Document Outline

• Pump Ends Series, p/n: 029-0020-61-0, Rev-A
  • Notice !
  • Contents
  • 1 Safety Precautions
    • 1.1 Definitions
    • 1.2 General
    • 1.3 Fuel Safety
    • 1.4 Battery Safety
  • 2 Overview
    • 2.1 Pump Ends
      • Figure 2-1: Typical Pump End Pumping Systems
        • 20FS-2M / 20FS-3M / 20FS-4M Series, with Gearbox
        • 30FS2 / 30FS3 / 30FS4 Series, with Gearbox
        • 40FB / 50FB Series, Bell Housing or Pedestal Mount (-U-U Series)
        • FB50 / FB75 / FB100 Series, Bell Housing Mount
        • 60FBG Series, with Gearbox
        • 60FJ Series, Bell Housing Mount
        • 80FC Series, Bell Housing Mount
        • 80FC (-G or -U) Series, with gearbox (-G) or pedestal (-U)
    • 2.2 Pumping System Overview
      • Figure 2-2: Typical 20FS Series Pump System Overview
      • Figure 2-3: Typical 30FS Series Pump System Overview
      • Figure 2-4: Typical 40 / 50FB Series Pump System Overview
      • Figure 2-5: Typical FB50, FB75 and FB100 Series Engine Mount Pump End Overview
      • Figure 2-6: Typical 60FBG Series Pump System Overview
      • Figure 2-7: Typical 80FC Series Pump System Overview
      • Figure 2-8: Typical 80FC-U Series Pedestal Pump System Overview
      • Figure 2-9: Check Valve Option, Discharge
    • 2.3 Principles of Operation
      • Centrifugal Force
      • Figure 2-10: Centrifugal Force - Rotating Disk
      • Figure 2-11: Pump Water Flow, Cutwater
    • 2.4 Pump Components
      • Volute, Pump Body
      • Figure 2-12: Typical Pump and Gearbox Overview
      • Impeller
      • Figure 2-13: Impeller Operation
      • Clearance Rings
      • Mechanical Seal
      • Figure 2-14: Typical Mechanical Seal Overview
      • Ball Bearings
    • 2.5 Gearbox Option
    • 2.6 Pedestal Mounting Option
      • Figure 2-15: Pedestal Mount
    • 2.7 Hale Engine Mount Bell Housing
      • Figure 2-16: Bell Housing Mount
  • 2a Accessories / Options
    • 2a.1 Anodes
      • Figure 2a-1: Hale 1-1/4” NPT Anode
    • 2a.2 Auxiliary Cooling
      • Gearbox Manifold Coolers
      • Figure 2a-2: Typical Gearbox Manifold Coolers
      • Heat Exchanger, “K” Series
    • 2a.3 Pressure and Relief Valve Control
      • Figure 2a-3: Model “K” Heat Exchanger
      • P Series Relief Valve System
      • Figure 2a-4: P Series Relief Valve Control
      • Thermal Relief Valves (TRV)
      • Figure 2a-5: Thermal Relief Valve, TRV
        • TRV-L Kit
    • 2a.4 Priming Systems
      • Figure 2a-6: Rotary Vane ESP Priming Pump
      • Priming Valves
      • Figure 2a-7: SPVR Priming Valves
      • Figure 2a-8: PVG Priming Valves
    • 2a.5 Pump Shift, Automatic (VPS / KPS)
      • Figure 2a-9: Automatic Pump Shift Overview
      • Figure 2a-10: Pump Shift Control Valve
    • 2a.6 Torrent SVS Valves
      • Figure 2a-11: Typical SVS Valve Primary Components
  • 3 Basic Operation
    • 3.1 Overview
    • 3.2 Fluid Levels
    • 3.3 Preparing to Tow
    • 3.4 Pumping Operations
      • Initial Start Up
      • Pumping Operations
      • Figure 3-1: Typical Portable Pump Installation
      • Draft Operation Limiting Factors
    • 3.5 Relief Valve Procedures
      • Standard Relief Valve Procedures
      • TPM Relief Valve Procedures
      • Figure 3-2: TPM / PMD Relief Valve Control
    • 3.6 Post Operation Procedures
  • 4 Preventive Maintenance
    • 4.1 Overview
      • Preventive / General Maintenance
        • Engine
        • Skid and/or Trailer
        • Pump, Gearbox and Pedestal
        • Accessories
    • 4.2 Post-Operation
    • 4.3 Extreme Conditions
      • During Freezing Weather
    • 4.4 Weekly
      • Gearbox Option
        • To Check / Add Oil
      • Figure 4-1: Typical Drain, Fill and Level Plugs
      • Pedestal Option
        • To Check / Add Oil
      • Figure 4-2: Typical Pedestal Oil Servicing
      • Check / Add Engine Fluids
      • Relief Valve Test
      • Governor Test
      • Priming System
      • Valve Maintenance
      • Verify All Gauges are in Working Order
      • Intake Strainers
      • Inspect Water and Foam Tanks
      • Operate Pump Controls
    • 4.5 Monthly
      • Valve Lubrication
      • Check Gearbox or Pedestal Lubrication
      • Pump and Flange Bolts
      • Priming System Test (Dry Vacuum Test)
      • Figure 4-3: PVG Priming Valve Handle
    • 4.6 Annually
      • Pump Head Bearing Lubrication
      • Figure 4-4: Pump Head Bearing Lubrication
      • Change Gearbox Oil
      • Change Pedestal Oil
      • Relief Valve System Check
      • Check Drain Lines to Multi-Drain
      • Clean Priming Pump
      • Performance Testing Overview
      • Figure 4-5: Pump Ratings (GMP/LPM)
      • Tank-to-Pump Flow Rate Test
      • Performance Testing Equipment and Materials
      • Performance Testing
      • Worn Clearance Rings and Impeller Hubs
      • Anode Check
      • Figure 4-6: Hale Anode
  • 5 Troubleshooting
    • 5.1 Engine and Trailer
    • 5.2 Pump
      • Figure 5-1: Sample, Serial Nameplate
        • Pump Loses Prime or Will Not Prime.
        • Insufficient Pump Capacity.
        • Insufficient Pressure.
        • Remote Control Difficult to Operate.
        • Engine Speeds Too HIGH for Required Capacity or Pressure.
        • Cavitation
        • Relief Valve Does Not Relieve Pressure When Relief Valves are Closed.
        • Relief Valve Does Not Recover and Return to Original Pressure Setting After Opening Valves.
        • Relief Valve Opens When Control Valves are Locked Out.
        • Unable to Obtain Proper Setting on Relief Valves.
        • Discharge Valves Are Difficult to Operate.
        • Water/Moisture in Pump Gearbox.
        • Rotation Symptoms.
      • Figure 5-2: Troubleshooting Chart
  • 6 Repair
    • 6.1 Overview
    • 6.2 General Repair Guidelines
      • Before You Begin...
      • Table 6-1: Typical Torque Values Chart
      • Gearbox and Pedestal Assemblies
    • 6.3 Cleaning and Inspection Guidelines
      • Bearings
      • Tools Required
  • 6a Servicing the Pump
    • 6a.1 General Preparation
    • 6a.2 20FS Series Pump Only
      • Bearing Housing
      • Figure 6a-1: 20FS Series, Pump and Bearing Housing Overview
      • Removing the Pump
        • Pump Body (Halves)
        • Impellers (2)
        • Mechanical Seal - 20FS Series Pump Only
        • Installation Notes - Pump Body and Impellers
      • Oil Seal, Pump Shaft
      • Figure 6a-2: Oil Seal, Pump Shaft
        • Installation - Pump Head
    • 6a.3 All other Pumps
      • Suction Flange
      • Figure 6a-3: Typical Suction Flange Option
        • Installation Notes - Suction Flange
      • Volute (Pump Body)
      • Figure 6a-4: Typical Pump Disassembly Overview
        • Installation Notes - Volute (Pump Body)
      • Impeller
        • For 30 FS series pump
        • For all other pump models
        • (See Figure 6a-4: “Typical Pump Disassembly Overview” on page 92.)
      • Figure 6a-5: Placing Edges for Impeller Removal
      • Clearance Rings, Impeller Measurement
      • Figure 6a-6: Clearance Ring and Impeller ID / OD Measurement
      • Installation Notes - Impeller
    • 6a.4 Pump Shaft Oil Seals, with Bell Housing
      • Pump Head Assembly - 30 FS Series Only
        • Pump Shaft Oil Seal, 30 FS Series
      • Figure 6a-7: Replacing 30 FS Series Pump Shaft Oil Seal
        • Installation Notes - Pump Head, 30 FS Series
      • Bell Housing (Flywheel) Adapter, FB40 - FB100 Series Only
        • Pump Shaft Oil Seal, 40 - 100 FB Series
      • Figure 6a-8: Replacing 40FB - 100FB Series Pump Shaft Oil Seal
        • Pump Shaft Bearings, FB40 - FB100 Series
        • Installation Notes - Pump Head, FB40 - FB100 Series
      • Bell Housing (Flywheel) Adapter, 80 FC Series Only
        • Pump Shaft Oil Seal, 80 FC Series Only
      • Figure 6a-9: Replacing 80 FC Series Pump Shaft Oil Seal
        • Pump Shaft Bearings, 80 FC Series Only
        • Installation Notes - Bell Housing Adapter, 80 FC Series Only
    • 6a.5 Pump Shaft Oil Seals, with Pedestal Mount
      • Pedestal Mount, Pump Shaft Oil Seals
      • Figure 6a-10: Pedestal Mount Pump Shaft Oil Seals (2), 40 / 5- FB-U and 80 FC-U Series
        • Pump Shaft Bearings
        • Installation Notes - Pedestal
    • 6a.6 Pump Shaft Oil Seals, with Gearbox
  • 6b Mechanical Seal Assembly
    • 6b.1 Removing the Seal
      • Figure 6b-1: Typical Mechanical Seal Assembly
    • 6b.2 Installing Seal
      • Figure 6b-2: Typical Mechanical Seal Insertion Tool
      • Impeller and Volute Installation Notes
  • 6c Gearbox Service
    • 6c.1 General Preparation
    • 6c.2 20 / 30 FSG Series Gearbox
      • Removing the Gearbox and Bell Housing
      • Figure 6c-1: 20 / 30 FS Series Gearbox and Bell Housing Overview
      • Drive Shaft Oil Seal
      • Drive Shaft and Gearbox Assembly
      • Pump Shaft
      • Gearbox Installation Notes - 20 / 30 FS Series
    • 6c.3 50 / 60 / 80 FBG Series Gearbox
      • Pump Shaft and Shaft Oil Seal
      • Figure 6c-2: Pump Shaft Oil Seal, 50/60/80 FBG Series, with Gearbox
      • Installation Notes - Pump Shaft and Seal, 50/60/80 FBG
      • Gearbox and Bell Housing Assemblies
        • Bell Housing (Flywheel) Adapter
        • Drive Shaft Oil Seal
      • Figure 6c-3: Gearbox and Bell Housing Overview, 50/60/80 FBG Series Pump End
        • Gearbox, Intermediate and Drive Shafts
      • Installation Notes - Gearbox and Bell Housing, 50/60/80 FBG
  • 7 Installation
    • 7.1 Overview
    • 7.2 Frame Mounting
      • General Mounting
    • 7.3 Plumbing Connections
    • 7.4 Fluid Levels
    • 7.5 Check Flywheel Run Out
      • S.A.E. Housing Pilot Bore
      • S.A.E. Housing Mounting Face
      • Flywheel Pilot Bearing Bore
      • Drive Disk Pilot Bore
      • Drive Disk Mounting Face
  • Appendix A: Glossary
  • Appendix A-1: Measurements
    • Conversion Chart
  • Appendix C: Alternate Lubricant Manufacturers
    • Table C-1: Alternate Lubricant Manufacturers
  • Appendix C1: Lube and Sealant Specifications
    • Table C1-2: Oil Capacity and Recommendation
    • Grease
    • Loctite Sealant
    • Oil
    • Recommended Cleaners
  • Appendix D: Hose Friction Loss
    • Table D-1: Hose Friction Loss (PSI / BAR 100 Feet)
  • Appendix E: Nozzle Size vs. Pressure
    • Chart E-1: Nozzle Flow and Pressure Ratings, Part 1
    • Chart E-2: Nozzle Flow and Pressure Ratings, Part 2
  • Appendix F: Cavitation
    • Figure F-1: Sample, Cavitation Regions
    • Process of Cavitation
    • Warning Signs of Cavitation (Discharge and Gauges)
      • Discharge Pressure
      • Vacuum Compound Gauge
    • To Eliminate Cavitation
    • During Operations
    • Figure F-2: Lift Loss from Temperature
    • Figure F-3: Lift Loss from Elevation
    • Preventive Measures
    • Figure F-4: Hose Size vs. Pump Rating Capacity
  • Express Warranty
    • Hale Products, Inc.
  • Drawing Package
    • Contents
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