02/10/2004 SMR-U Stainless Steel Rear Mount Pump DESCRIPTION AND MAINTENANCE MANUAL PART 1: MAINTENANCE INSTRUCTIONS 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.
NOMINAL PERFORMANCE Model WSA2010 Aluminium Model WSB2010 Bronze Model WSA3010 Aluminium Model WSB3010 Bronze Model WSA4010 Aluminium Nominal output 2000 l/min at 10 Bar & 3m lift Nominal output 3000 l/min at 10 Bar & 3m lift 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.
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 & REAR WEAR RING 9 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 DELIVER
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.
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.
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.
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.
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.
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.
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.
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.
B G A F E C D H I 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).
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.
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.
Section 7 PRIMING SYSTEMS POSITIVE DISPLACEMENT PISTON PRIMERS To Remove End Covers Access to each identical primer, mounted on each side of the bearing housing, is as follows: The primer end cover contains a priming valve and inlet and outlet valves and is removed by the removal of 4 nuts and washers (see Fig 8-1).
On re-assembly, a new diaphragm, seal washer and O rings should be fitted without exception and care should be taken to ensure that the vent hole in the end cap is clear and towards the base of the unit. All components must be clean and dry before reassembly.
Beneath the piston in the cylinder bore are 4 socket head screws retaining an end cap which in turn retains an O ring, a metal sleeve with an internal 2 piece glyd ring and a variseal in the bottom of the bore. If these components are withdrawn, the seals should be renewed before assembly. Careful examination of the cylinder bore and piston rod should be carried out and if any serious scoring or wear has taken place, should be replaced.
Supplement for World Series Pump Maintenance – WT and WS Models Mk 3 Piston Primer (One piece piston) fitted to WT Models from Serial number 2000 WS Models from Serial number 9000 Disassembly/Assembly instructions for the piston assembly, part number 56960/06. 1. The piston assembly fitted to these models is a one-piece unit which is held in position by the return spring. A spring retainer and a pair of split collets retain the spring against the end of the piston rod. 2.
PRIMING SYSTEMS Continued WATER RING PRIMER The Water Ring Primer is available as an alternative to the Piston Primer system. It is mounted above the bearing housing and driven by a fibre wheel in contact with a pulley at the end of the main pump shaft. Operation of the Water Ring Primer is fully automatic, when the pump is started the primer is driven by the pulley wheel turning the fibre wheel, air is evacuated from the pump allowing water to enter and build water pressure inside the volute.
To fit a new friction drive pulley, remove the pulley from the shaft as detailed above, undo the four nuts, bolts and washers securing the pulley to the centre piece. Fit the new pulley. Refitting of the pulley assembly is a reversal of the dismantling instructions. Ensure that a new tab washer is always used on re-assembly. To examine the non-return valve on top of the primer, undo the four bolts and washers retaining the priming valve inlet to the valve body and cover.
Section 8 PUMP BODY To Remove Remove the low-pressure manifold, volute body and impeller (Sections 3,5 and 6) and remove the carbon seal assembly (Section 5). Unscrew the six nuts and spring washers securing the pump body to the bearing housing. Using a hide faced hammer, progressively tap around the pump body until it is separated from the bearing housing, taking care to withdraw the pump body from the two primer feed tubes at approximately the 4 and 8 o’clock positions.
All components must be clean and free from blemishes. Place a new O ring over the protruding main bearing and into the chamfer in the bearing housing. With a new oil seal mounted in the seal housing, fill seal lip with LM grease. Locate the assembly on to the main bearing, engage 6 socket head cap screws finger tight to ensure the seal housing sits flat on the face of the bearing. Tighten 6 screws progressively until the tightening torque is 28Nm (21 lbs. ft).
Section 10 REAR END OIL SEAL AND WEAR RING For access to the rear end shaft and oil seal, it is necessary to disconnect propeller shaft from pump drive flange and drain oil from the bearing housing by removing the drain plug (rear end, centre bottom) catching the oil in a suitable receptacle. Remove the tacho sender and fit shaft locking screw (Tool No 60275/11) locating the spigot in to one of the drive flange holes. Remove the drive flange nut and lockwashers.
Section 11 BEARING HOUSING The following section should only be necessary if worn or damaged bearings are suspected. To Remove It is necessary to strip the pump assembly in accordance with all the foregoing sections and drain the bearing housing of oil.
Section 12 Pump Tests Vacuum Test Place the blanking cap(s) in position on the inlet(s) of the pump and close the delivery valves. Run the pump at 1000 - 2000 rpm and observe the compound needle. When a vacuum of .7bar is obtained, stop the pump. This vacuum should be maintained for at least 15 sec. If the pump will not hold the vacuum with the blanking caps in position, a leak is present in the pump, and the pressure test detailed below must be carried out to trace it.
Section 13 Delivery Valve Maintenance 1. Ball Valves 2. UK Type with Instantaneous Connector 3.
Section 14 Delivery Valves Ball Valve Type The ball valve should not be dismantled unless it is functioning unsatisfactorily. There are two possible faults and the method of correcting them is as follows: 1. Water leaking round the ball This is due to the O Ring not pressing tightly enough against the ball. Remove the bolts and spring washers and separate the coupling end tube from the ball valve housing. Turn the O Ring over so that it presents a new face to the Ball Valve, or fit a new O Ring.
Screw-down Type Godiva Part Number 56544/01 Light Alloy and 56544/05 Gunmetal (Instantaneous Connector Versions) Pump Delivery Valve 2 1/2" Female Instantaneous (single twist) to BS336 Dia.
Instantaneous Outlet Servicing Procedure: 1 2 3 4 5 6 7 8 9 Knob Closure Disc Twist Release Knob Twist Release Cam Twist Release Bolt 2 1/2" Inst Seal 2 1/2" Twist Release Body Nut Coil Spring Sel-Lock Pin Dia.B Inspection A. Flush out equipment with clean water after use B. Inspect equipment monthly and follow maintenance procedures at least once every year C. Inspect release mechanism for free movement D.
Servicing Procedures - Continental Delivery Valves Item 1 3 4 4.1 5 6 7 8 9 10 11 12 13 14 Description Body, incl. Nipple Spindle Guide Sleeve O-Ring X-Ring Guide Axle Complete Tap Washer Valve Plate Complete Tap Washer Compression Spring Release Knob Assembly Handwheel Washer Cap Nut Function The valve opens and closes by turning the handwheel anti-clockwise and clockwise respectively and has an integrated, automatic non-return device.
Limited Warranty EXPRESS WARRANTY: Hale Products Inc. (Hale) hereby warrants to the original buyer that products manufactured 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: HALES obligation is expressly conditioned on the Product being: Subjected to normal use and service.
SMR-AC Addendum “A” Compressed Air Foam System CAFSPro Hale Products Inc. ◆ A Unit of IDEX Corporation 700 Spring Mill Avenue ◆ Conshohocken, PA 19428 U.S.A. Telephone: 610-825-6300 ◆ FAX: 610-825-6440 Web............www.haleproducts.
NOTICE ! Class1 cannot assume responsibility for product failure resulting from improper maintenance or operation. Class1 is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice. All Class1 products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully assembled and thoroughly tested.
Adde ndum - Table of C ont ents ❑ Contents Page SMR-AC CAFSPro Installation Addendum Addendum: SMR-AC Installation........................................................................ 5 A.1 Unpacking ........................................................................................................................... 5 Lifting the System ...............................................................................................................................
❑ A dde ndum - Ta ble of Contents Contents - continued Page Notes _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ___________
SMR -AC Ins talla tion a nd Se tup ❑ Addendum: SMR-AC Installation This SMR-AC Installation Addendum is in addition to and is to be used in conjunction with the CAFSPro Installation Guide, Hale p/n: 029-0020-78-0. Additional installation is required by the builder / installer as the Oil Separator Tank must be externally mounted, requiring additional plumbing. A.1 UNPACKING The SMR-AC CAFSPro system is shipped primarily assembled on two skids.
❑ SMR -AC Ins talla tion a nd Se tup WARNING - continued ! PLACE A BRACE, APPROXIMATELY 3’ (1 METER) BETWEEN THE LIFTING STRAPS / CHAINS TO PREVENT APPLYING EXCESSIVE PRESSURE TO THE MANIFOLDS AS THE SYSTEM IS LIFTED INTO PLACE. APPLY A STRAP AROUND THE FRONT SUCTION INLET AS SHOWN TO DEVELOP A THREEPOINT LIFT, MAKING SURE THE SYSTEM IS BALANCED. ALSO SEE FIGURE A-1: “LIFTING THE SMR-AC SYSTEM (THREE-POINT LIFT).” Figure A-1: Lifting the SMR-AC System (Three-Point Lift) A.
SMR -AC Ins talla tion a nd Se tup ❑ Whether mounting directly to the chassis, or constructing a separate bracket, accepted brackets must be used. Shock absorption is provided and must be included in any mounting modification. (See Figure A-2: “Shock Mounting.”) All mounting brackets must be constructed from structural angled steel, having minimum dimensions of 4” x 36” x 1/2” (102 x 914 x 13 mm). Use minimum 5/8”, Grade 8 bolts with flat washers and lock nuts.
❑ SMR -AC Ins talla tion a nd Se tup Attach female eye-bolts, 12 mm, to the top cross bracket mounting studs for lifting. Mount the separator tank having the inlet port sightly BELOW the compressor discharge port to ensure back-flush does not enter the compressor, which would severely damage the unit. (See Figure A-4: “Lifting Separator Tank.”) Mount the tank using 7/16”-14, Grade 8 screws, flat and lock washers and nuts.
SMR -AC Ins talla tion a nd Se tup ❑ Figure A-5: Overview, SMR-AC System Connections Addendum - SMR-AC CAFSPro Installation Guide p/n: 029-0020-78-0 55
❑ SMR -AC Ins talla tion a nd Se tup A.4 OIL SEPARATOR TANK For a general overview of the oil separator tank connection, see Section “Drawing Package” on page 67. (See Figure A-6: “Separator Tank Installation Overview.”) Figure A-6: Separator Tank Installation Overview The following connections are made by the system builder/installer: ❑ (#1) Compressor discharge air / oil mixture to oil separator tank INLET. Use 1-1/2” (38 mm), wire reinforced hose. For example, Aeroquip FC350-24.
SMR -AC Ins talla tion a nd Se tup ❑ Use 1-1/4” (32 mm), wire reinforced hose for maximum air flow. For example, Aeroquip FC350-20. Note: Two check valves are provided in this discharge line to ensure water is not back-flushed into the oil separator tank. ❑ (#3) Oil separator tank DISCHARGE to heat exchanger. Use 7/8” (22 mm), wire reinforced hose. For example, Aeroquip FC35016. (See Figure A-6: “Separator Tank Installation Overview,” on page 56.) ❑ (#4) Air sensing valve to duplex gauge.
❑ SMR -AC Ins talla tion a nd Se tup Note: A minimum 1” (25.4 mm) connection is required to test the system per NFPA standards. A.5 AIR FILTER For reliable operation, the CAFS air filter must be located in a clean, freshair environment, usually in the dunnage area above the pump compartment. DO NOT damage the filter during assembly and be sure the mounting area offers protection.
SMR -AC Ins talla tion a nd Se tup ❑ (See Figure A-6: “Separator Tank Installation Overview,” on page 56.) Also see Figure A-7: “Depressurizing Valve Assembly” on page 57. A.7 FLUID LEVELS To meet various shipping regulations, oil within the pump gearbox and separator tank assemblies is drained prior to shipping from the factory. IMPORTANT ! AT INSTALLATION AND BEFORE OPERATION, ALL FLUIDS MUST BE ADDED TO THE APPROPRIATE LEVELS.
❑ SMR -AC Ins talla tion a nd Se tup Notes ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ __________________________________________
