................19
IMPELLER.................................................................................................................................................20
PUMP HEAD ...........................................................................................................................................20
PUMP SHAFT (4D6G-35) ......................................................................................................................21
MECHANICAL SEAL REPLACEMENT .................................................................................................22
PART LIST HALE 4D6G-35 .......................................................................................................................23
PART LIST HALE 4DG4 & 4DGK4-30 .....................................................................................................26
PART LIST VPS CYLINDER ......................................................................................................................31
PART LIST VPS CONTROL VALVE .........................................................................................................32
4D6G-35 COMPONENT IDENTIFICATION ............................................................................................33
4D6G-35 PUMP PART IDENTIFICATION ...............................................................................................34
4DG4/4DGK4-30 COMPONENT IDENTIFICATION ..............................................................................35
4DG4/4DGK4-30 PUMP PART IDENTIFICATION .................................................................................36
4D6G-35 INSTALLATION ...........................................................................................................................37
4DG4 & 4DGK4-30 INSTALLATION .........................................................................................................38

i

1. INTRODUCTION
A. Overview
Hale 4D Series pumps are designed for
handling fuel or de-mineralized water in the
aircraft service industry. Hale 4D series pumps
are driven primarily by a split-shaft MG series
gearbox. A special transmission PTO version of
the 4DG4 is available for additional
configuration flexibility.
RATED CAPACITY
PUMP MODEL FUELING/DEFUELING WATER
600 GPM (2271 LPM) 500 GPM (1893 LPM) @
4DG4/4DGK4-30
@130 PSI (9 BAR) 150 PSI (10 BAR)
800 GPM (3028 LPM) @ 800 GPM (3028 LPM) @
4D6G
130 PSI (9 BAR) 50 PSI (3 BAR)
Depending on the 4D series pump selected
capacities are as follows.
4D series pumps are available with a 4 inch or 6
inch Victaulic suction connection. Discharge
connections are 4 inch Victaulic facing either
the front or rear of the apparatus.
Models of 4D pumps are as follows:
4DG4: The 4DG4 pump has a 4-inch Victaulic
suction connection and one or two 4-inch
Victaulic discharge connections. This pump is
available in five separate split shaft gearbox
ratios (1:1.27, 1:1.92, 1:2.18, 1:2.67, and 1:3.00)
for capacities of 600 GPM (2271 LPM) at 130 PSI
(9 BAR) for fuel applications or 500 GPM (1893
LPM) at 150 PSI (10 BAR) for water applications.
4DGK4-30: The 4DGK4-30 model pump is built
to strict military standards. The pump has a 4-
inch Victaulic suction connection and a front
facing 4-inch Victaulic discharge connection.
This pump is available with a 1:2.96 gearbox
ratio for peak performance. The 4DGK4-30
pump is equipped with a pneumatic shift
indicator switch.
4D Series Pumps
4D6G-35: The 4D6G-35 model pump is built
for high performance commercial
applications. The design of the 4D6G-35 allows
for quick field maintenance and serviceability.
The pump has a 6-inch Victaulic suction
connection and a front facing 4-inch Victaulic
discharge connection. This pump has a 1:3.56
gearbox ratio for peak performance.
This manual reviews the principles of operation
of Hale 4D series pumps and provides a
description of the pump component parts.
B. Principles of Operation
Centrifugal Force
Hale 4D series pumps are centrifugal pumps
that operate on the principle of centrifugal
Figure 1 Centrifugal Force From a Rotating
Disk
force created by a rapidly spinning disk. Figure
1 shows that an amount of fluid has been
placed at the center of a disk. The disk is
rotated at some speed, and the fluid is thrown
from the center toward the outer
circumference of the disk. The velocity that the
fluid travels from the center directly relates to
the diameter of the disk and the speed of
rotation. When a fluid is confined in a closed
container (such as the pump body), the
velocity is converted to pressure and pressure
rises to a level that depends on the speed of
rotation. There are three interrelated factors
that regulate the performance of a centrifugal
pump:
1
4D Series Pumps

q SPEED (RPM). If the speed of rotation common shaft.

increases with flow held constant, the fluid
pressure increases.
q PRESSURE. Pressure is usually measured in
Pounds Per Square Inch (PSI) (BAR). If
pressure changes with speed held constant,
the flow {(measured in gallons per minute
(GPM)) or (liters per minute (LPM))} will
change inversely, that is, if pressure
increases, flow decreases.
As the impeller rotates the fluid moving
outward in the impeller will create a vacuum in
the suction eye allowing the pump to lift the
fluid into the volute. As fluid is evacuated from
the suction passage atmospheric pressure
pushes the fluid through the suction passage.
Generally, the pump consists of the following
major components:

q FLOW. Flow is usually measured in the q Pump body

number of gallons of fluid 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.
A centrifugal pump is preferred due to its ability
to fully utilize 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 BAR), and the inlet
pressure is 45 PSI (3 BAR), the pump must only
produce the difference in pressure of 75 PSI (5
BAR). This contributes to low engine and pump
speeds with reduced maintenance.
Decreased maintenance is aided by the fact a
centrifugal pump has basically only two
moving parts the impeller and the shaft.
4D series pumps are single stage pumps
meaning there is a single impeller on a
q Impeller and Shaft Components
q Gearbox
4D Series Pump Operation
Hale 4D series pumps use a single impeller to
develop the required volume and pressure.
Figure 2 shows the flow of fluid through the Hale
4D series pump. The 4D series pump utilizes an
impeller with a single suction channel where
fluid enters. The impeller develops discharge
pressure and directs the fluid to a single
cutwater and then to the discharge opening.
The impeller is radially and axially balanced.
The cutwater is wedge shaped and divides the
fluid between the volute and the pump
discharge.

CUT WATER DIFFUSER

DISCHARGE
VANES

EYE
INTAKE
Figure
Figure 21-2.Impeller Operation
Impeller Operation

2

Cavitation
Cavitation occurs when a centrifugal pump is
attempting to discharge more fluid than it is
receiving. When cavitation occurs, a high
vacuum is created near the eye of the
impeller.
Cavitation is often referred to as “the pump
running away from the fluid supply”. This
means that the operator is trying to pump more
fluid out of the pump than is going into the
pump.
To eliminate cavitation, the operator must be
aware of the warning signs and correct the
situation, or serious damage to the pump and
impeller will occur. The most reliable indication
that a pump is approaching cavitation is when
an increase in engine RPM does not cause an
increase in pump discharge pressure. A low
barometer or high elevation will also lower the
amount of atmospheric pressure and can
contribute to cavitation.
The operator must not depend entirely on the
vacuum gage (if one is installed in the
application) to indicate when a pump is
nearing cavitation. This is because the vacuum
gage is usually tapped into the intake
chamber several inches away from the leading
edge of the impeller eye where the greatest
amount of vacuum occurs. The most common
way to eliminate cavitation is to decrease the
amount of fluid being discharged. This is
accomplished by decreasing engine speed or
closing discharge valves. This will allow pressure
to increase but this will result in a reduction of
flow.
Refueler pumps are generally gravity feed from
the tank therefore cavitation is less of an issue
unless design limits are exceeded.
C. Parts of Pump
Basic Parts of Hale 4D Pumps
The basic parts of a Hale 4D series centrifugal
4D Series Pumps
pump are briefly described in the following
text.
Pump Body
The pump body and related parts are
constructed from aluminum.
The Hale 4D series pump body is a single piece.
Service of the impeller, clearance rings and
mechanical seal is accomplished by removing
the pump body. This can often be
accomplished without removing the entire
pump and gearbox assembly from the
apparatus. Additionally, a minimum of piping
need be removed since the connections use
Victaulic type couplings.
The pump has a suction inlet on the front. The
incoming fluid is directed to the impeller
through the suction piping.
Impeller
The impeller, made of anodized aluminum,
provides velocity to the fluid. This part is
mounted on a shaft that is rotated by the
gearbox. The fluid enters the rotating impeller
at the intake (or eye), and is confined by the
shrouds and the vanes mounted in the impeller
to build pressure. The vanes guide the fluid
from the inlet to the discharge. Vanes curve
away from the direction of rotation so the fluid
moves toward the outer edge. The shrouds
form the sides of the impeller, and keep the
fluid confined to centrifugal acceleration.
Figure 2 traces a drop of fluid from the intake of
the impeller to the discharge outlet. The
impeller is mounted so that the discharging
tube is widest at the pump outlet. The body or
volute collects the fluid. A further increase in
pressure and a decrease in velocity take place
in the diffuser which is cast into the pump body.
Clearance Rings
Clearance rings prevent the fluid that is
pressurized and leaving the pump volute from
returning to the intake of the impeller.
Centrifugal pumps have clearance rings at the
3
4D Series Pumps
impeller intake to prevent leakage. This is
accomplished by limiting the radial clearance
between the spinning impeller and the
stationary clearance ring.
A clearance ring usually has a radial clearance
of about 0.0075-inch or a 0.015-inch diameter.
However, the clearance will increase over time
as the pump is operated. Wear is due to
foreign material found in the fluid. Clearance
rings are designed for replacement as the
clearance increases from usage and wear.
If a pump is operated without fluid for
extended periods or without discharging fluid, it
may overheat. This may damage the pump
and the drive mechanism.
Bearings
Bearings support and align the impeller shaft
for smooth operation.
Mechanical Seal
The mechanical seal is standard on 4D series
CARBON
SEAL RING RETAINER
O-RING DIAPHRAGM
STATIONARY
SEAT SPRING
PUMP SHAFT
TOWARDS IMPELLER
PUMP HEAD SIDE
Figure 3 Mechanical Seal Parts
pumps. As shown in figure 3, a stationary seat is
in constant contact with a rotating carbon seal
ring face to prevent leakage. The seal
diaphragm is made of a rubber elastomer that
is specifically designed for high temperature
operations.
4
D. Pump Drives
4D series pumps are primarily operated from
the truck chassis drive shaft through a split-shaft
gearbox. The split shaft gearbox has a sliding
gear shaft that selectively directs the engine
power to the pump or the apparatus drive axle.
The split-shaft gearbox is capable of handling
full engine horsepower, enabling the pump to
meet optimum performance levels as well as
torque requirements for over the road
applications.
Hale offers a variety of pump gear ratios to
accommodate a wide range of apparatus
manufacturer requirements based on engine
speed and available horsepower. The gearbox
consists of the gearbox, gear set, and input
and output shafts that are made of heat-
treated nickel steel. This unit can withstand the
full torque of the engine in road operating
conditions up to 16,000 pounds-feet (21,693 N-
m).
Alternatively the pump can be operated using
a PTO from the truck transmission, a PTO before
the engine drive transmission or a PTO from the
four-wheel drive transfer case.
Shifting
The split-shaft gearbox is normally equipped
with a power shift system, an in-cab control
valve is provided for mode selection. This
control valve locks in place for pump
operation. An indicator switch is provided to
alert the operator when the gearbox has fully
shifted from road to pump position.
Additionally, provision is provided for manual
shift due to failure of the power shift system.
Different pump models utilize different
indicating switches. Some indicator switches
are pneumatic while others are electric
dependent on which pump model is selected.

2. OPERATING PROCEDURES
A. Overview
This section supplies information and
procedures for the operation of Hale 4D series
pumps.
B. Operating Procedures
NOTICE: THE PROCEDURES IN THIS SECTION ARE
GENERAL OPERATING PROCEDURES. THEY DO
NOT REPLACE THE PROCEDURES AND POLICIES
ESTABLISHED BY YOUR COMPANY, NOR DO THEY
REPLACE THE RECOMMENDATIONS AND
PROCEDURES PROVIDED BY THE APPARATUS
MANUFACTURER MANUAL.
General Operation
1. Position the truck for the best hookup
layout.
NOTICE: REFER TO COMPANY PROCEDURES ON
SETTING WHEEL CHOCKS AS WELL AS LAY OUT
AND CONNECTION OF HOSES.
NOTICE: ALL VALVES, DRAIN COCKS, AND CAPS
SHOULD BE CLOSED.
CAUTION: 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.
2. Bring the truck to a complete stop before
you attempt to shift from road to pump.
3. Apply the truck parking brake.
4. Shift the truck transmission to the NEUTRAL
position.
5. Move the in-cab pump shift control valve
from the ROAD position to the PUMP
position. The shift warning lights should
come on in a second or two, indicating a
complete shift.
6. If the truck manufacturer has used another
in-cab valve to achieve pump shift or has
4D Series Pumps
INDICATOR
LIGHT ROAD
POSITION
NEUTURAL
POSITION
CONTROL
HANDLE
PANEL PUMP
PLACARD POSITION
Figure 4 In-Cab Pump Shift Control
an electric switch, follow the instructions
supplied with that valve.
7. After pump shift is completed, put the truck
transmission in the proper pump operating
range or gear. For most operation
conditions this will be direct drive (1:1) ratio.
In addition, the speedometer should read 5
to 15 MPH after the 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 speedometer will not read 5 to 15 MPH
after shifting to the pump position. See the
chassis manual for details.
WARNING: DO NOT LEAVE THE CAB OR ATTEMPT
TO PUMP UNTIL ALL THE GREEN PUMP LIGHTS IN
THE CAB AND PANEL ARE ON.
8. 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.
WARNING: DO NOT OPEN THROTTLE UNLESS ALL
GREEN PUMP INDICATOR LIGHTS ARE ON.
9. Verify that the pump panel shift indicator
green “OK TO PUMP” light is on.
10. If necessary, open the suction valve.
5
4D Series Pumps
11. If necessary to eliminate air pockets open
appropriate valve to let air out or prime the
pump.
12. Note the discharge pressures, and intake
pressures as applicable, then open the
engine throttle gradually until the master
discharge gauge indicates the desired
pressure.
13. Set the automatic relief valve according to
your company policy or governor system .
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 fluid the suction piping will
supply. To increase the pressure when this
occurs, reduce the pump flow. The master
intake gauge reading must be maintained at 5
PSI (.5 BAR), minimum.
As the throttle is opened, the pressure gauge
reading 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
available from the supply.
14. Open the discharge valve(s).
15. After completion of pumping gradually
reduce the pump pressure until the engine
is at an idle speed.
16. Verify that the operator’s hand throttle or
governor control has returned to idle speed.
17. Shift the truck transmission into the NEUTRAL
position, and wait four seconds. Check to
make sure the speedometer reads 0.
18. Moving pump shift control valve lever to the
ROAD position. The in-cab and panel
pump indicator lights should go out when
the pump transmission starts to shift into the
ROAD position.
6
Emergency Pump Shift Procedures
Before implementing manual override shift
procedures, repeat recommended
procedures. If the shift fails to take place,
follow these procedures.
1. Bring the truck to a complete stop.
2. Apply the truck parking brake, and chock
the wheels.
3. Shift the truck transmission to the NEUTRAL
position.
4. For Pump or Road position, put the in-cab
shift control in the Neutral position. (Neutral
position is exactly in the middle of the road
and pump position.
5. Shut down the engine.
WARNING: DO NOT ATTEMPT EMERGENCY SHIFT
PROCEDURES WHILE THE ENGINE IS RUNNING.
6. Employ manual override procedure at the
shift cylinder on the pump gearbox as
follows:
NOTE: The shift stroke is approximately 2-1/16
inches (52 mm). Make sure the gearbox is fully
shifted and shift indicators show proper mode.
7. An eyebolt is provided in the shift shaft to
accept a drift punch or screwdriver. By
inserting this tool into the hole provided, it
will enable you to pull or push the shaft
manually. Pull the shift shaft Out for Pump
Position (after in-cab control valve
selection), or push shift shaft for Road
Position (after in-cab control valve
selection). If the shift stroke cannot be
completed manually, turn the driveshaft
slightly by hand to realign the internal gears
and repeat the manual shift effort.
 4D Series Pumps

Post Operation Procedures

1. Fill out the pump run log, indicating total

pumping time.

2. Report all pump, vehicle equipment

malfunctions, and irregularities to the proper
authority.

7
4D Series Pumps

3. PREVENTATIVE MAINTENANCE

After each use

Check seals for leaks

Check piping for leaks

Close all valves and caps

Weekly

Verify operation of pump shift indicator

Check drive lines

Monthly

Check all drive line and flange bolts to ensure

No bolts are missing

All bolts are tight

Bolts used are Grade 8 strength

Check pump mounting bolts to ensure

No bolts are missing

All bolts are tight

Annually

Replace gearbox oil with recommended oil

type.

Recommended oil types must have an API GL-

5 rating.

Examples are:

Sunoco DuraLube 75W-80 Synthetic

SAE EP90 or 80W-90

8
 4D Series Pumps

4. TROUBLESHOOTING

The following table 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 this table. 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

HALE 4D SERIES PUMP TROUBLE ANALYSIS

CONDITION
PUMP WILL NOT ENGAGE
Automatic Transmission With
Power Shift System
POSSIBLE CAUSE
Insufficient air in shift system
Air leaks in shift system
SUGGESTED CORRECTION
Repeat recommended shift
procedures with transmission in
neutral position
Release braking system
momentarily. Then reset and
repeat recommended shifting
procedures.
Repeat recommended shift
procedures.
Check system for loss of air.
Check for leaks in system.
Employ manual override
procedures if necessary.

Attempt to locate and repair

leak(s). Leakage, if external,
may be detected audibly.
Leakage could be internal and
not as easily detected.

9
4D Series Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

PUMP LOSES PRIME OR IT WILL
NOT PRIME
INSUFFICIENT PUMP CAPACITY
Suction lifts too high
Blocked suction strainer
Suction connections
Air Trap in Suction Line
Pump Pressure too low when
nozzle is opened
Air Leaks
Insufficient engine power
Relief Valve improperly set
Engine Governor set
incorrectly
Do not attempt lifts exceeding
22 feet except at low
elevation.
Remove obstruction from
suction hose strainer.
Clean and tighten all suction
connections. Check suction
hose and hose gaskets for
possible defects.
Avoid placing any part of the
suction hose higher than the
suction intake. Suction hose
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.
Prime the pump again and
maintain higher pump pressure
while opening discharge valve
slowly.
Attempt to locate and correct
air leaks
Engine power check or tune
up may be required for peak
engine and pump
performance.
If relief valve control is set for
too low a pressure, it will allow
relief valve to open and
bypass fluid. Reset Relief Valve
control per the procedures
provided.
Engine governor, if set too low
a pressure when on automatic,
will decelerate engine speed
before desired pressure is
achieved. Reset the governor
per manufacturer’s
procedures.

10

CONDITION POSSIBLE CAUSE
INSUFFICIENT PUMP CAPACITY Truck transmission in wrong
(Cont’d) gear or clutch is slipping
Air Leaks
INSUFFICENT PRESSURE Check similar causes for
insufficient capacity
REMOTE CONTROL DIFFICULT Lack of lubrication
TO OPERATE
ENGINE SPEEDS TOO HIGH FOR Truck transmission in wrong
REQUIRED CAPACTICTY OR range or gear
PRESSURE
Lift too high, suction hose too
small
Defective suction hose
4D Series Pumps
SUGGESTED CORRECTION
Recheck the pumping
procedure for the
recommended transmission or
gear range. 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).
See air leaks under “PUMP
LOSES PRIME OR WILL NOT
PRIME”.
Recheck pumping procedure
for 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)
Lubricate the remote control
linkages and collar with oil.
Check recommended
procedures for correct
transmission selection.
Higher than normal lift (10 feet)
will cause higher engine
speeds, high vacuum and
rough operation. Use larger
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.
11
4D Series Pumps

CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION

ENGINE SPEEDS TOO HIGH FOR Blockage of suction hose entry
REQUIRED CAPACTICTY OR
PRESSURE (Cont’d)
Worn pump impeller and
clearance rings
Impeller blockage
Clean suction hose strainer of
obstruction and follow
recommended practices for
laying suction hose. Keep off
the bottom of the fluid supply
but a least 2 feet below the
surface of the fluid.
Installation of new parts
required.
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)

DISCHARGE VALVES DIFFICULT Lack of lubrication Recommended weekly

TO OPERATE lubrication of discharge and
suction valve, use a good
grade of petroleum base or
silicone grease.

Valve in need of more Add gasket to the valve cover

clearance per the truck 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.

12

5. MAINTENANCE AND REPAIR
PROCEEDURES
WARNING: HALE 4D SERIES PUMPS ARE
DESIGNED TO PUMP FLAMMABLE FLUIDS. WHEN
SERVICING REFUELING/DE-FUELING PUMPS
CARE MUST BE TAKEN TO ENSURE FIRE AND
EXPLOSION HAZARDS ARE REMOVED FROM THE
WORK AREA.
GENERAL REPAIR GUIDELINES:
1. Match mark or note the orientation of
components before disconnecting or
removing them to aid in proper reassembly.
2. Where grease is called for use a Lithium
Based Grease with 1 to 3% Molybdenium
Disulfate. The following are examples of
approved greases:
Dow Corning BR2-PLUS
LUBRIPLATE-FISKE #3000
SHELL SUPER DUTY GREASE
IMPERIAL #777
MOBIL GREASE SPECIAL
SUNOCO MOLY #2EP
3. Use SAE EP-90 or 80W-90 API GL-5 oil in the
gearbox. Use of Sunoco DURAGEAR SAE
75W-90 (or equal) synthetic oil is also
recommended. Gearbox oil capacity is
approximately 3 quarts (11.4 liters).
4. When installing the mechanical seal apply
a generous coating of PAC-EASE Rubber
Lubricant Emulsion (or equal) on the rubber
seal parts to ease installation.
5. When replacing fasteners the use of grade
5 360O nylon patchlock fasteners is
recommended. If the original fasteners are
reused apply a coating of Loctite 242 (or
equal) before installing.
WARNING: THE PUMP AND GEARBOX WEIGH
APPROXIMATELY 250 LBS (113 KG). USE PROPER
LIFTING DEVICE WHEN REMOVING OR
INSTALLING PUMP AND GEARBOX ASSEMBLY.
4D Series Pumps
GEARBOX AND PUMP REMOVAL
1. Park the vehicle on a level surface. Shut
down the engine. Set the parking brake
and chock the front and rear tires. Obtain
access to the pump and gearbox using
safe practices.
2. Drain the pump and piping then disconnect
suction and discharge piping from pump.
3. Remove the ¾ NPT drain plug and drain the
gearbox oil into a suitable container.
4. Disconnect the drive shafts from the
gearbox.
5. Disconnect the speedcounter cable,
electrical switches and airlines.
6. Attach proper lifting device before
loosening or removing mounts.
7. Disconnect mounting brackets then remove
pump and gearbox assembly from
apparatus.
8. Place pump and gearbox assembly on a
stable work stand. Make sure the oil
breather and gearbox cover are in the up
direction. Make sure the shift shaft is in the
road (in) position.
GEARBOX AND PUMP INSTALLATION
1. Place pump and gearbox assembly on a
stable platform. Attach proper lifting
device to pump and gearbox assembly.
2. Lift pump and gearbox assembly into
position on apparatus. Connect mounting
brackets and secure using proper fasteners.
3. Align for proper driveline angle for proper
operation.
4. Connect the drive shafts to the gearbox.
5. Connect electrical switches, airlines and
speedcounter cable.
6. Install the ¾ NPT drain plug. Remove the ½
NPT oil fill and level plug located next to the
VPS cylinder.
13
4D Series Pumps
7. Fill gearbox to the level plug with proper
grade of oil. Approximate capacity is 3
quarts (11.4 Liters)
8. Reconnect suction and discharge piping to
the pump.
9. Test apparatus and pump for proper
operation observing piping and seals for
leaks
GEARBOX COVER
REMOVAL
1. Remove the air vent from the gearbox
cover.
2. Remove (12) 5/16-18 x 3/4 in long cap
screws then remove the gearbox cover and
gasket.
3. Scrape all remaining gasket material from
the gearbox and mating surfaces.
INSTALLATION
1. Apply a light coating of general purpose
grease to the gasket and gearbox mating
surfaces.
2. Align gasket and cover on gearbox.
3. Apply Loctite 242 (or equal) then secure
cover using (12) 5/16-18 x 3/4 in long cap
screws. Tighten to 40 ft-lb (54 Nm)
4. Install air vent on gearbox cover.
SLIDING GEAR SHAFT
REMOVAL AND DISASSEMBLY
1. Remove gearbox cover.
2. Unscrew (4) 7/16-14 x 1 in long cap screws
then remove the front bearing cap with
attached components. Remove the gasket
from the front bearing cap and gearbox.
3. Place the front bearing cap assembly on a
stable work surface with the drive flange
facing down.
14
4 Remove speedcounter adapter and gear
from bearing cap.
4. Using retaining ring pliers remove retaining
ring from the sliding gear shaft. Remove the
214G bearing from the front bearing cap
and sliding gear shaft.
5. Take the front bearing cap off the sliding
gear shaft. Using a press, remove oil seal
from the front bearing cap. If damaged,
remove bushing from speed counter hole in
front bearing cap.
INSPECTION
1. Clean bearings and other components
using parts cleaner.
2. Carefully inspect bearings and seals for
signs of excessive wear.
3. Obtain new components from Hale
Products.
REASSEMBLY AND INSTALLATION
1. Insert new bushing in speed counter hole in
front bearing cap.
2. Carefully press a new oil seal into the front
bearing cap.
3. Carefully slide bearing cap over the sliding
gear shaft
4. Slide 214G bearing over the sliding gear
shaft. Install retaining ring to hold bearing in
place.
5. Install speed counter gear and adapter.
6. Using a light coating of general purpose
grease to hold gasket in place align a new
gasket to the front bearing cap.
7. Place the needle bearing onto the end of
the sliding gear shaft.
8. Carefully aligning the sliding gear shaft with
the sliding gear, install sliding gear and front
bearing cap into gearbox.

9. Apply a coating of Loctite 242 (or equal)
then install (4) 7/16-14 x 1 in long cap screws
and torque to 40 ft-lb (54 Nm)
10. Install gearbox cover
TAIL SHAFT
REMOVAL AND DISASSEMBLY
1. Remove gearbox cover and sliding gear
shaft.
2. Reach through the gearbox cover opening
and remove sliding gear from the tail shaft.
3. Unscrew (4) 7/16-14 x 1 in long cap screws
then remove the rear-bearing cap with
attached components. Remove the gasket
from the rear bearing cap and gearbox.
4. Place the rear bearing cap assembly on a
stable work surface with the drive flange
facing down.
5. Using retaining ring pliers remove retaining
ring from the tail shaft. Remove the 214K
bearing from the rear bearing cap and tail
shaft.
6. Remove the retaining rings then the 214KG
bearing from the rear bearing cap and the
tail shaft.
7. Use a press to remove the oil seal from the
rear bearing cap.
INSPECTION
1. Clean bearings and other components
using parts cleaner.
2. Carefully inspect bearings and seals for
signs of excessive wear.
3. Obtain new components from Hale
Products
REASSEMBLY AND INSTALLATION
1. Carefully press a new oil seal into the front
bearing cap.
2. Carefully slide bearing cap over the tail
4D Series Pumps
shaft
3. Slide 214KG bearing over the tail shaft.
Install retaining rings to hold bearing in
place.
4. Slide 214K bearing over the tail shaft in rear
bearing cap.
5. Install retaining ring to hold bearing in place
6. Using a light coating of general purpose
grease to hold gasket in place align a new
gasket to the rear bearing cap.
7. Install tail shaft and rear bearing cap into
gearbox.
8. Apply a coating of Loctite 242 (or equal)
then install (4) 7/16-14 x 1 in long cap screws
and torque to 40 ft-lb (54 Nm)
9. Install sliding gear shaft and gearbox cover.
VPS
REMOVAL
1. Loosen 3/8-16 nut and remove rod end and
nut from end of shift shaft.
2. Unscrew (2) 5/16-18 x 1 in long screws and
(2) 5/16-18 nuts.
3. Remove VPS cover and seal ring.
4. Using a scribe remove scraper and seal ring
from the VPS cover taking care to not
damage the sealing edge of the groove..
5. Remove (2) 5/16-18 studs from VPS cylinder.
6. Remove retaining ring from shift shaft. Pull
shift shaft out until VPS piston can be
removed from shaft.
7. Remove VPS piston from shaft then remove
seal rings.
8. Remove remaining retaining ring from shaft.
9. Unscrew (2) 7/16-14 x 1 in long cap screws
then remove VPS cylinder and gasket.
15
4D Series Pumps

CAP O-RING
PISTION SEAL RING

(2) 5/16- UNC x LG SCREWS PISTON

SHIFT SHAFT CYLINDER
WIPER SEAL RING
NUT

PISTON O-RING
ROD END

CAP SEAL RING RETAINING

RINGS*
VPS CAP
CARBON
(2) 5/16- UNC x LG STUD SEAL RING

SHIFT CYLINDER
(2) 5/16- UNC NUTS
* MAKE SURE THE FLAT SIDE OF RETAINING RINGS FACE AWAY FROM THE PISTON
Figure 5 VPS Parts

10. Remove seal ring from VPS cylinder.
INSTALLATION
1. Install new seal ring in VPS cylinder groove.
2. Using a light coating of general purpose
grease to hold it in place install gasket on
gearbox. Align VPS cylinder and secure
using (2) 7/16-14 x 1 in long cap screws.
3. Install one retaining ring on inner groove of
shift shaft making sure the flat side of the
retaining ring faces into the cylinder away
from the piston face.
4. Apply a light coating of general purpose
grease to seal rings before installation.
Install new seal rings to the inner and outer
grooves of the piston then install piston on
shaft. Make sure the flat side of the piston is
towards the inside of the cylinder.
5. Install outer retaining ring on the shift shaft
to hold the piston in place making sure the
flat side of the retaining ring faces away
from the piston face.
6. Make sure the piston and shaft move freely
in the shift cylinder.
7. Apply Loctite 242 (or equal) to (2) 5/16-18
studs and install in VPS cylinder.
8. Apply a light coating of general purpose
grease then install the scraper and seal
rings in the VPS cover.
9. Install VPS cover with scraper and seal rings
over the shaft.
10. Apply Loctite 242 (or equal) then install (2)
5/16-18 x 1 in long screws and (2) 5/16-18
nuts.
11. Install rod end and 3/8-16 nut on end of shift
shaft. Lock the rod end with the nut.
4DG4 and 4D6G-35 SHIFT SWITCH
REMOVAL
1. Disconnect control connection.
2. Unscrew ½-20 x ½ in long set-screw then
remove spring and ball.
3. Remove (2) 7/16-14 x 1 in long cap screws,
then remove the gearshift shaft cap then
remove gasket from the mating surface of
the gearbox.

16
 4D Series Pumps

SETSCREW SETSCREW

SPRING SPRING

BALL BALL

SHIFT SHAFT SHIFT SHAFT

GEARSHIFT
SHAFT CAP GEARSHIFT
SWITCH SHAFT CAP
SWITCH
CAPSCREW
STUD BALL
GEARBOX NUT
GEARBOX
Figure 6 4DG4/4D6G-35 Shift Switch Figure 7 4DGK4-30 Shift Switch

4. Remove switch(es) from gearshift cap. 4. Detach switch from the switch bracket.

INSTALLATION 5. Lift switch ball out of the gearshift cap.

1. Apply a light coating of general purpose
grease to hold gasket in place then place
gasket on gearbox.
2. Align the gearshift shaft cap. Apply Loctite
242 (or equal) and install (2) 7/16-14 x 1 in
long cap screws.
3. Install ball and spring. Secure using ½-20 x ½
in long set-screw.
6. Unscrew ½-20 x ½ in long set-screw then
remove spring and ball.
7. Remove 7/16-14 x 1 in long cap screw and
remove 7/16-14 nut. Remove gearshift shaft
cap then remove gasket from the mating
surfaces of gearshift shaft cap and
gearbox.
8. If damaged, remove stud from gearbox.

4. Install a new seal ring on the switch(es) then
install switch(es) on gearshift cap.
5. Reconnect control connection.
4DGK4-30 SHIFT SWITCH
REMOVAL
1. Disconnect control connection.
2. Unscrew the #10-32 x 5/8 in long screws and
remove along with their lockwashers.
3. Remove the switch bracket and switch
attached. Remove the gasket from mating
surfaces of switch bracket and gearshift
cap.
8. Remove switch(es) from gearshift cap.
INSTALLATION
1. If required apply a light coating of Loctite
242 (or equal) to 7/16-14 stud and install in
gearbox
2. Apply a light coating of general purpose
grease to hold gasket in place then place
gasket on gearbox.
3. Align the gearshift shaft cap. Apply Loctite
242 (or equal) and install 7/16-14 x 1 in long
cap screw and 7/16-14 nut.
4. Install ball and spring. Secure using ½-20 x ½
in long set-screw.

17
4D Series Pumps
5. Place switch ball into the gearshift cap.
6. Install a new seal ring on the switch then
install switch on switch bracket.
7. Apply a light coating of grease to the
gasket. Align gasket and switch bracket to
gearshift cap.
8. Secure switch bracket using lockwashers
and the #10-32 x 5/8 in long screws.
9. Reconnect control connection.
SHIFT FORK
REMOVAL
1. Remove Sliding Gear Shaft Assembly, Tail
Shaft Assembly, VPS Assembly and Shift
Switch.
2. Release the gearshift fork by unscrewing 7/
16-14 x 1-3/4 in long cap screw.
3. Pull the shift-shaft from the gearbox and
remove gearshift fork from inside the
gearbox.
INSTALLATION
1. While holding the shift fork in place insert
shift shaft into gearbox housing through shift
fork.
2. Install 7/16-14 x 1-3/4 in long cap screw and
tighten to 25 ft-lb (34 Nm).
3. Install Shift Switch, VPS Assembly, Tail Shaft
Assembly, and Sliding Gear Shaft Assembly.
INTERMEDIATE GEAR (4D6G-35)
REMOVAL
1. Remove gearbox cover, sliding gear shaft
assembly and tail shaft assembly.
2. Remove (6) 7/16-14 x 1 in long cap screws,
washers, plates and gaskets.
3. Reach through the gearbox cover opening
and remove retaining rings from both sides
of the intermediate gear.
18
4. Tap the intermediate gear shaft to remove
from gearbox.
5. Remove intermediate gear from the
gearbox and, using a bearing puller,
remove the NJ-306ECJ bearings from
intermediate gear.
INSTALLATION
1. Using a press install the NJ-306ECJ bearings
into the intermediate gear.
2. Reaching in through the gearbox cover
opening align intermediate gear with the
intermediate gear shaft opening.
3. Tap the intermediate gear shaft into
gearbox through the intermediate gear.
4. Reach through the gearbox cover opening
and install retaining rings on both sides of
the intermediate gear.
5. Apply a light coating of general purpose
grease to the gaskets and place on
gearbox.
6. Apply Loctite 242 (or equal) then install (6)
7/16-14 x 1 in long cap screws, plates and
washers. Tighten capscrews to 40 ft-lb (54
Nm).
7. Install tail shaft assembly, sliding gear shaft
assembly and gearbox cover.
INTERMEDIATE GEAR (4DG4 and 4DGK4-
30)
REMOVAL
1. Remove gearbox cover, sliding gear shaft
assembly and tail shaft assembly.
2. Remove (2) 7/16-14 x 1 in long cap screws,
washers and gaskets.
3. Reach through the gearbox cover opening
and remove retaining rings from both sides
of the intermediate gear.
4. Tap the intermediate gear shaft to remove
from gearbox. Remove pin.

5. Remove intermediate gear from the
gearbox and, using a bearing puller,
remove the 306G bearings from
intermediate gear.
INSTALLATION
1. Using a press install the 306 bearings into the
intermediate gear.
2. Reaching in through the gearbox cover
opening align intermediate gear with the
intermediate gear shaft opening.
3. Tap the intermediate gear shaft into
gearbox through the intermediate gear.
Make sure slot for pin aligns with slot in
gearbox housing. Install pin.
4. Reach through the gearbox cover opening
and install retaining rings on both sides of
the intermediate gear.
5. Apply a light coating of general purpose
grease to the gaskets and place on
gearbox.
6. Apply Loctite 242 (or equal) then install (2)
7/16-14 x 1 in long cap screws and washers.
Tighten capscrews to 40 ft-lb (54 Nm).
7. Install tail shaft assembly, sliding gear shaft
assembly and gearbox cover.
NOTE: The pump body can be removed while
the pump and gearbox assembly are mounted
on the apparatus. Before working on the
pump disconnect suction and discharge piping
and drain the pump body.
PUMP BODY
REMOVAL
1. Remove the ¼ NPT pipe plug from the
pump body.
2. Remove (12) 7/16-14 x 1-1/4 in long cap
screws and washers that hold the pump
body assembly to the pump head
assembly.
3. Remove pump body from the pump head
4D Series Pumps
being careful not to damage clearance
ring and impeller.
4. Remove remaining gasket material from the
mating surface of the pump body and the
pump head.
INSPECTION
Before attempting assembly of the pump, the
following components must be checked.
Replace the components if inspection
indicates they are not within tolerances
specified.
1. Inspect the impeller for signs of wear.
Replace impeller if hubs are worn or
damaged beyond repair. Measure the
outside diameter of the impeller hubs:
New impeller hub diameter = 4.752 to 4.754
in (120,701 to 120,752 mm)
Wear limits = 4.747 to 4.754 in (120,574 to
120,752 mm)
2. Inspect clearance rings for signs of wear.
Measure the inside diameter of the
clearance rings while they are pressed into
the pump body and pump head.
New clearance ring diameter (pressed) =
4.770 to 4.777 in (121,158 to 121.336 mm)
Wear Limits = 4.770 to 4.787 in (121,158 to
121,590 mm)
INSTALLATION
1. If required remove worn clearance ring
then press a new clearance ring into the
pump body.
2. Apply a light coating of grease to the
gasket and align on the pump head.
3. Install pump body to the pump head being
careful not to damage clearance ring and
impeller.
4. Apply a coating of Loctite 242 (or equal)
and install (12) 7/16-14 x 1-1/4 in long cap
screws and washers that hold the pump
19
4D Series Pumps
body assembly to the pump body.
5. Install the ¼ NPT pipe plug in the pump
body.
IMPELLER
REMOVAL
1. Remove pump body.
2. Remove pin that locks the impeller nut to
the pump shaft.
3. While holding the impeller with a strap
wrench, remove impeller nut.
4. Pull impeller from the pump shaft. After
impeller is removed, remove impeller key.
5. If replacing mechanical seal, remove the
mechanical seal spring and mechanical
seal bellows from pump shaft. Remove
stationary seat from pump head.
INSPECTION
Inspect the impeller for signs of wear.
Replace impeller if hubs are worn or
damaged beyond repair. Measure the
outside diameter of the impeller hubs.
INSTALLATION
1. If the mechanical seal is being replaced,
apply a generous coating of Pac-Ease
Rubber Lubricant Emulsion (or equal) to the
o-ring on the outside of the stationary seat.
Carefully slide the stationary seat over the
pump shaft and press the stationary seat
into the pump head. Use the disk from the
seal packaging to push the stationary seat
in place. Without touching the running face
make sure the stationary seat is seated in
the bore of the pump head.
2. If the mechanical seal is being replaced,
apply a generous coating of Pac-Ease
Rubber Lubricant Emulsion (or equal) to the
pump shaft and seal diaphragm. Without
touching the carbon seal ring push the
carbon seal ring, diaphragm, retainer and
drive ring onto the shaft. Keep the shaft
20
well lubricated and make sure the carbon
seal ring seats against the stationary seat. If
binding occurs apply additional lubricant.
Slide any springs, cupwashers, etc supplied
with the seal onto the shaft. Make sure the
spring seats on the drive flange.
3. Install impeller key in slot on pump shaft.
Carefully slide impeller over pump shaft
aligning keyway with impeller key.
4. While holding the impeller with a strap
wrench, tighten impeller nut.
5. Install pin to lock the impeller nut to the
pump shaft.
6. Install pump body.
PUMP HEAD
REMOVAL
1. Remove pump body and impeller.
2. Remove (4) 7/16-14 x 1 in long cap screws
and washers that secure the pump head to
the gearbox.
3. Remove the pump head from the gearbox
being careful not to damage the pump
shaft.
4. Remove gasket from the mating surfaces of
the pump head and gearbox.
5. Use a press to remove the oil seal and
mechanical seal seat from the pump head.
INSPECTION
Inspect clearance ring for signs of wear.
Measure the inside diameter of the
clearance ring while it is pressed into the
pump head.
INSTALLATION
1. Use a press tool to install a new oil seal
2. Apply a generous coating of Pac-Ease
Rubber Lubricant Emulsion (or equal) to the
o-ring on the outside of the stationary seat.
Press the stationary seat into the pump
 4D Series Pumps

head. Use the disk from the seal cup seats in gearbox bore.
packaging to push the stationary seat in
place. Without touching the running face 3. Install bearing cup and cone assembly on
make sure the stationary seat is seated in opposite side of gearbox.
the bore. 4. Install pump head.
3. Apply a coating of general purpose grease 5. Obtain an assortment of shims before
to the gasket and align gasket on the pump proceeding with installation of the bearing
head. cap. Install a dial indicator to measure
4. Install the pump head on the gearbox bearing play on the impeller end of the
being careful not to damage the oil seal, pump shaft.
stationary seat and pump shaft. NOTE: Axial shaft float or bearing play must
5. Apply Loctite 242 (or equal) and install (4) 7/ be set at 0.003 to 0.005 in using shim set
16-14 x 1 in long cap screws and washers to (Hale P/N 046-6760-00-0). More than one
secure the pump head to the gearbox. shim set may be required.
Tighten capscrews to 40 ft-lb (54 Nm)
Each shim set consists of the following shims:
6. Install impeller and pump body.
3pcs 0.005 in thk BLUE
PUMP SHAFT (4D6G-35)
3pcs 0.0075 in thk CLEAR
REMOVAL
4 pcs 0.020 in thk YELLOW
1. Remove pump body, impeller and pump
head. 6. Place 3 or 4 yellow shims behind the
bearing cover. Install bearing cover and shims
2. Unscrew (4) 7/16-14 x 1 in long cap screws using (4) 7/16-14 x 1 in long cap screws.
allowing removal of bearing cover and Tighten cap screws to 40 ft-lb (54 Nm).
shims. Clean the mating surfaces of all shim
material. 7. Observe and record bearing play on dial
indicator. If necessary remove bearing
3. Using the proper pushing tool remove the
pump shaft and attached components out
of the gearbox from the bearing cover side
to the pump side. BEARING GEARBOX
CAP HOUSING
BEARING
4. Note the orientation of bearing cups and CONE
cones for proper reassembly.
MEASURE
BEARING PLAY
5. Remove tapered roller bearing cones from
each side of pump shaft. If necessary
remove the cups from the gearbox bores. If
necessary use a bearing removal tool.
BEARING PLAY MUST BE
INSTALLATION SET TO 0.003 to 0.005 IN AS
MEASURED WITH DIAL
INDICATOR AT END OF
1. Install bearing cone assembly on impeller PUMP SHAFT
side of pump shaft.
SHIMS BEARING
2. Carefully slide pump shaft through gearbox CUP
from impeller side making sure the bearing Figure 8 PUMP BEARING SHIM PLACEMENT
(4D6G-35)

21
4D Series Pumps

cover and add or remove shims as

2. Apply a generous coating of Pac-Ease
required. Reinstall bearing cover and
Rubber Lubricant Emulsion (or equal) to the
measure bearing play. Repeat until proper
pump shaft and seal diaphragm. Without
bearing play of 0.003 to 0.005 in is achieved
touching the carbon seal ring push the
as measured on the dial indicator. Shaft
carbon seal ring, diaphragm, retainer and
should rotate smoothly and freely.
drive ring onto the shaft. Keep the shaft
8. Install impeller and pump body. well lubricated and make sure the carbon
seal ring seats against the stationary seat. If
MECHANICAL SEAL REPLACEMENT binding occurs apply additional lubricant.
Slide any springs, cupwashers, etc supplied
REMOVAL with the seal onto the shaft. Make sure the
spring seats on the drive flange.
1. Remove pump body and impeller.
3. Install impeller and pump body.
2. Remove old mechanical seal stationary

CARBON
SEAL RING
DIAPHRAGM
PUMP HEAD
RETAINER SPRING
O-RING IMPELLER
STATIONARY
SEAT

TOWARDS IMPELLER
PUMP HEAD PUMP SHAFT SIDE

Figure 9 Mechanical Seal Parts

seat from the pump head.

3. Make sure all remaining components are

clean and free of damage.

INSTALLATION

1. Apply a generous coating of Pac-Ease

Rubber Lubricant Emulsion (or equal) to the
o-ring on the outside of the mechanical
seal stationary seat. Carefully slide the
stationary seat over the pump shaft being
careful to not touch the face of the seal
with fingers. Use the disk from the seal
packaging to push the stationary seat in
place. Without touching the running face
make sure the stationary seat is seated in
the bore.

22
 4D Series Pumps

PART LIST HALE 4D6G-35

PART NUMBER QTY DESCRIPTION
1 001-0331-01-0 1 4D6 PUMP BODY
2 002-0210-04-0 1 4D6G PUMP HEAD
3 004-0371-08-0 1 4D6G-35 GEARBOX HOUSING
4 005-0680-01-0 2 INTERMEDIATE SHAFT COVER
5 016-0342-01-0 1 4DG IMPELLER
6 017-0581-00-0 1 IMPELLER KEY
7 018-1406-02-0 12 SCREW 5/16-18 UNC X 3/4 INCHES LONG PLATED
8 018-1810-07-0 23 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED
9 018-1810-19-0 2 SCREW 7/16-14 UNC X 1 INCHES LONG
10 018-1812-07-0 4 SCREW 7/16-14 UNC X 1-1/4 INCHES LONG
11 018-1812-17-0 12 SCREW 7/16-14 UNC X 1-1/4 INCHES LONG
12 018-1816-02-0 1 SCREW 7/16-14 UNC X 1-3/4 INCHES LONG ZINC PLATED
13 018-5002-00-0 4 SCREW #4 X 1/4 INCHES LONG PLATED
14 028-0041-05-0 1 GEARSHIFT FORK
15 031-1250-00-0 1 SLIDING GEAR
16 031-1410-00-0 1 INTERMEDIATE GEAR
17 037-3001-00-0 1 PUMP SHAFT
18 037-3010-00-0 1 INTERMEDIATE GEAR SHAFT
19 044-0310-00-0 1 AIR VENT
20 044-0430-02-0 1 GEARBOX COVER
21 044-1710-00-0 1 BEARING CAP TAPERED ROLLER BEARINGS
22 046-0440-00-0 1 GASKET
23 046-5130-01-0 2 GEARBOX BEARING COVER GASKET
24 046-5270-01-0 1 GASKET
25 046-5340-01-0 1 PUMP HEAD GASKET
26 046-6390-00-0 2 SHAFT GASKET
27 046-6760-00-0 1 PUMP SHAFT SHIM SET
28 064-0526-12-0 1 SPRING PIN
29 077-1180-04-0 2 710S118 RETAINING RING
30 077-2810-00-0 1 79S281 RETAINING RING
31 097-0250-00-0 12 WASHER
32 097-0260-01-0 4 SEALING WASHER
33 101-0082-00-0 1 GEARBOX SERIAL NUMBER PLATE
34 110-7040-01-0 1 4DG IMPELLER NUT
35 217-0201-06-0 1 1/4 NPT ALUMINUM SQUARE HEAD PLUG
36 217-0401-00-0 1 1/2 NPT PLUG
37 217-0501-00-0 1 3/4 NPT PLUG
38 217-0501-08-0 1 3/4 NPT MAGNETIC PIPE PLUG
39 250-8010-00-0 1 NEEDLE BEARING
40 250-8170-00-0 2 NJ-306ECJ BEARING
41 250-8190-00-0 2 TAPERED ROLLER BEARING
42 296-2610-00-0 1 PUMP SHAFT OIL SEAL
43 296-5022-00-0 1 MECHANICAL SEAL
44 321-0150-00-0 2 CLEARANCE RING

23
4D Series Pumps

PART LIST HALE 4D6G-35

PART NUMBER QTY DESCRIPTION
537-1530-00-0 1 TAIL SHAFT ASSEMBLY
45 008-0561-00-0 1 REAR BEARING CAP
46 077-2750-01-0 3 RETAINING RING
47 077-5000-00-0 1 79S5000 RETAINING RING
48 101-1730-00-0 1 SHAFT FLANGE CAUTION STICKER
49 250-0214-00-0 1 214K BEARING
50 250-0214-06-0 1 214KG BEARING
51 296-2540-00-0 1 OIL SEAL
52 537-1750-00-0 1 TAIL SHAFT

537-1530-04-0 1 SLIDING GEAR SHAFT ASSEMBLY

53 008-0571-00-0 1 FRONT BEARING CAP
54 077-2750-01-0 1 RETAINING RING
55 101-1730-00-0 1 SHAFT FLANGE CAUTION STICKER
56 142-0160-00-0 1 SLINGER
57 250-0214-06-0 1 214KG BEARING
58 296-2540-00-0 1 OIL SEAL
59 537-1740-00-0 1 SLIDING GEAR SHAFT
60 007-0040-00-0 1 SPEEDCOUNTER ADAPTER
61 008-0070-00-0 1 SPEEDCOUNTER ADAPTER CAP
62 031-0170-00-0 1 SPEEDCOUNTER DRIVE GEAR
63 046-1620-00-0 1 SPEEDCOUNTER GASKET
64 048-0070-00-0 1 SPEEDCOUNTER BUSHING

GEARSHIFT SWITCH ASSEMBLY

65 008-0053-02-0 1 GEARSHIFT SHAFT CAP
66 018-2104-61-0 1 SCREW 1/2-20 UNF X 1/2 INCHES LONG PLATED
67 039-0050-00-0 1 BALL
68 040-8210-00-0 1 SEAL RING
69 042-0060-00-0 1 SPRING
70 046-5060-00-0 1 GASKET
71 200-2450-00-0 1 GEARSHIFT SWITCH
72 217-3410-00-0 1 9/16-18 DUST CAP PLUG

MISCELLANEOUS COMPONENTS NOT SHOWN IN EXPLODED VIEW DRAWING

546-0720-00-0 1 MIDSHIP LIGHT & NAMEPLATES
200-0540-02-0 5 BULB-14 V,0.24 AMP,3.4 W,2 CP
200-0540-08-0 1 LIGHT ASSY FOR PLATE NO.512J
200-0540-12-0 5 INDICATOR LIGHT BODY
200-0540-14-0 5 GREEN LENS
518-0030-00-0 1 SCREW PACK FOR PANEL PLATE

101-0252-00-0 2 INDICATOR LIGHT PLATE

101-0291-00-0 2 INSTRUCTION PLATE
101-0310-00-0 1 GEARBOX OIL WARNING TAG
101-0381-00-0 1 OPERATOR PANEL PLATE

24
 8
4 19
26 7 20
18
29
63 30
61 16 24
29
64 8
21 1
55 62
60 40 27
8

59 23 51
41
57
56 44
54
58
15 5
53
28 34
44
36 17
6

41
26
32 35
44 4 29 11
21
SEE VPS PARTS LIST 14
FIGURE 8 46
54
42
3
12 50
38 33 11
13 47 31
46
2

49
9 11 22
70

72 23
68
65 45
51
71 39
67
69
52
66 48

PART LIST HALE 4D6G-35

25
4D Series Pumps
4D Series Pumps

PART LIST HALE 4DG4 & 4DGK4-30

PART NUMBER QTY DESCRIPTION
1 001-0320-01-0 1 4D PUMP BODY (DISCHARGE OPPOSITE SUCTION SIDE)
001-0320-03-0 1 4D PUMP BODY (DISCHARGE SUCTION SIDE)
001-0320-04-0 1 4D PUMP BODY (DISCHARGE FRONT AND REAR)
2 002-0210-01-0 1 4D PUMP HEAD
3 004-0371-02-0 1 GEARBOX HOUSING (2.67 & 1.92 RATIO) (4DG4)
004-0371-03-0 1 GEARBOX HOUSING (3.00 & 2.18 RATIO) (4DG4)
004-0371-04-0 1 GEARBOX HOUSING (1.27 RATIO) (4DG4)
004-0371-06-0 1 GEARBOX HOUSING (4DGK4-30)
4 005-0680-01-0 2 INTERMEDIATE SHAFT COVER (4DG4)
5 016-0341-01-0 1 4DG IMPELLER (4DG4)
016-0342-01-0 1 4DG IMPELLER (4DGK4-30)
6 017-0020-00-0 1 KEY
7 017-0520-00-0 1 GEAR KEY
8 017-0580-00-0 1 IMPELLER KEY (4DG4)
017-0581-00-0 1 IMPELLER KEY (4DGK4-30)
9 018-1406-02-0 12 SCREW 5/16-18 UNC X 3/4 INCHES LONG PLATED (4DG4)
018-1406-82-0 12 SCREW 5/16-18 UNC X 3/4 INCHES LONG PLATED (4DGK4-30)
10 018-1806-02-0 4 SCREW 7/16-14 UNC X 3/4 INCHES LONG PLATED (4DG4)
11 018-1810-07-0 23 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED (4DG4)
018-1810-83-0 19 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED (4DGK4-30)
12 018-1812-17-0 12 SCREW 7/16-14 UNC X 1-1/4 INCHES LONG
13 018-1816-02-0 1 SCREW 7/16-14 UNC X 1-3/4 INCHES LONG ZINC PLATED (4DG4)
018-1814-82-0 1 SCREW 7/16-14 UNC X 1-1/2 INCHES LONG ZINC PLATED (4DGK4-30)
14 018-2012-70-0 1 SCREW 1/2-13 UNC X 1-1/4 INCHES LONG PLATED (4DG4)
15 018-5002-00-0 4 SCREW #4 X 1/4 INCHES LONG PLATED (4DG4)
018-5002-04-0 4 SCREW #4 X 1/4 INCHES LONG PLATED (4DGK4-30)
16 018-8040-00-0 1 STUD (4DGK4-30)
17 028-0041-03-0 1 GEARSHIFT FORK (4DG4)
028-0041-00-0 1 GEARSHIFT FORK (4DGK4-30)
18 031-0461-00-0 1 PUMP GEAR (22 TEETH) (4DG4)
031-0471-00-0 1 PUMP GEAR (16 TEETH) (4DG4)
031-0481-00-0 1 PUMP GEAR (25 TEETH) (4DG4)
031-1050-00-0 1 PUMP GEAR (18 TEETH) (4DG4)
031-1060-00-0 1 PUMP GEAR (28 TEETH) (4DG4)
031-1230-00-0 1 PUMP GEAR (25 TEETH) (4DGK4-30)
19 031-1070-00-0 1 SLIDING GEAR (28 TEETH) (4DG4)
031-1080-00-0 1 SLIDING GEAR (48 TEETH) (4DG4)
031-1250-00-0 1 SLIDING GEAR (4DGK4-30)
20 031-1090-00-0 1 INTERMEDIATE GEAR (37 TEETH) (4DG4)
031-1430-00-0 1 INTERMEDIATE GEAR (4DG4)
031-1240-00-0 1 INTERMEDIATE GEAR (4DGK4-30)
21 037-1131-00-0 1 PUMP SHAFT (4DG4)
037-1133-01-0 1 PUMP SHAFT (4DGK4-30)
22 037-0530-00-0 1 INTERMEDIATE GEAR SHAFT
037-3010-00-0 1 INTERMEDIATE GEAR SHAFT
23 044-0260-00-0 1 AIR VENT (4DG4)

26
 4D Series Pumps

PART LIST HALE 4DG4 & 4DGK4-30

PART NUMBER QTY DESCRIPTION
044-0310-00-0 1 AIR VENT (4DGK4-30)
24 044-0840-00-0 1 GEARBOX COVER (4DG4)
044-0430-02-0 1 GEARBOX COVER (4DGK4-30)
25 044-0880-00-0 1 BEARING COVER (4DG4)
044-1180-01-0 1 BEARING COVER (4DGK4-30)
26 046-0440-00-0 1 PUMP GASKET
27 046-5130-01-0 2 GEARBOX BEARING COVER GASKET
28 046-5270-01-0 1 DRIVE UNIT COVER GASKET
29 046-5340-00-0 1 PUMP HEAD GASKET
30 046-6390-00-0 2 SHAFT GASKET (4DG4)
31 064-0526-12-0 1 SPRING PIN (4DGK4-30)
32 064-6260-00-0 1 DOWEL PIN 1/8 DIA X 3/8 INCHES LONG STEEL (4DGK4-30)
33 077-1180-04-0 2 710S118 RETAINING RING
34 077-2810-00-0 1 79S281 RETAINING RING (4DG4)
35 097-0250-00-0 16 WASHER (4DG4)
097-0250-00-0 12 WASHER (4DGK4-30)
36 097-0260-01-0 4 SEALING WASHR
37 097-0450-00-0 2 INTERMEDIATE SHAFT WASHER (4DGK4-30)
38 097-0890-01-0 1 WASHER 400 SERIES STAINLESS (4DG4)
39 101-0082-00-0 1 GEARBOX SERIAL NUMBER PLATE
40 110-7040-01-0 1 4DG IMPELLER NUT (4DGK4-30)
41 159-0540-00-0 1 PUMP SHAFT SPACER
42 217-0201-06-0 1 1/4 NPT ALUMINUM SQUARE HEAD PLUG
43 217-0401-00-0 1 1/2 NPT PLUG
44 217-0501-00-0 1 3/4 NPT PLUG (4DGK4-30)
45 217-0501-08-0 1 3/4 NPT MAGNETIC PIPE PLUG
46 250-0208-26-0 1 208MG BEARING
47 250-0307-20-0 1 307M BEARING
48 250-8010-00-0 1 NEEDLE BEARING
49 250-8170-00-0 2 NJ-306ECJ BEARING (4DG4)
250-0306-06-0 1 306KG BEARING (4DGK4-30)
50 296-2610-00-0 1 PUMP SHAFT OIL SEAL
51 296-5021-01-0 1 MECHANICAL SEAL
52 321-0150-00-0 2 CLEARANCE RING

537-1530-00-0 1 TAIL SHAFT ASSEMBLY

53 008-0561-00-0 1 REAR BEARING CAP
54 077-2750-01-0 3 RETAINING RING
55 077-5000-00-0 1 79S5000 RETAINING RING
56 101-1730-00-0 1 SHAFT FLANGE CAUTION STICKER
57 250-0214-00-0 1 214K BEARING
58 250-0214-06-0 1 214KG BEARING
59 296-2540-00-0 1 OIL SEAL
60 537-1750-00-0 1 TAIL SHAFT

27
4D Series Pumps

PART LIST HALE 4DG4 & 4DGK4-30

PART NUMBER QTY DESCRIPTION
537-1530-01-0 1 SLIDING GEAR SHAFT ASSEMBLY (4DG4)
537-1530-04-0 1 SLIDING GEAR SHAFT ASSEMBLY (4DGK4-30)
61 008-0571-00-0 1 FRONT BEARING CAP
62 077-2750-01-0 1 RETAINING RING
63 101-1730-00-0 1 SHAFT FLANGE CAUTION STICKER
64 142-0160-00-0 1 SLINGER
65 250-0214-06-0 1 214KG BEARING
66 296-2540-00-0 1 OIL SEAL
67 537-1740-00-0 1 SLIDING GEAR SHAFT
68 040-0180-00-0 1 SEAL RING (4DG4)
69 007-0040-00-0 1 SPEEDCOUNTER ADAPTER
70 008-0070-00-0 1 SPEEDCOUNTER ADAPTER CAP
71 046-1620-00-0 1 SPEEDCOUNTER GASKET
72 031-0170-00-0 1 SPEEDCOUNTER DRIVE GEAR
73 048-0070-00-0 1 SPEEDCOUNTER BUSHING

GEARSHIFT SHAFT CAP ASSEMBLY (4DG4)

74 008-0053-02-0 1 GEARSHIFT SHAFT CAP (4DG4)
75 018-2104-61-0 1 SCREW 1/2-20 UNF X 1/2 INCHES LONG PLATED (4DG4)
76 039-0050-00-0 1 BALL
77 040-8210-00-0 1 SEAL RING
78 042-0060-00-0 1 SPRING
79 046-5060-00-0 1 GASKET (SHIFT SWITCH_
80 200-2450-00-0 1 GEARSHIFT SWITCH (4DG4)
81 217-3410-00-0 1 9/16-18 DUST CAP PLUG (4DG4)

GEARSHIFT SHAFT CAP ASSEMBLY (4DGK4-30)

82 008-0051-00-0 1 GEARSHIFT SHAFT CAP (4DGK4-30)
83 018-1105-26-0 2 SCREW #10-32 X 3/4 INCHES LONG STAINLESS STEEL
84 018-2104-84-0 1 SCREW 1/2-20 UNF X 1/2 INCHES LONG PLATED (4DGK4-30)
85 019-1950-00-0 1 SWITCH BRACKET
86 038-1660-00-0 1 SWITCH
87 039-0050-00-0 1 BALL
88 039-1180-00-0 1 SWITCH BALL
89 040-8210-00-0 1 SEAL RING
90 042-0060-00-0 1 SPRING
91 044-1430-00-0 1 VENT
92 046-0950-01-0 1 SWITCH GASKET
93 046-5060-00-0 1 GASKET

28
 4D Series Pumps

PART LIST HALE 4DG4 & 4DGK4-30

PART NUMBER QTY DESCRIPTION
MISCELLANEOUS COMPONENTS NOT SHOWN ON EXPLODED VIEW DRAWING
200-0540-02-0 5 BULB-14 V,0.24 AMP,3.4 W,2 CP (4DGK4-30)
200-0540-08-0 1 LIGHT ASSY FOR PLATE NO.512J (4DGK4-30)
200-0540-12-0 5 INDICATOR LIGHT BODY (4DGK4-30)
200-0540-14-0 5 GREEN LENS (4DGK4-30)
518-0030-00-0 1 SCREW PACK FOR PANEL PLATE

101-0252-00-0 2 INDICATOR LIGHT PLATE (4DGK4-30)

101-0291-00-0 2 INSTRUCTION PLATE (4DGK4-30)
101-0310-00-0 1 GEARBOX OIL WARNING TAG
101-0381-00-0 1 OPERATOR PANEL PLATE

29
 4
11
30
23
11 32 9
24
22
33
71 34
37
70 X 33 20
28
73 38 1
63 72 14
69 49
11 10
25
67 27 51
65
64 52
62
66 47
5
61 19
31 40
41 52
4
18
7
8
X 35 42
SEE VPS PARTS LIST 44 11 29 11
37
FIGURE 21
17 4
30 46
54
50
15
11
13 58
45 39 12
15 55 36
54
2
86 91 89
79 9 85 57
83 11 26
4D Series Pumps

92 11
81 88
77 27
74 14
80 93 53
X 59
76 48
78 87 82
75 90
84 60
56
PART LIST HALE 4DG4 & 4DGK4-30

30
 4D Series Pumps

PART LIST VPS CYLINDER

5
17 18
10

2
15

16 8
3 15
12
7

11

14

13
9

6
PART NUMBER QTY DESCRIPTION
1 007-0080-02-0 1 VPS CYLINDER
2 018-1410-02-0 2 SCREW 5/16-18 UNC X 1 INCHES LONG PLATED (4DG4 & 4D6G)
018-1410-82-0 2 SCREW 5/16-18 UNC X 1 INCHES LONG PLATED (4DGK4-30)
3 018-1412-63-0 2 SCREW 5/16-18 UNC X 1-1/4 INCHES LONG (4DG4 & 4D6G)
018-1412-86-0 2 SCREW 5/16-18 UNC X 1-1/4 INCHES LONG (4DGK4-30)
4 018-1810-19-0 2 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED (4DG4)
018-1810-23-0 2 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED (4D6G)
018-1810-85-0 2 SCREW 7/16-14 UNC X 1 INCHES LONG PLATED (4DGK4-30)
5 028-0050-00-0 1 ROD END (4DG4 & 4D6G))
028-0050-01-0 1 ROD END (4DGK4-30)
6 037-1341-00-0 1 GEARSHIFT SHAFT
7 040-0410-00-0 1 SEAL RING
8 040-1130-03-0 1 40-3G56 SEAL RING
9 040-1169-03-0 1 40Q-3G75 SEAL RING
10 040-2109-00-0 1 40Q-4N75 SEAL RING
11 040-3349-00-0 1 40Q-6N262 SEAL RING
12 044-0210-01-0 1 VPS COVER
13 046-5060-00-0 1 GASKET
14 073-0020-01-0 1 VPS PISTON
15 077-0750-05-0 2 78S75 RETAINING RING
16 110-1400-02-0 2 NUT 5/16-18 UNC PLATED HEX
17 110-1600-02-0 1 NUT 3/8-16 UNC PLATED HEX
18 296-0020-00-0 1 VPS SCRAPER
101-0850-03-0 1 VPS REPAIR INSTRUCTIONS (NOT SHOWN)

31
4D Series Pumps

PART LIST VPS CONTROL VALVE

3 5

2 4

PART NUMBER QTY DESCRIPTION

538-0180-00-0 1 VPS CONTROL VALVE
1 538-0181-01-0 1 VPS CONTROL VALVE
2 018-1205-44-0 4 SCREW 1/4-20 UNC X 5/8 INCHES LONG PASSIVATED
3 101-0072-00-0 1 VPS INSTRUCTION PLATE
4 110-1200-02-0 4 NUT 1/4-20 UNC ZINC PLATED STEEL
5 200-0540-00-0 1 GREEN INDICATOR LIGHT ASSEMBLY
200-0540-02-0 1 BULB-14 V,0.24 AMP,3.4 W,2 CP
200-0540-12-0 1 INDICATOR LIGHT BODY
200-0540-14-0 1 GREEN LENS

32
 4D Series Pumps

SLIDING GEAR
SHIFT FORK (SHOWN IN PUMP POSITION)

SHIFT SHAFT
GEAR SHIFT
SWITCH
ASSEMBLY

VPS ASSEMBLY 214KG BEARING

214K BEARING
214KG BEARING
REAR BEARING
OIL SEAL CAP

SLIDING GEAR TAIL SHAFT

SHAFT ASSEMBLY
ASSEMBLY
OIL SEAL

FRONT BEARING
CAP
1/4 NPT DRAIN
PLUG
PUMP
HEAD
INTERMEDIATE PUMP
GEAR IMPELLER BODY

INTERMEDIATE
GEAR SHAFT

IMPELLER
BEARING NUT
COVER
6 INCH VICTAULIC
PIN
SUCTION

IMPELLER
PUMP
KEY
SHAFT

SHIMS
CLEARANCE
GEARBOX RING
HOUSING TAPERED OIL SEAL MECHANICAL
ROLLER SEAL
BEARING ASSEMBLY

CLEARANCE OPTIONAL 4 INCH

RING VICTAULIC
4 INCH VICTAULIC DISCHARGE
DISCHARGE AVAILABLE

4D6G-35 COMPONENT IDENTIFICATION

33
4D Series Pumps

1/4 NPT DRAIN PLUG

INTERMEDIATE GEAR AND SHAFT

IMPELLER
PUMP BODY

IMPELLER NUT

BEARING COVER
PIN

IMPELLER KEY
PUMP SHAFT

SHIMS
GEARBOX HOUSING CLEARANCE RING
TAPERED ROLLER
BEARING
MECHANICAL
SEAL ASSEMBLY
OIL SEAL

PUMP HEAD CLEARANCE RING

4D6G-35 PUMP PART IDENTIFICATION

34
 4D Series Pumps

SLIDING GEAR
SHIFT FORK (SHOWN IN PUMP POSITION)

SHIFT SHAFT
GEAR SHIFT
SWITCH
ASSEMBLY

VPS ASSEMBLY 214KG BEARING

214K BEARING

214KG BEARING
REAR BEARING
OIL SEAL CAP

SLIDING GEAR TAIL SHAFT

SHAFT ASSEMBLY
ASSEMBLY
OIL SEAL

FRONT BEARING
CAP
PUMP
HEAD 1/4 NPT DRAIN
PLUG

INTERMEDIATE
GEAR IMPELLER PUMP
BODY
INTERMEDIATE
GEAR SHAFT

IMPELLER
BEARING NUT
COVER
4 INCH VICTAULIC
PIN
SUCTION

IMPELLER
PUMP SHAFT KEY

307M BEARING
SPACER
CLEARANCE
PUMP GEAR KEY RING
PUMP GEAR
GEARBOX HOUSING MECHANICAL
OIL SEAL SEAL
208MG BEARING
ASSEMBLY

CLEARANCE OPTIONAL 4 INCH

RING VICTAULIC
4 INCH VICTAULIC DISCHARGE
DISCHARGE AVAILABLE

4DG4/4DGK4-30 COMPONENT IDENTIFICATION

35
4D Series Pumps

1/4 NPT DRAIN PLUG

INTERMEDIATE GEAR IMPELLER PUMP

BODY
INTERMEDIATE SHAFT PIN

INTERMEDIATE GEAR SHAFT

IMPELLER NUT

PIN
BEARING COVER
IMPELLER KEY
PUMP SHAFT

307M BEARING
SPACER
PUMP GEAR KEY CLEARANCE RING
PUMP GEAR
GEARBOX HOUSING
208MG BEARING MECHANICAL SEAL ASSEMBLY
OIL SEAL CLEARANCE RING
PUMP HEAD

4DG4/4DGK4-30 PUMP PART IDENTIFICATION

36
 4D Series Pumps

OIL BREATHER

GEARBOX COVER

3/4 NPT
PLUG

3/4 NPT MAGNETIC

DRAIN PLUG
(BEHIND PUMP)

5/8-11 UNC x 1 INCH DEEP

MOUNTING HOLES
USE MINIMUM SAE GRADE 5 SCREWS

1/2 NPT OIL FILL

AND LEVEL PLUG
ROAD

PUMP

4D6G-35 INSTALLATION

37
4D Series Pumps

PNEUMATIC SHIFT INDICATOR

(AVAILABLE ON 4DGK4-30)
OIL BREATHER

GEARBOX COVER

3/4 NPT MAGNETIC

DRAIN PLUG
(BEHIND PUMP)

5/8-11 UNC x 1 INCH DEEP

MOUNTING HOLES
USE MINIMUM SAE GRADE 5 SCREWS

1/2 NPT OIL FILL

AND LEVEL PLUG
ROAD

PUMP

4DG4 & 4DGK4-30 INSTALLATION

38
 4D Series Pumps

4DG4 RECOMMENDED SPARES LIST

PART NUMBER QTY DESCRIPTION
016-0341-01-0 1 IMPELLER
017-0580-00-0 1 IMPELLER KEY
040-8210-00-0 1 SEAL RING
046-0440-00-0 1 PUMP BODY GASKET
046-1620-00-0 1 SPEEDCOUNTER COVER GASKET
046-5060-00-0 2 SHIFT CYLINDER AND CAP GASKET
046-5130-01-0 2 BEARING CAP GASKET
046-5270-01-0 1 MG GEARBOX COVER GASKET
046-5340-00-0 2 PUMP HEAD & BEARING COVER GASKET
046-5390-00-0 2 INTERMEDIATE SHAFT COVERGASKET
077-1180-04-0 2 710S118 RETAINING RING
077-2750-00-0 4 RETAINING RING
077-2810-00-0 1 79S281 RETAINING RING
077-5000-00-0 1 79S5000 RETAINING RING
200-2450-00-0 1 SHIFT SWITCH
200-0540-02-0 3 LIGHT BULB
250-0208-26-0 1 208MG BEARING
250-0214-00-0 1 214K BEARING
250-0214-06-0 2 214KG BEARING
250-0307-20-0 1 307M BEARING
250-8170-00-0 2 NJ-306ECJ BEARING
296-2610-00-0 1 PUMP SHAFT OIL SEAL
296-2540-00-0 1 GEARBOX OIL SEAL
296-5021-01-0 1 MECHANICAL SEAL
321-0150-00-0 2 CLEARANCE RING

39
4D Series Pumps

4DGK4-30 RECOMMENDED SPARES LIST

PART NUMBER QTY DESCRIPTION
016-0342-01-0 1 IMPELLER
017-0581-00-0 1 IMPELLER KEY
038-1660-00-0 1 SHIFT SWITCH
040-8120-00-0 1 SEAL RING
046-0440-00-0 1 PUMP BODY GASKET
046-0460-00-0 2 INTERMEDIATE SHAFT COVERGASKET
046-0950-01-0 1 SWITCH GASKET
046-1620-00-0 1 SPEEDCOUNTER COVER GASKET
046-5060-00-0 2 SHIFT CYLINDER AND CAP GASKET
046-5130-01-0 2 BEARING CAP GASKET
046-5270-01-0 1 MG GEARBOX COVER GASKET
046-5340-00-0 2 PUMP HEAD & BEARING COVER GASKET
077-1180-04-0 2 710S118 RETAINING RING
077-2750-00-0 4 RETAINING RING
077-5000-00-0 1 79S5000 RETAINING RING
200-0540-02-0 3 LIGHT BULB
250-0208-26-0 1 208MG BEARING
250-0214-00-0 1 214K BEARING
250-0214-06-0 2 214KG BEARING
250-0306-06-0 2 306KG BEARING
250-0307-20-0 1 307M BEARING
296-2610-00-0 1 PUMP SHAFT OIL SEAL
296-2540-00-0 1 GEARBOX OIL SEAL
296-5021-01-0 1 MECHANICAL SEAL
321-0150-00-0 2 CLEARANCE RING

40
 4D Series Pumps

4D6G-35 RECOMMENDED SPARES LIST

PART NUMBER QTY DESCRIPTION
016-0342-01-0 1 IMPELLER
017-0581-00-0 1 IMPELLER KEY
040-8210-00-0 1 SEAL RING
046-0440-00-0 1 PUMP BODY GASKET
046-1620-00-0 1 SPEEDCOUNTER COVER GASKET
046-5060-00-0 2 SHIFT CYLINDER AND CAP GASKET
046-5130-01-0 2 BEARING CAP GASKET
046-5270-01-0 1 MG GEARBOX COVER GASKET
046-5340-01-0 1 PUMP HEAD & BEARING COVER GASKET
046-5390-00-0 2 INTERMEDIATE SHAFT COVERGASKET
046-6760-00-0 AR SHIM SET
077-1180-04-0 2 710S118 RETAINING RING
077-2750-00-0 4 RETAINING RING
077-5000-00-0 1 79S5000 RETAINING RING
200-2450-00-0 1 SHIFT SWITCH
200-0540-02-0 3 LIGHT BULB
250-0214-00-0 1 214K BEARING
250-0214-06-0 2 214KG BEARING
250-8170-00-0 2 NJ-306ECJ BEARING
250-8190-00-0 2 TAPERED ROLLER BEARINGS
296-2610-00-0 1 PUMP SHAFT OIL SEAL
296-2540-00-0 1 GEARBOX OIL SEAL
296-5022-00-0 1 MECHANICAL SEAL
321-0150-00-0 2 CLEARANCE RING

41
 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