02/10/2004
PART 1: MAINTENANCE INSTRUCTIONS
SMR-U
Stainless Steel Rear Mount Pump
DESCRIPTION AND MAINTENANCE MANUAL
PRELIMINARY
Hale SMR Pump Serial Number:____________________________________
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. z A Unit of IDEX Corporation z 700 Spring Mill Avenue z Conshohocken, PA 19428 z TEL: 610-825-6300 z FAX: 610-825-6440
MANUAL P/N 029-0020-77-0, REV 1, © 2004 HALE PRODUCTS, INC., PRINTED IN U.S.A.
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.
NOMINAL PERFORMANCE
Model WSA2010 Aluminium
Nominal output 2000 l/min at 10 Bar & 3m lift
Model WSB2010 Bronze
Model WSA3010 Aluminium
Nominal output 3000 l/min at 10 Bar & 3m lift
Model WSB3010 Bronze
Model WSA4010 Aluminium
Nominal output 4000 l/min at 10 Bar & 3m lift
Model WSB4010 Bronze
RECOMMENDED SPARES
Thank you for choosing the GODIVA Fire Pump – designed and built to provide
many years of trouble-free service.
Whilst we consider that it is the best fire pump available today, we also recognise
that any ‘rotating machinery’ is subject to wear and therefore recommend that you
request our 2 years’ Recommended Spares Listing.
This stock holding will enable you to maintain the pump in cases where minor
defects occur and minimise any possibility of your pump being ‘off-the-run’ for
extended periods.
©Godiva, Warwick
September 2000
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CONTENTS
SECTION PAGE
SAFETY-RELEVANT DATA 4
GENERAL DESCRIPTION 5
LUBRICATION 6
PROTECTION AGAINST FROST 7
SECTION: 1 SUCTION TUBE & FRONT WEARING RING 8
2 WEARING RING MAINTENANCE 8
3 LOW PRESSURE IMPELLER & 9
REAR WEAR RING
4 CARBON SEAL & SEATING ASSEMBLY 11
5 VOLUTE BODY 13
6 LOW PRESSURE MANIFOLD 14
7 PRIMING SYSTEM 15
8 PUMP BODY 17
9 FRONT END OIL SEAL & WEAR RING 17
10 REAR END OIL SEAL & WEAR RING 19
11 BEARING HOUSING 20
12 PUMP TESTS 21
13 DELIVERY VALVES 22
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SAFETY-RELEVANT DATA
for VEHICLE BUILDER/INSTALLER
Thank you for purchasing a Godiva Pump.
Vehicle Manufacturers will find full details regarding installation in the
relevant section of this manual.
A risk assessment of the Vehicle Pump Range has been conducted in line with the
Machinery Directive 89/392/EEC, with the following results:
INSTALLATION
The pump MUST BE SECURELY INSTALLED to the vehicle chassis.
MAINTENANCE
It is the responsibility of the user to ensure that the equipment is maintained in a safe operational condition, as per regulation 5 in the Provision and Use of Work Equipment Regulations 1998.
PUMP DRIVE AND PRIMING SYSTEMS
A guard is available to enclose the priming system drive if this is deemed necessary.
The vehicle-mounted pump is NOT a machine (see Declaration of Incorporation) and
the guarding of this area together with the drive system of the pump MUST BE
CONSIDERED by the Vehicle Builder when incorporating the pump into HIS
machine.
NOISE
The manufacturer of the machine into which the pump is incorporated MUST
INDICATE any protective equipment that may be required. Test data may be
sourced from Godiva where required.
THERMAL RELIEF VALVE
The WS Series single pressure pump can be fitted with an optional THERMAL
RELIEF VALVE which is fitted to assist in the prevention of over heating which could
occur through incorrect operation of the pump, ie running the pump at high speed
with all the discharge valves closed.
OPERATION
When installed into a fire-fighting appliance, TRAINED PERSONNEL must operate
these pumps ONLY.
Engineering Director
1 July 1998
F W Mason
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GENERAL DESCRIPTION
The Godiva WS series single stge pump is a single pressure pump. It delivers
high volume, low pressure (LP) output water.
The pump is generally driven in a clockwise direction viewed from the drive end. The
pump may also be specified configured to rotate in a counter-clockwise direction.
The pump drive shaft, which runs on angular contact and roller bearings in an oil
bath, is of stainless steel. Shaft sealing of the pump is by a special Godiva
mechanical seal face, which ensures efficiency and long life without adjustment. The
electronic tachometer sender is mounted adjacent to the drive flange.
Priming of the pump is achieved automatically by means of a pair of positive
displacement piston primers mounted on either side of the bearing housing. These
primers begin to operate as soon as the pump drive shaft begins to rotate, driven by
an eccentric bearing on the pump shaft. Air within the pump will be expelled and as
long as the suction connections have been made and the hose end submerged, the
pump will prime and the pistons will disengage by 1.5 bar. The pump should be
primed at any speed between 1000-2500 rpm. The pump speed should not be
increased further until the primers have disengaged and the pump is primed.
An optional alternative priming system – the Godiva water ring primer – is available
in place of the piston primer system. With the water ring primer, when the pump is
started, the primer shaft is driven by its fibre driving wheel which contacts the pulley
on the pump drive shaft and is lifted off by a disengaging cylinder as the pump is
primed and pressure builds up in the pump. An alternative to friction pulley drive is
belt-drive through an electro-magnetic clutch. When the pump is primed and
pressure builds up, a pressure switch turns off the clutch drive.
Non-return valves are built into both the piston and water ring priming systems to
prevent air flowing back through the primers, thus “breaking the prime”.
As the pump is reduced to idling and the pressure within the pump decreases, the
pistons will once again reengage to act as a pump and discharge any water
remaining in the pump.
A World Series Options Manual is available which shows many of the standard
specifications currently available together with an indication of their positions relative
to datum points on the pump.
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LUBRICATION
The oil bath provided for the pump drive shaft bearings has a capacity of 0.75 litres
(1.3 pints) and should be topped up when necessary with 10w/40-15w/40 multigrade
engine oil. It is recommended that the oil bath is drained and refilled with fresh oil
about every twelve months.
To check the oil level, remove the filler/dipstick, which is situated on the bearing
housing immediately behind the pump body. Add fresh oil through the oil filler
aperture until it reaches the dipstick level. Refit the oil filler plug securely. Run the
pump for a short period and then re-check the oil level. The oil level should be
checked with the dipstick screwed down into its fixed position.
The oil drain plug is situated at the rear of the bearing housing below the pump drive
flange as shown on Fig 1-1.
Fig 1-1 Bearing housing oil filler, level and drain plug
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PROTECTION AGAINST FROST
As a precautionary measure, when frost is anticipated, drain all water from the pump
and its ancillaries.
Removing the drain plug from the base of the volute drains the pump. If the primer
exhaust is piped away to above the primer outlets, these must be provided with drain
valves.
If the water ring primer is fitted, removing the drain plug at the base of the water trap
housing drains it.
IMPORTANT: It is essential to carry out the pump tests detailed in Section 13
whenever any part of the pump or priming system is dismantled.
This will ensure that reassembly has been carried out correctly
and that there are no leaks.
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Section 1
SUCTION TUBE AND FRONT WEARING RING
To Remove
To remove the suction tube, remove priming pipe and foam inductor (if fitted) from
RH side, and Tank Fill line (if fitted) from LH side of suction tube. Remove the M10
nuts, spring washers and plain washers to allow the withdrawal of suction tube and
front wearing ring if necessary. The front wearing ring has two identical O rings, one
of which is face mounted towards suction tube and the second being in a groove
behind its flange.
To Refit
Clean all flange faces and lightly grease new O rings before refitting.
Check the large internal diameter of the wearing ring in several places (see Fig 2-1).
If it exceeds dimension ‘A’ 140.60 mm (5.535 in) for WS 2010 and WS 3010 model
pumps, or 171.00 mm (6.732in) for WS 4010 models, at any point, the wearing ring
must be renewed.
Fig. 2-1
To Refit
Refitting is a reversal of the removal instructions. Use new O rings lightly greased
before refitting and should be fitted with diameter A towards the impeller.
Section 2
WEARING RING MAINTENANCE
A
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A
SECTION 3
LOW PRESSURE IMPELLER AND REAR WEAR RING
To Remove
In order to access the low pressure impeller, it is only necessary to disconnect
pipework as described in Section 1, then remove the 12 off M12 bolts from the volute
cover plate which may then be withdrawn together with suction tube etc giving direct
access to the low pressure impeller leaving the volute body in situ. Remove the
tacho sender and fit shaft locking screw (Tool No 60275/11) locating the spigot into
one of the drive flange holes. Remove the impeller nut and the pair of lock washers
and withdraw the impeller from the keyed pump shaft. It may be necessary to use
special tool 60275/04 to remove the impeller from the pump shaft.
Maintenance
Check the wearing diameter on the impeller in several places (see Fig 3-1). If the
diameter is less than stated in the table below, a new impeller should be fitted.
Fig 3-1 Checking the wearing diameters of the low pressure impeller
B
Pump Type Front Diameter (A) Rear Diameter (B)
WS2010 and
WS 3010
WS4010
139.319 mm
5.485 in
169.67 mm
6.680 in
135.33 mm
5.238 in
170.56 mm
6.715 in
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To Refit
Refitting is a reversal of the removal instructions. It is recommended that new O
rings are fitted to impeller end face and shaft and a new pair of lockwashers are
fitted before refitting the impeller nut which should be tightened to 400Nm (295 lbs ft)
torque. To refit front cover plate, a new O ring should be fitted to the cover plate
spigot before assembly.
Rear Wear Ring
The rear wear ring (accessible after the removal of the low pressure impeller) is
retained by 4 off M8 socket head screws. After removal of these screws, the rear
wear ring may be jacked out by means of two screws inserted into the adjacent
tappings.
Checking the wearing diameters of rear wear ring
2010/3010
X 4010 X
Pump Type Dia X
WS2010 and
134.12mm
WS 3010
WS4010
169.62mm
To Refit
Clean all surfaces before re-assembly. Apply Loctite 242 to screw threads before
refitting and tightening.
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Section 4
CARBON SEAL AND SEATING ASSEMBLY
When the impeller is removed, the mechanical carbon face seal is accessible for
examination. In the event of excessive leakage past the carbon seal and out of the
drain hole in the pump head, remove impeller per Sections 3. Examine the carbon
seal. If the face of the carbon seal-seating ring is scored, it is essential to replace it
and to fit a new seating ring, which is mounted within the rear face of the impeller.
To remove the carbon seal seating ring, remove two M6 nyloc nuts and washers and
gently remove it, taking care not to lose the wave spring. The stationary carrier may
be left in place if only the wearing faces are being replaced.
The silicon carbide ring fitted in the rear side of the low pressure impeller may be
levered out, by means of a small instrument screwdriver inserted between the ring
and its rubber cup.
Re-assembly of the seal is completed as described below. Please note: Mechanical Seals are precision-engineered devices and extreme care must be taken to ensure that no damage occurs to the lapped faces.
Read the fitting instructions before installation of the seal.
Ensure that the lapped faces are absolutely clean throughout the entire installation.
Soiled faces must to be cleaned with appropriate degreasing cleaner
and soft tissue.
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B
G
F
E
C
D
H
I
A
1. Ensure that the Pump Body (A) and Impeller (B) bores are clean and free from
burrs and sharp edges.
2. Lubricate the O Ring (C) with a suitable lubricant and carefully assemble the
Seal Head Assembly (D) into the Pump Body (A), lining up the cut-outs in the
Seal Head Assembly (D) with the threaded Studs (E).
3. Fit Washer (F) to each of the Studs (E) followed by the Lock Nuts (G). The lock
nuts should be tightened half a turn at a time so that the Seal Head Assembly
(D) is pulled squarely into the Pump Body. Ensure that the Lock Nuts are fully
secured.
4. Ensure Carbon Face (H) is clean and free from grease, if not use a degreasing
cleaner and soft tissue. Apply clean water to the carbon face.
5. Take Impeller (B) and carefully push the Mating Ring Assembly (I) into the bore
using Fitting Tool Number 60275/08. Ensure that the Face of the Mating Ring
Assembly is fitted squarely in the impeller housing within 0.1mm.
6. Carefully fit the Low Pressure Impeller onto the shaft and continue with pump
build.
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Section 5
VOLUTE BODY
It is extremely unlikely in normal servicing that the volute body will require to be
removed, but in the event of removal the front cover plate should be removed as in
Section 3. The volute is mounted on to the pump body by means of twelve studs,
nuts and washers. The seal at both front and rear faces of the volute is by O ring
seals, which should be replaced if the joint face is disturbed. This volute may be
mounted on either standard rotation pumps or reverse rotation pumps, and must be
fitted the correct way round (see the cast on arrow near to the manifold connecting
face, normally on the right hand side). The 12-mounting studs should always face
the rear of the pump.
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Section 6
LOW PRESSURE MANIFOLD AND FILTER HOUSING
To Remove
Assuming that the gauge, thermal relief and foam connections have been
disconnected, it is necessary to remove the primer discharge pipe from the filter
housing to the pump body. Remove 8 off M8 bolts to remove the filter body. The
low pressure manifold is connected to the volute body by means of 4 off M10 bolts
surrounding the thermal relief valve and 2 M10 stainless steel socket head cap
screws inside the manifold casing (these 2 screws are fitted with bonded seals to
prevent leakage). The manifold may now be removed. The gasket between the
manifold and the filter housing will require renewal at this stage. The seal between
the volute body and manifold is an O ring.
The main outlets to the manifold (6 off) are sealed by means of O rings, seated in
grooves in the manifold faces.
Reassembly
When reassembling the manifold, all O rings should be replaced and Loctite 242
should be applied to all threads before refitting.
Filter Housing
The housing contains the primer disengagement filter, accessible from the front
panel area. This filter however, must not be removed whilst the pump is in
operation.
The flow across the filter is from outside to inside the cylindrical profile. The filter is
intended to restrict particle size in water entering the primer disengaging circuit.
©Godiva, Warwick
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