Document Outline

• Safety.pdf
  • 1 Safety Precautions
    • 1.1 Definitions
    • 1.2 Guidelines
• Introduction.pdf
  • 2 Introduction
    • 2.1 Description
    • 2.2 Principle of Operation
      • Centrifugal Force
        • Figure 2-1: Centrifugal Force - Rotating Disk
      • Pump Stages
        • Single-Stage
          • Figure 2-2: Water Flow, Typical Hale Single-Stage Pump
          • Figure 2-3: Single-Stage Pump Overview
        • Two-Stage
        • Volume (Parallel) Operation
          • Figure 2-4: Two-Stage Pump VOLUME Operation
          • Figure 2-5: Two-Stage Pump Overview
        • Pressure (Series) Operation
          • Figure 2-6: Two-Stage Pump PRESSURE Operation
        • Volume vs. Pressure Operation
        • Transfer Valve
        • Choosing Volume or Pressure Operation
        • General Guidelines
    • 2.3 Muscle Pump Components
      • Pump Body
        • Qmax, Qmid, and Qtwo Pumps
          • Figure 2-7: Typical Midship Two-Stage Centrifugal Pump
        • Qpak, Qflo and Qflo-Plus Pumps
      • Impeller
        • Figure 2-8: Impeller Operation
      • Clearance Rings
    • 2.4 Pump Seals
      • Packing Seals
        • Figure 2-9: Pump Packing Seal Assembly
      • Mechanical Seal
        • Figure 2-10: Mechanical Seal Assembly
      • Auto Lube ®
        • Figure 2-11: AutoLube Feature
    • 2.5 Pump Drives
    • 2.6 Gearbox
      • Figure 2-12: Typical Gearbox Overview
      • A-Series
      • G-Series
      • K-Series
      • J-Series
      • R-Series
      • Power Shift - Optional
      • Engine Rotation Option - Qmax-U and Qtwo-U
        • Figure 2-13: Pump/Engine Rotation
      • HALE Power Takeoff (PTO) Driven Midship Pumps
    • 2.7 Serial Number Identification
      • Figure 2-14: Typical Midship Pump Serial Number Location
• Accessories.pdf
  • 3 Accessories / Options
    • 3.1 Anodes
      • Figure 3-1: Hale 1-1/4” NPT Anode
    • 3.2 Auxiliary Cooling
      • Heat Exchanger, “K” Series
        • Figure 3-2: Model “K” Heat Exchanger
    • 3.3 Pressure and Relief Valve Control
      • Relief Valve System
        • Figure 3-3: PMD Series Relief Valve Control (Shown)
      • Thermal Relief Valves (TRV)
        • Figure 3-4: Thermal Relief Valve, TRV
        • TRV-L Kit
    • 3.4 Priming Systems
      • Figure 3-5: Rotary Vane ESP Priming Pump
      • Priming Valves
        • Figure 3-6: SPVR Priming Valve (Shown)
        • Figure 3-7: PVG Priming Valves
    • 3.5 Pump Shift, Automatic (VPS / KPS)
      • Figure 3-8: Automatic Pump Shift Overview
      • Figure 3-9: Pump Shift Control Valve
    • 3.6 Torrent SVS Valves
      • Figure 3-10: Typical SVS Valve Primary Components
    • 3.7 Additional Midship Accessories
      • Auxiliary Heat Exchanger / Cooler, Model K
        • Figure 3-11: Model “K” Heat Exchanger
      • Booster Pump Option, 2HP
        • Figure 3-12: 2HP Booster Pump Option
      • In-Line / Discharge Valves
      • Drain Valves
      • Suction Valves
        • Figure 3-13: Master Intake Valve (MIV)
      • Tank Suction Valves
      • Total Pressure Master (TPM) Relief Valve System
        • Figure 3-14: Hale (TPM) Total Pressure Master Relief Valve System
        • How the TPM Works
          • Figure 3-15: Typical TPM Relief Valve System, Condition 1
          • Figure 3-16: Typical TPM Relief Valve System, Condition 2
          • Figure 3-17: Typical TPM Relief Valve System, Condition 3
• Operation.pdf
  • 4 Basic Operation
    • 4.1 Overview
    • 4.2 Fluid Levels
    • 4.3 Stationary Pumping Operations
      • Pumping From a Hydrant, General Operation
        • Figure 4-1: Driver’s Compartment Indicator Lights
        • Figure 4-2: Pump Operator’s Panel
      • TPM Operation from a Hydrant
      • Draft Limiting Factors
      • Pumping From Draft
      • Pumping from On Board Water Tank (Split-Shaft PTO)
    • 4.4 Pumping In Relay
      • Relay Procedures
    • 4.5 Tandem (Series) Pumping
      • Tandem Procedures
    • 4.6 Pump-To-Road Shift Procedures
    • 4.7 Pump and Roll
    • 4.8 Relief Valve Procedures
      • Standard Relief Valve Procedures
      • TPM Relief Valve Procedures
        • Figure 4-3: TPM / PMD Relief Valve Control
      • TPM System with Engine Governor
        • Increasing Pressure
        • Decreasing Pressure
    • 4.9 Emergency Pump Shift Procedures
    • 4.10 Post Operation Procedures
• MidshipPumpMaintenanceChecklist.pdf
  • Midship Pump Maintenance Check List
    • Recommended “Weekly” Procedures
    • Recommended “Annual” Procedures
• PreventiveMaintenance.pdf
  • 5 Preventive Maintenance
    • 5.1 Overview
    • 5.2 Post Operation
    • 5.3 Extreme Conditions
      • During Freezing Weather
        • Pumping Salt Water, Contaminated Water, or Foam Solution
    • 5.4 Weekly
      • Relief Valve and TPM Test
      • Governor Test
      • Transfer Valve Test (Two-Stage Pumps Only)
      • Priming System Test
      • Pump Shift Warning Lights
      • Valve Maintenance
      • Intake Strainers
      • Verify All Gauges are in Working Order
      • Operate Pump Controls
      • Inspect Water and Foam Tanks
      • Check Auxiliary Engine
    • 5.5 Monthly
      • Valve Lubrication
      • Suction Check Valve Testing, Two-Stage Pumps
      • Gearbox Lubrication
      • Packing Gland Adjustment
        • Adjustment
      • Pump, Drive Line and Flange Bolts
      • Priming System Test (Dry Vacuum Test)
        • Figure 5-1: Priming Valve Handle
    • 5.6 Annual
      • Replace Gearbox Oil
      • Relief Valve System Check
      • Check Drain Lines to Multi-Drain
      • Clean Priming Pump
      • MIV Relief Valve Test and Adjustment
      • Performance Testing Overview
        • Tank-to-Pump Flow Rate Test
      • Performance Testing Equipment and Materials
      • Performance Testing
      • Thermal Relief Valve Test
      • Repacking the Seal
        • Figure 5-2: Pump Packing Seal Assembly
      • Worn Clearance Rings and Impeller Hubs
      • Anode Check
        • Figure 5-3: Hale 1-1/4” NPT Anode
        • Figure 5-4: Muscle Pump Service Chart, Part 1 of 3
        • Figure 5-5: Muscle Pump Service Chart, Part 2 of 3
        • Figure 5-6: Muscle Pump Service Chart, Part 3 of 3
• Troubleshooting.pdf
  • 6 Troubleshooting
• Repair.pdf
  • 7 Repair and Corrective Maintenance
    • 7.1 Overview
    • 7.2 General Repair Guidelines
      • Before You Begin...
      • Remove the Gearbox Assembly
    • 7.3 Cleaning and Inspection Guidelines
      • Bearings
      • Tools Required
    • 7.4 Removing the Pump Assembly
      • Figure 7-1: Typical Muscle (Midship) Pump Overview
      • Figure 7-2: Lifting Eyebolt Attachment Layout
      • Installing the Assembly to the Apparatus
    • 7.5 Removing the Gearbox
      • G Series Gearbox
        • Figure 7-3: Typical G Series Gearbox Removal
        • Removal - G Series
        • Installation - G Series
      • J Series Gearbox
        • Removal - J Series
          • Figure 7-4: Typical J Series Gearbox Removal
        • Installation - J Series
      • K Series Gearbox
        • Removal - K Series
          • Figure 7-5: K Gearbox Removal
        • Installation - K Series
    • 7.6 QMID/QMAX/QTWO AutoLube ® Service
      • Figure 7-6: AutoLube Assembly Overview
    • 7.7 Impeller Assembly
      • QMID/QMAX/QTWO Removing Impeller and Clearance Rings
        • Figure 7-7: Qmax / Qtwo Assembly Overview
      • Disassembly - QMAX/QMID Single-Stage Pump
      • Assembly - QMAX/QMID Single-Stage Pump
      • Disassembly - QTWO Two-Stage Pump
      • Assembly - QTWO Two-Stage Pump
      • Inspection - Clearance Rings
        • Figure 7-8: Clearance Ring and Impeller ID / OD Measurement
      • Installing the Impeller and Clearance Rings
• PackingAndMechanicalSealMaintenance.pdf
  • 8 Packing and Mechanical Seal Maintenance
    • 8.1 Packing Seal Replacement
      • Figure 8-1: Pump Packing Seal Overview
      • Figure 8-2: Packing / Mechanical Seal Assembly Overview
    • 8.2 Mechanical Seal Replacement
      • Qmax and Qtwo Pumps with G Series Gearbox
        • Figure 8-3: Qmax, Qmid, and Qtwo Mechanical Seal Assembly Overview
        • Removing the Seal
          • Figure 8-4: Mechanical Seal Overview / Replacement
        • Installing the Seal
      • Qmax and Qtwo Pumps with K Series Gearbox
        • Removing the Seal
          • Figure 8-5: QmaxK and QtwoK Mechanical Seal Assembly Overview
          • Figure 8-6: Mechanical Seal Overview / Replacement
        • Installing the Seal
      • Impeller Assembly and Mechanical Seal Qflo, Qflo-Plus and Qpak Pump
        • Removing the Mechanical Seal
          • Figure 8-7: Qflo / Qflo-Plus / Qpak Mechanical Seal Assembly Overview
          • Figure 8-8: Mechanical Seal Overview / Replacement
      • Installing the Seal
• GearboxMaintenance.pdf
  • 9 Gearbox Maintenance
    • 9.1 G Series Gearbox Maintenance
      • Disassembly
        • Intermediate and Sliding Gear Shaft Assemblies
          • Figure 9-1: Intermediate Shaft and Sliding Gear, Typical G Series Gearbox
        • Tail Shaft Assembly
          • Figure 9-2: Tail Shaft Assembly
        • Power Gearshift Assembly
          • Figure 9-3: Power Gearshift Assembly
        • Sliding Gear and Fork
        • PTO Drive Option, Qflo / Qflo Plus / Qpak Series Pump
          • Figure 9-4: PTO Drive Option
      • Assembly
        • Gearshift Cap
        • Sliding Gear Assembly
        • Tail Shaft and Gear Shift Assemblies
        • PTO Drive Option
        • Intermediate Shaft Assembly
    • 9.2 J Series Gearbox Maintenance
      • Disassembly
        • Idler Shaft Disassembly
          • Figure 9-5: Typical J Series Gearbox Assembly
        • Input Shaft Disassembly
      • Assembly and Installation
        • Input Shaft Assembly
        • Idler Shaft Assembly
    • 9.3 K Series Gearbox Maintenance
      • Oil seals (Input/Tail Shafts)
        • Figure 9-6: Oil Seal Replacement
      • Tail Shaft Assembly
        • Figure 9-7: Tail Shaft Assembly
        • Removal And Disassembly
        • Inspection
        • Reassembly and Installation
          • Figure 9-8: Shaft End Gap
      • Input Shaft
        • Figure 9-9: Input Shaft Assembly
        • Removal and Disassembly
        • Inspection
        • Reassembly and Installation
      • KPS Power Shift Assembly
        • Figure 9-10: KPS Shift Cylinder Assembly
        • Removal
        • Installation
      • KPS Shift CAP and Switch
        • Figure 9-11: KPS Shift Cap Assembly
        • Removal
        • Installation
      • Gear Shift Fork
        • Removal
        • Installation
        • Idler Shaft
          • Figure 9-12: Idler Shaft Assembly
        • Removal
        • Inspection
        • Installation
• Installation.pdf
  • 10 Installation
    • 10.1 Overview
    • 10.2 Mounting
      • Mounting Holes
        • Figure 7-1: Lifting Eyebolt Attachment Layout
    • 10.3 Driveline Issues
      • Drive Line and Flange Bolts
      • Issues
    • 10.4 Plumbing Connections
    • 10.5 Panel Mounted Accessories
    • 10.6 Fluid Levels
• Glossary.pdf
  • Appendix A: Glossary
• Measurements and Conversions.pdf
  • Appendix B: Measurements and Conversions
• AlternateLubricantManufacturers.pdf
  • Appendix C: Alternate Lubricant Manufacturers
• LubeAndSealantSpecifications.pdf
  • Appendix D: Lube and Sealant Specifications
    • Grease
    • Loctite Sealant
    • Oil
    • Recommended Cleaners
• HoseFrictionLoss.pdf
  • Appendix E: Hose Friction Loss
• NozzleSizeVsPressure.pdf
  • Appendix F: Nozzle Size vs. Pressure
• Cavitation.pdf
  • Appendix G: Cavitation
    • Figure G-1: Sample, Cavitation Regions
    • G.1 Process of Cavitation
    • G.2 Warning Signs of Cavitation (Discharge and Gauges)
      • Discharge Pressure
      • Vacuum Compound Gauge
    • G.3 Eliminating Cavitation
      • During Operations
      • Preventive Measures
      • Strainers
• MidshipFlowRates.pdf
  • Appendix H: Midship Flow Rates
    • Table F-1: Midship Flow Rates (Sheet 1 of 2)
• Hale Express Warranty.pdf
  • Express Warranty
• Cover - Muscle DRAWINGS, 029-0020-63-0, Rev -C, 02-01-06.pdf
  • Drawing Package
  • Part 2
    • QFLO Series
    • QPAK Series
    • QMAX Series
    • QTWO Series
    • QMID Series
    • Gearbox and Primer Pump
    • Available Accessories and Options