Operation and Maintenance Manual
 

Hydraulic Submersible Unit

 
 
310 South Sequoia Parkway
Canby, OR. 97013

Rev. 001

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Contents
SECTION I - ORDER OF OPERATIONS ...................................................................................................................... 4 
Start-Up ........................................................................................................................................................................... 4 
Shut Down ...................................................................................................................................................................... 6 
SECTION II - HYDRAULIC SUBMERSIBLE PUMP ................................................................................................ 10 
Inspection ..................................................................................................................................................................... 11 
Recording Model & Serial Numbers ..................................................................................................................... 11 
Warranty Information .............................................................................................................................................. 13 
Pump Description ....................................................................................................................................................... 13 
Pump Operation .......................................................................................................................................................... 14 
Recommended Oils: ............................................................................................................................................... 15 
Maintenance / Disassembly – Reassembly ...................................................................................................... 18 
Disassembly .................................................................................................................................................................. 19 
Suction Strainer Removal ........................................................................................................................................ 19 
Volute Removal ........................................................................................................................................................... 20 
Impeller Removal ....................................................................................................................................................... 20 
Brackplate Removal .................................................................................................................................................. 21 
Gland Removal ............................................................................................................................................................ 22 
Hydraulic Motor Removal ........................................................................................................................................ 23 
Adapter Bracket Removal........................................................................................................................................ 24 
Bearing Frame Disassembly ................................................................................................................................... 24 
Bearing Removal ........................................................................................................................................................ 25 
Reassembly ................................................................................................................................................................... 25 
Bearing reinstallation ............................................................................................................................................... 26 
Mechanical seal installation (frame seal) ......................................................................................................... 27 
Volute reinstallation .................................................................................................................................................. 27 
Strainer / suction stand reinstallation ............................................................................................................... 27 
Post-assembly checks ............................................................................................................................................... 28 
SECTION III – DIESEL ENGINE ................................................................................................................................. 29 
Maintenance Schedule ............................................................................................................................................. 29 
Engine Performance Data ....................................................................................................................................... 32 
General Arrangement ............................................................................................................................................... 35 
Engine Harness to Panel Harness Connector ................................................................................................... 36 
SECTION IV – LOFA PANEL ......................................................................................................................................... 37 

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APPENDIX I ............................................................................................................................................................................ 55 
MAINTENANCE LOG .......................................................................................................................................................... 55 
Griflube Bio-Syn Material Safety Data Sheet (MSDS) ................................................................................... 61 
Hydraulic Schematic .................................................................................................................................................. 67 
Wiring Diagram ........................................................................................................................................................... 68 
 

   

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SECTION I - ORDER OF OPERATIONS

Start-Up
Read each step completely prior to executing the step. A detailed image can be referenced in Figures 1 and 2
1) Open unit doors to gain access to LOFA panel and manual or pendant controls

NOTE - Complete daily checklist as described in Appendix I

2) Insert key into LOFA panel and wait 3-5 seconds for engine glow plugs to heat up
If a warning symbol appears on the LOFA Panel check that both of the
emergency stop buttons are not pushed in.
3) Start Engine from LOFA Panel

NOTE - visually inspect warning lights on top of the unit.

Red light = Engine shut off condition.
Yellow light = Low fuel / low oil.
Green light = System is running

NOTE – Be aware of the location of the emergency stop buttons. If a

warning symbol appears on the LOFA Panel check that both of the
emergency stop buttons are not pushed in.

NOTE – Hydraulic Pressure Compensator is set at the factory. If adjustment is required, please
contact Pioneer Pump.

4) Lift Pump

Note: There are two redundant control interfaces for operating the winch, boom and hose reel. The
Pendant and Manual Control Levers are spring centered as a safety
measure.
o Pendant: Use Winch-Up button to raise pump high enough to
clear the frame of the hydraulic unit.

OR

o Manual lever: Use Winch lever to raise pump high enough to clear
the frame of the hydraulic unit. Pull the manual lever towards you
to raise the pump.

Note: The winch is equipped with an anti-two block system to prevent

running the pump into the winch. If the hose is caught on the metal
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 switch, push the cable as shown to release. If the safety measure has been engaged while using the
pendant, push the release button as shown in the figure.

5) Discharge Hose
It is recommend that the customer discharge hose be connected to the Hydraulic Submersible Pump discharge
flange prior to executing step 6.

6) Extend Boom
o Pendant: Using “Hose – Out” button provide slack in the hydraulic hose system. Using “Boom –
Out” button begin extending boom. While boom is extending use the “Hose – Out” button to feed
hydraulic hose from the hose reel. Continue this process until the boom has reached its fully
extended position.

OR

o Manual lever: Using “Boom” lever begin extending boom by pushing the lever. While boom is
extending use the “Hose” lever to feed hydraulic hose from the hose reel. Continue this process
until the boom has reached its fully extended position.

WARNING - BE SURE TO CHECK THE HOSE FOR ANY PINCH POINTS / HANG UPS WHILE
EXTENDING BOOM AS WELL AS LOWERING THE PUMP.

WARNING - THE HYDRAULIC HOSE SHOULD NEVER BE PULLED TIGHT AS A RESULT OF BOOM
EXTENSION OR LOWERING THE PUMP. SPECIAL ATTENTION MUST BE PAID TO FEED HOSE REEL AS
DESCRIBED ABOVE.

7) Lower Pump
o Pendant: Using the “Winch – Down” button begin to lower the pump.
While the hydraulic submersible pump is being lowered be sure to
continue to feed slack in the hydraulic hose line using the “Hose – Out”
button.

OR

o Manual Lever: Using the “Winch” lever begin to lower the pump by
pulling the lever. While the hydraulic submersible pump is being lowered be sure to continue to
feed slack in the hydraulic hose line using the “Hose” lever by pushing the lever.

NOTE - Hydraulic submersible pump must be completely submerged in water prior to startup
8) Start the pump

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 Using the on/off switch located near the manual controls, turn the pump on by switching the dial to the
on position
9) Bring the engine to full speed using the LOFA Panel.
 

Shut Down
10) Reduce the engine speed to idle conditions.
11) Shut off the Pump
Using the on/off switch located near the manual controls, turn the pump off by switching the dial to the
off position
12) Raise the pump
o Pendant: Using the “Winch – Up” button begin to raise the pump. While the hydraulic
submersible pump is being raised be sure to continue to wind any slack in the hydraulic hose
line using the “Hose – In” button.

OR

o Manual Lever: Using the “Winch” lever begin to raise the pump. While the hydraulic submersible
pump is being raised be sure to continue to wind any slack in the hydraulic hose line using the
“Hose” lever.
Note: The winch is equipped with an anti-two block system to prevent running the pump into the
winch.

13) Retract the Boom

o Pendant: Using “Hose – In” button wind any slack in the hydraulic hose system while
simultaneously using “Boom – In” button to retract boom. Continue this process until the boom
has reached its fully retracted position.

OR

o Manual lever: Using “Hose” lever wind any slack in the hydraulic hose system while
simultaneously using “Boom” lever to retract boom. Continue this process until the boom has
reached its fully retracted position.
14) Disconnect the discharge hose from the pump
15) Lower the pump onto the pump stand located inside the fire pump unit
o Pendant: Using the “Winch – Down” button begin to lower the pump. While the hydraulic
submersible pump is being lowered be sure to continue to feed slack in the hydraulic hose line
using the “Hose – Out” button.

OR

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 o Manual Lever: Using the “Winch” lever begin to lower the pump. While the hydraulic
submersible pump is being lowered be sure to continue to feed slack in the hydraulic hose line
using the “Hose” lever.

16) Turn off the engine

NOTE – It is recommended that the entire pump unit be rinsed off with fresh water following use in
sea water.

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Step 13

Step 6

Step 4

Step 12

Step 7&15

Figure 1: Pendant Control

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Step 13&6

Step 4

Step 7, 12, 15

Figure 2: Manual Controls 

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SECTION II - HYDRAULIC SUBMERSIBLE PUMP

 
   

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Inspection
 

All equipment is inspected at the factory prior to shipment. However, you should inspect all equipment upon
arrival for shipping damage and item shortages from the packing slip. Report any damage or shortages to the
freight carrier and Pioneer Pump, Inc.
 

Recording Model & Serial Numbers

 

Please record the model and serial number for your Pioneer Pump in the spaces provided below. The factory
will need this information when you require parts or service.

Pump Model: _____________________________________________

Pump Serial Number: ______________________________________
Engine/Motor Serial #: _____________________________________
Engine/Motor Model Mgf: __________________________________

WARNING!!!
This manual provides installation, operation and maintenance instructions for your Pioneer Pump and
is intended to make your personnel aware of any procedure that requires special attention because of
potential hazards to personnel or equipment. Read all instructions carefully and remember, pump
installations are seldom identical. Therefore, this manual cannot possibly provide detailed
instructions and precautions for each specific application. Thus, it is the owner/installer’s
responsibility to ensure that applications not addressed in this manual are performed only after
establishing that neither operator safety nor pump integrity are compromised by the installation.

WARNING!!!
Centrifugal Pumps are designed for specific service and may or may not be suited for any other
service without loss of performance or potential damage to equipment/personnel. If there is ever any
doubt about suitability for a specific purpose; contact your Pioneer Pump, Inc. representative or the
factory for assistance.

Remember: Pump performance may be affected by changes in pumpage such as, specific
gravity, viscosity, temperature, operating speed and NPSHA (net positive suction head
available).

WARNING!!!
Before attempting to service this pump, read this manual carefully. Operators and maintenance
personnel should have a good understanding of all aspects of this pump and the pumping conditions.
Failure of operating personnel to be familiar with all aspects of pump operation outlined in this manual
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could contribute to equipment damage, bodily injury or possible death.

WARNING!!!
Before any servicing:

1) Read this manual carefully.

2) Shut down driver and lock out incoming power to ensure that the pump will remain
inoperative.

3) If the pump or components are hot, allow adequate cooling prior to servicing the unit.

4) Close the suction and discharge valves.

5) Vent the pump slowly and drain completely.

WARNING!!!
If this pump is used to handle any hazardous materials that can cause illness, either
directly or indirectly, take precautions by wearing approved protective clothing and use
appropriate safety equipment. Also, review section on Vacuum Pump venting.

WARNING!!!
Use lifting and moving equipment in good repair and with adequate capacity to prevent
injuries to personnel or damage to equipment. Attach lifting equipment to the lifting
device fitted to the pump. If chains or cable are wrapped around the pump to lift it,
make certain that they are positioned so as not to damage the pump, and so that the
load will be balanced. The bail on trailer or skid mounted units is intended for use in
lifting the pump assembly only. Suction and discharge hoses and piping must be
removed from the pump before lifting.

CAUTION!!! When servicing this pump, use only components provided by Pioneer
Pump, Inc. Any use of non-authorized parts could result in substandard performance,
damage to equipment and possible injury to personnel. Non-authorized parts will also
void the warranty.

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Warranty Information
 
LIMITED WARRANTY: Seller warrants for two one years from the date of shipment Seller’s manufactured products to the
extent that Seller will replace those having defects in materials or workmanship when used for the purpose and in the
manner which Seller recommends. If Seller’s examination shall disclose to its satisfaction that the products are defective,
and an adjustment is required, the amount of such adjustment shall not exceed the net sales price of the defective products
and no allowance will be made for labor or expense of repairing or replacing defective products or workmanship or damage
resulting from the same. Seller warrants the products which it sells of other manufacturers to the extent of the warranties of
their respective makers. Where engineering design or fabrication work is supplied, buyer’s acceptance of Seller’s design or
of delivery of work shall relieve Seller of all further obligation, other than as expressed in Seller’s product warranty. THIS IS
SELLER’S SOLE WARRANTY. NO OTHER WARRANTIES, WRITTEN OR ORAL, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, ARE
MADE OR AUTHORIZED. NO AFFIRMATION OF FACT, PROMISE, DESCRIPTION OF PRODUCT OF USE OR
SAMPLE OR MODEL SHALL CREATE ANY WARRANTY FROM MANUFACTURER, UNLESS SIGNED BY THE
PRESIDENT OF THE MANUFACTURER. Seller neither assumes, nor authorizes any person to assume for it, any other
obligation in connection with the sale of its engineering designs or products. This warranty shall not apply to any products or
parts of products which (a) have been repaired or altered outside of Seller’s factory, in any manner; or (b) have been
subjected to misuse, negligence or accidents; or (c) have been used in a manner contrary to Seller’s instruction or (c) have
been used in a manner contrary to Seller’s instruction or recommendations. Seller shall not be responsible or design errors
due to inaccurate or incomplete information supplied by Buyer or its representative.

Pump Description
 

Model HS64C10 hydraulic submersible

Max. Allowable Working Pressure (MAWP) – 400psi
Min Continuous Stable Flow @ 1,720 rpm (MCSF) – 100 gpm
Minimum Submergence – Top of lifting bail
Hydraulic supply flow rate: 54 gpm
Relief valve setting: 5100 psi

Hydraulic motor:
Sunfab SCM-056W-N-SC4-C14-S2U
Maximum continuous pressure rating: 5075 psi
Maximum continuous operating speed: 5300 rpm

Hydraulic supply line is to be connected to the “A” port of the motor, and the return line is to be
connected to the “B” port of the motor. This connection will provide counter-clockwise rotation
of the centrifugal pump when viewed looking into the centrifugal pump suction.

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Pump Operation
 

Lubrication
This is a “frame-mounted” centrifugal pump where the pump impeller shaft is mounted on antifriction bearings
separate from the bearings in the hydraulic motor. These impeller shaft bearings are lubricated by the hydraulic
fluid from the hydraulic motor “case leakage.” Before operating the pump, the bearing housing must be initially
filled with oil. Initial filling is accomplished by removing the hydraulic motor and filling the frame so that the oil
level just covers the bearing with the pump in the vertical position.
Once the pump is in operation, there will be a continuous circulation of hydraulic oil from the motor into the
bearing housing and back to the hydraulic supply tank via the “case drain line” connected between the bearing
housing and the return line. This line must be connected at all times during the operation of the submersible
pump in order to maintain bearing lubrication and to minimize pressure on the mechanical seal which retains the
hydraulic oil in the bearing housing.

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Pump Operation cont’d

Connections

Connect the high pressure hydraulic supply line to the motor port labeled “A.” Connect the hydraulic return line
to the motor connection labeled “B.” The hydraulic motor is a “bi-directional” design, but proper rotation will be
guaranteed using the “A / B” ports as labeled.

WARNING! Hydraulic oil at pressure, sometimes in excess of 4900 psi, is potentially very dangerous. Be
certain that the hose fittings are tightly connected. Hose fittings should be attached to the motor’s NPT ports
using Teflon ® tape or carefully applied thread compound

WARNING! Never tighten connections with hydraulic lines under pressure. Small leaks at high pressure
can injure or kill.

Sharp kinks in rubber hoses are to be avoided. Use proper elbows for smooth hose transitions where the angle
exceeds the minimum bend radius of the particular hose.

WARNING! Never operate a hydraulic system without a properly sized and functioning relief valve. In
the absence of a relief valve, pressures can build to a level that will exceed the ratings of the hydraulic hose,
pump or motor. Resulting rupture can lead to serious injury or death.
 

Recommended Oils:
 

This hydraulic system was initially filled and tested with Griflube Bio-Syn synthetic, biodegradable oil. The data
sheets for this oil are reproduced on the next two pages.

It is the pump user’s responsibility to source and use this or a hydraulic oil with equivalent properties. The
choice to use synthetic or biodegradable oils is left to the pump user; however, the specifications of any
alternative oil must be equivalent or better.

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Maintenance / Disassembly – Reassembly

 

WARNING! Shut off hydraulic power unit and disconnect hydraulic motor from hydraulic lines before
performing any disassembly. Escape of hydraulic oil under high pressure can cause severe injury or death.
Contact with rotating parts can cause severe injury or death.

Refer to the following illustration for part names and numbers.

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Disassembly
 

The following procedures outline a complete disassembly, which can be terminated at any stage, depending on
the maintenance required. Specific parts are referenced in bold type. Corresponding part numbers are called
out in the accompanying figure.
 

Suction Strainer Removal

 

Remove the three screws that hold the cylindrical screen to the suction stand. This will expose the bolts holding
the stand to the pump volute. Remove these to detach strainer / stand assembly.

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Volute Removal

Remove the volute fasteners, and the volute should slide off the brackplate register. It may help to try and
rotate the volute by hand if it doesn’t slip off freely. If it still doesn’t come off easily, install two of the volute
fasteners in the “jackscrew” taps on the flange of the brackplate, and tighten them to push the volute off. Be
sure to replace the Volute o-ring when reassembling the pump.

If the suction wear-ring is to be replaced, it can be removed via the following procedure. Using a small drill bit,
drill two pilot holes, 180° opposite one another, along the length of the wear-ring (parallel to the centerline axis
of the ring). Then, using these pilot holes, drill with a bit slightly smaller in diameter than the thickness of the
wear-ring. Now it should be possible to drive a thin wedge between the outside diameter of the wear-ring and
the bore of the suction cover and collapse the wear-ring for removal.  

Impeller Removal
 

A large screw driver or pry bar with a square shaft can be inserted between the shrouds of the impeller to hold it
stationary while removing the impeller lock screw. Alternately, a strap wrench or oil filter wrench can be used on
the outside diameter of the impeller inlet to prevent it from turning. The impeller was installed at the factory
using Loctite® and so may be fairly difficult to unscrew. If an air wrench or long-handled wrench will not loosen

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the impeller screw, use a propane torch to heat the area around the lock screw, and this will usually cause the
Loctite® to release. The impeller washer can then be removed by hand. It may be possible to simply pull the
impeller off by hand. If the impeller does not come off by hand, insert two pry bars behind the impeller back
shroud and pry gently, taking care not to bend or crack the shroud. It is a good idea to try and locate the pry
bars adjacent to the impeller vanes to help avoid damaging the shroud. Plastic wood-splitting wedges can also
be placed behind the impeller, 180° opposite one another, and simultaneously tapped with hammers.
Alternately a large diameter gear-puller can be used. Remove the impeller key from the shaft keyway.
 

Brackplate Removal
 

Remove the brackplate to bearing frame fasteners. The brackplate should slide off. If it does not immediately
come loose, give it a tap with a “soft-blow” mallet. If it is necessary to remove the Hub wear-ring, it can also be
drilled and collapsed like the suction wear-ring. Take care that the seal gland, which is held in place by being
sandwiched between the brackplate and bearing housing, doesn’t fall against the shaft or tip excessively, or the
mechanical seal’s stationary seat may be damage.
 

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Gland Removal
 

Once the Brackplate is removed, the seal gland will be loose and can simply be pulled off over the shaft. Take
care not to bump or drag the mechanical seal stationary seat against the shaft, or it may be damaged.

To remove the mechanical seal stationary seat from the seal gland, place the blade of a screwdriver or the end
of a punch against the exposed back-side edge of the stationary seat and tap gently with the heal of the hand.
The mechanical seal rotating element can now be removed. It may be helpful to lubricate the exposed portion of
the shaft with motor oil or similar lubricant before attempting to pull the rotating element off. Be sure to replace
the brackplate o-ring upon reassembly.
 

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Hydraulic Motor Removal

 

Remove the lifting bale fasteners and detach the lifting bale. Remove the Hydraulic motor fasteners. The
splined shaft of the hydraulic motor engages a female spline in the bearing housing shaft. The hydraulic motor
can now be pulled straight out until the splines are completely disengaged.

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Adapter Bracket Removal

 

Remove the adapter bracket fasteners. The adapter bracket and adapter bracket o-ring can now be removed
by hand from the bearing housing. Be certain to replace the adapter bracket o-ring upon reassembly. There is
also a small drain-back o-ring in a counterbore on the bearing frame-side of the adapter bracket. Be certain to
replace this o-ring upon reassembly.
 

 
 

Bearing Frame Disassembly

 

The bearing/shaft assembly can now be removed from the bearing housing by tapping on the pump-end of the
shaft with a “dead blow” hammer, or a press can be used.

 
The bearing spacer in the bore of the drive-end of the bearing housing will slide out when the shaft is pulled out.

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Bearing Removal
 

Remove the bearing lock-nut and bearing lockwasher. This will require the use of a spanner wrench. The
shaft/bearing assembly should be secured in a vice for this procedure. The largest diameter of the shaft can be
clamped in the vice without concern for marring this surface with the vice teeth; there are no components that
slide over or mount to this surface. Once the bearing lock-nut and lockwasher have been removed, it will be
necessary to use a puller or hydraulic press to remove the drive-end bearing and pump-end bearing from the
shaft. The drive-end bearing spacer can be removed by hand prior to pulling the bearing. If the bearings are to
be reused, be certain that puller jaws bear only against the inside races (shaft-side) of the bearings.
 

 
 

Reassembly
 

For the most part, reassembly is the exact opposite of the disassembly process, but a few methods must be
followed for best success. The proper torque for the various fasteners is important. All fasteners on this
hydraulic submersible pump are either 304SS or 316SS

There are numerous o-ring associated with the various components; it is extremely critical that each of these be
replaced in their proper locations during reassembly.
 

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TORQUE VALUES

SIZE MATERIAL
UNC
GRADE 5 GRADE 8
304/316 SS BOLTS BOLTS

¼ 3.0 lb-ft 9 lb-ft 13 lb-ft

5/16 7.0 lb-ft 19 lb-ft 27 lb-ft

3/8 13 lb-ft 34 lb-ft 48 lb-ft

7/16 20 lb-ft 54 lb-ft 77 lb-ft

1/2 31 lb-ft 83 lb-ft 117 lb-ft

9/16 45 lb-ft 120 lb-ft 170 lb-ft

5/8 63 lb-ft 165 lb-ft 234 lb-ft

3/4 112 lb-ft 293 lb-ft 415 lb-ft

7/8 180 lb-ft 474 lb-ft 670 lb-ft

1 270 lb-ft 710 lb-ft 1000 lb-ft

1 1/4
540 lb-ft 1421 lb-ft 2000 lb-ft

Bearing reinstallation
 

Ideally, the bearings should be heated with an inductive bearing heater designed for the purpose. However, in
lieu of a bearing heater, a conventional oven or toaster oven can be used to heat the bearing to no more than
250°F. Once the bearing is adequately heated, then, using heavy leather gloves, the bearing can be slid onto
the shaft and firmly up against the shaft shoulder. As soon the bearing is removed from the heat source, the
installation process must be carried out very quickly, or the bearing will seize to the shaft in the wrong location.

The bearings can also be installed with a press. In this case, care must be taken to press only against the inner
race. Never press against the outer race when installing bearings.

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Once the drive-end bearings have been mounted on the shaft, the bearing spacer is installed onto the shaft and
up against the bearing inner race. Then the lockwasher is installed against the bearing spacer. Make sure that
the tab on the inside diameter of the washer engages the short keyway in the shaft. The “fingers” of the washer
point away from the bearing. Next, install the bearing locknut with the chamfered side toward the bearing.
Snug the nut up against the washer. The bearing manufacturers do not provide torque values for the bearing
nut. A good practice is to get the nut as tight as possible using the spanner wrench by hand, and then tighten
the nut more, using a dead-blow mallet or an extension on the handle of the spanner, until one of the notches of
the nut lines-up with one of the tabs on the washer. Now bend one of the tabs down until it completely engages
the slot in the nut. No special procedure or orientation is required for the pump-end bearing. Reassembly of the
bearing housing, shaft/bearing assembly, adapter bracket and hydraulic motor is the opposite of the
disassembly procedure.

If a new hub wear-ring is to be installed in the brackplate, it is easiest to do this before reattaching the
brackplate to the bearing frame assembly. The wear-ring is installed by placing its chamfered side against the
edge of the bore and tapping with a dead-blow hammer or block of hardwood until it starts into the bore. Once it
has started all the way around its perimeter, then it can be driven in with very hard blows from the hammer
and/or wood block.

Mechanical seal installation (frame seal)

 

Once the bearings, shaft and hydraulic motor have been reinstalled into the bearing housing, the mechanical
seal must be installed. Lightly lubricate the bore of the seal gland with a 30 wt. motor oil or similar. Lubricate
the o-ring of the mechanical seal stationary seat as well. Now, using your thumbs, press the mechanical seal
stationary seat into the bore until it is firmly against the bottom of the gland bore. Make certain that the polished
side of the seat is facing away from the bottom of the gland bore. Place the seal-spring guide over the shaft and
up against the pump-end bearing. The seal spring will engage the inside diameter of the spring-guide flange.
Lightly lubricate the surface of the shaft upon which the mechanical seal will be mounted, and slide the
mechanical seal and spring assembly over the shaft until the spring is captured between the guide and the
rotating portion of the mechanical seal. The polished rotating face of the mechanical seal must be toward the
end of the shaft (away from the bearing). Install the gland o-ring into its groove, and immediately install the
gland. This will compress the seal spring, so the gland will have to be held in place while the brackplate is
pushed up against it and fastened to the bearing housing.

Volute reinstallation
 

Fit a new volute o-ring over the register of the brackplate and up against the bolting flange. Apply a bead of
grease to the o-ring. Slide the volute over the register, making certain to orient the volute so that the discharge
nozzle points in the same direction as before disassembly. Rotate the volute into the desired angular position,
and install and torque the volute fasteners.
 

Strainer / suction stand reinstallation

 

Reattach the top plate of the strainer / suction stand to the suction flange of the volute. Reinstall the “cylindrical”
portion of the strainer to the stand.
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Post-assembly checks
 

Once the pump has been completely reassembled, remove the hydraulic motor, and with the pump in a vertical
position, fill the frame with hydraulic oil per previous instructions.

Before reinstalling the hydraulic motor and its o-ring, reach into the pump suction and rotate the impeller by
hand to make certain that the shaft rotates freely.

Make sure that all volute and frame plugs and the “case drain line” are in place. If the case drain line is not
connected to the power supply, it will be necessary to elevate the fee end so that the oil does not drain out of
the bearing housing.

If the supply and return lines are not connected to the hydraulic motor, place pipe plugs in the motor
connections to keep any debris out of the system.

CAUTION: Make certain that the pump bearing housing is properly filled with hydraulic oil before operating the
pump. Check all hydraulic supply and return line connections and line condition.

WARNING! Before initial (first time) start-up, make sure all personnel are clear of the power unit, hydraulic
supply and return lines and pump discharge line. A sudden failure of a hydraulic line or fitting at high pressure
could result in serious injury or death.

WARNING! Make sure that the free end of the pump discharge line is secured so that it can’t “whip.” A
flailing hose end, especially if terminated with a flange, can be deadly.
   

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SECTION III – DIESEL ENGINE

Maintenance Schedule

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Engine Performance Data

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General Arrangement

   
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Engine Harness to Panel Harness Connector

  

 
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SECTION IV – LOFA PANEL

   
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APPENDIX I
MAINTENANCE LOG
HOUR METER READING: CHECK OR CHANGE EVERY INTERVAL SHOWN
CHECKPOINT
BELOW

ENGINE AND HYDRAULIC

Daily

1000

1125

1250

1375

1500
125

250

375

500

625

750

875
MOTORS/HOSES

Air Intake Piping ‐ Check X 

X 
Engine Lubricating Oil Level ‐ Check
X 
Air Tanks and Reservoirs ‐ Drain
X 
Crankcase Breather Tube ‐ Inspect
X 
Engine Coolant Level ‐ Check
X 
Fuel‐Water Separator ‐ Drain

Check Fuel Lines X X X X X X

X X X X X X
Check Hydraulic Lines for wear
X X X X X X
Air Cleaner Restriction ‐ Check

Air Compressor Mounting Hardware ‐ X X X X X X

Check
X X X X X X
Charge‐Air Cooler ‐ Check
X X X X X X
Charge‐Air Piping ‐ Check

Radiator Hoses ‐ Check X X X X X X

X X X X X X
Air Intake piping ‐ Inspect

Fan, Cooling ‐ Check X X X X X X

Coolant Level ‐ Check X X X X X X
Drive Belts ‐ Check X X X X X X

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MAINTENANCE LOG CONTINUED

Per hours or every
HOUR METER READING: CHECK OR CHANGE EVERY INTERVAL time frame.
CHECKPOINT
SHOWN BELOW Whichever occurs
first

6 mo.
3 mo.
1625

1750

1875

2000

2125

2250

2375

2500

2625

2750

2875

3000

1 yr.

2 yr.
ENGINE AND HYDRAULIC MOTORS/HOSES

Air Intake Piping ‐ Check

Engine Lubricating Oil Level ‐ Check
Air Tanks and Reservoirs ‐ Drain
Crankcase Breather Tube ‐ Inspect
Engine Coolant Level ‐ Check
Fuel‐Water Separator ‐ Drain
Check Fuel Lines X X X X X  X X X
Check Hydraulic Lines for wear X X X X X  X X X
Air Cleaner Restriction ‐ Check X X X X X  X X X
X X X X X  X X X
Air Compressor Mounting Hardware ‐ Check

Charge‐Air Cooler ‐ Check X X X X X  X X X

Charge‐Air Piping ‐ Check X X X X X  X X X

Radiator Hoses ‐ Check X X X X X  X X X
Air Intake piping ‐ Inspect X X X X X  X X X
Fan, Cooling ‐ Check X X X X X  X X X
Coolant Level ‐ Check X X X X X  X X X
Drive Belts ‐ Check X X X X X  X X X

   

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MAINTENANCE LOG CONTINUED

CHECKPOINT HOUR METER READING: CHECK OR CHANGE EVERY INTERVAL SHOWN BELOW    

ENGINE AND HYDRAULIC

Daily

1000

1125

1250

1375

1500
125

250

375

500

625

750

875
MOTORS/HOSES

Engine Oil & Filter - Change X X X

X X X
Engine Coolant ‐ Antifreeze Check
X X X
Fuel Filter (s pin on type) ‐ Change
X X X
Lubricating Oil and Filters ‐ Change
X X X
Radiator Pressure Ca p ‐ Check
X
Hyd. Oil Filter - Change

Cooling Fan Belt Tensioner ‐ Check X

X
Fan Hub, Belt‐Driven ‐ Check

Air Compressor Dis charge Line ‐

Check

Cooling System‐ Flus h

Vibration Damper, Rubber ‐ Check

Vibration Damper, Viscous ‐ Check

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MAINTENANCE LOG
CONTINUED
Per hours or
every time
HOUR METER READING: CHECK OR CHANGE EVERY INTERVAL SHOWN
CHECKPOINT frame.
BELOW
Whichever
occurs first.

ENGINE AND HYDRAULIC

6 mo.
3 mo.
1625

1750

1875

2000

2125

2250

2375

2500

2625

2750

2875

3000

1 yr.

2 yr.
MOTORS/HOSES

Engine Oil & Filter - Change X X X  X

Engine Coolant ‐ Antifreeze Check X X X  X

Fuel Filter (s pin on type) ‐ Change X X X  X

Lubricating Oil and Filters ‐ Change X X X  X

Radiator Pressure Ca p ‐ Check X X X  X

Hyd. Oil Filter - Change X X  X  

Cooling Fan Belt Tensioner ‐ Check X X  X

Fan Hub, Belt‐Driven ‐ Check X X  X

Air Compressor Dis charge Line ‐ X X  X

Check
X X  X
Cooling System ‐ Flus h

Vibration Damper, Rubber ‐ Check X X  X

Vibration Damper, Viscous ‐ Check X X  X

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HYDRAULIC SUBMERSIBLE PUMP

If the hydraulic fluid condition is monitored and appears in need of changing, then the bearing housing should be opened and
Bearings flushed (via removal of the hydraulic motor) and, at that time, the shaft should be turned by hand in order to feel for “notches” or
other abnormal noises coming from the bearings.

The hydraulic system should be monitored for signs of water contamination. If contamination is noted, the mechanical seal should be checked. This can
Mechanical Seals be accomplished by running the unit, out of the water, and observing the seal gland, over a reasonable period of time (five minutes) for leakage of
hydraulic fluid.

Wear‐rings Wear‐rings should be replaced, ideally, when a significant reduction in performance is noted and/or when the initial clearances have doubled.

   

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Hydraulic Oil Quick Check 
 

The hydraulic tank need to have 10% dead air space. 

To do a quick check remove the hydraulic oil quick check cap shown 
in Figure 3.  HYDRAULIC OIL FILL CAP  2” [50MM]
The distance from the fluid level to the top of the fill port must be 
2.00” [50 mm] (see figure 4.) 

  Figure 4: Hydraulic oil fill cap  Figure 3: Quick check 

 
5‐1/8” 
 
[130mm] 
 
FROM 
An alternative location to check the hydraulic fluid is in the fuel level gauge. The 
hydraulic fluid level should be at the black mark which measures 5‐1/8” [130mm] from  BOTTOM OF 
the bottom of the tank.  
TANK TO 
FLUID LEVEL 

Figure 5: Hydraulic oil fill gauge 

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Griflube Bio-Syn Material Safety Data Sheet (MSDS)

 
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Hydraulic Schematic

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Wiring Diagram
 

 
 

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