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Godiva WTA3010 Maintenance Instructions And Workshop Manual

World series; wt series multi-pressure pump
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©Hale Products Europe LTD, Warwick
GP/146/99
WTmaint - Issue9. 10-2005October 2005
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GP/146/99. Issue 9. October 2005
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  • Page 1 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 World Series ©Hale Products Europe LTD, Warwick GP/146/99 WTmaint - Issue9. 10-2005October 2005...

  • Page 2: Issue

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 ©Hale Products Europe LTD, Warwick GP/146/99 WTmaint - Issue9. 10-2005October 2005...
  • Page 3 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 AMENDMENT RECORD for WT Multi-pressure Pump Maintenance Manual Number Date Page Amendment Instruction Pub/. Issue August 2005 Inclusion of Amendment Issue 7, Record on page 2 August 2005 August 2005 Inclusion of minimum Issue 7, 1200rpm idle speed to August 2005...

  • Page 4: Issue

    Model WTB6010 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’...

  • Page 5: Table Of Contents

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 CONTENTS SECTION PAGE SAFETY GENERAL DESCRIPTION LUBRICATION PROTECTION AGAINST FROST SECTION: SUCTION TUBE & FRONT WEARING RING WEARING RING MAINTENANCE LOW PRESSURE IMPELLER REAR WEAR RING & COVER PLATE HIGH PRESSURE IMPELLER CARBON SEAL & SEATING ASSEMBLY VOLUTE BODY LOW PRESSURE MANIFOLD &...

  • Page 6: Safety

    SAFETY - VEHICLE BUILDER / INSTALLER SAFETY-RELEVANT DATA 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...

  • Page 7: General Description

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 GENERAL DESCRIPTION Diagram 1 Whilst the pump High Pressure Selector (change over) valve is in the open position, water which enters the high pressure stage during the low pressure mode will circulate back to the low pressure stage, thus preventing high pressure from being generated.
  • Page 8 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 The Godiva WT Series two-stage pump is a dual pressure pump. It can be used for high volume, low pressure (LP) output or for low volume, high pressure (HP) output, or both simultaneously. When the pump is running, LP flow is always available, but HP is available only if the HP selector valve is in the closed position.

  • Page 9: Lubrication

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 10: Protection Against Frost

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 PROTECTION AGAINST FROST As a precautionary measure, when frost is anticipated, drain all water from the pump and its ancillaries. The pump is drained by removing the drain plug from the base of the volute. It is highly recommended that this is removed and the volute fitted with a drain valve system terminating with a ball valve at a convenient location on the vehicle.

  • Page 11: Suction Tube & Front Wearing Ring

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 12: Low Pressure Impeller

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.
  • Page 13 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 14: High Pressure Impeller

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 4 HIGH-PRESSURE IMPELLER To Remove With the volute cover plate and the low pressure impeller removed (Section 3) unscrew the twelve M10 socket head cap screws securing the high pressure impeller cover plate. Insert 2 M8 socket screws into the extractor holes in the cover plate and screw them in evenly until the cover plate moves forward.
  • Page 15 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Using a depth micrometer, measure the clearance between the pump body cover plate seating face and the impeller blade edge (see Fig 4-1). The depth micrometer should read 0.23/33mm (0.009-0.013in). If the measurement is more than this, remove the nut, washer and spacer, add shims to correct the clearance, re-assemble and re-check.

  • Page 16: Carbon Seal & Seating Assembly

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 To Refit When the correct clearance has been obtained, fit the cover plate. After ensuring the joint face (A) on the pump body and the joint face on the cover plate are clean, smooth and free from deformation, align the holes in the cover plate with the holes in the pump body and clamp, using twelve M10 x 1.5mm stainless steel socket head screws tightened to a torque of 57nm (42 lbs ft).
  • Page 17 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 The silicon carbide ring fitted in the rear side of the HP impeller may be levered out, by means of a small instrument screwdriver inserted between the ring and its rubber cup. Reassembly 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.

  • Page 18: Volute Body

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 6 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.

  • Page 19: Low Pressure Manifold

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 7 LOW PRESSURE MANIFOLD AND FILTER HOUSING To Remove Assuming that the HP pump discharge connections have been disconnected together with gauge, thermal relief and foam connections, it is necessary to remove the primer discharge pipe from the filter housing to the HP pump body.
  • Page 20 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 The change over valve is clamped between the filter housing and the bypass connector housing and is retained by 4 off M10 bolts. Also constrained between the 2 housings is the cylindrical pressure relief valve and sealed on its outside diameter by 2 O rings.

  • Page 21: Priming System

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 8 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 detached by the removal of 4 nuts and washers (see Fig 8-1).
  • Page 22 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.
  • Page 23 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.
  • Page 24 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.
  • Page 25 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 PRIMING SYSTEMS Continued FILTER in PISTON PRIMER TUBE From WT serial number 2369 (mid-2003) the pump is fitted with a filter in the tube that connects the suction tube to the piston primers. This is designed to protect the piston primers from the ingress of debris, particles as small as a grain of sand, that can hold the priming valve open and allow water and debris into the bore and piston of the primers.
  • Page 26 MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 27: Hale Products Europe Ltd, Warwick

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 28: Front End Oil Seal & Wear Ring

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 9 PUMP HEAD To Remove Remove the low pressure manifold, volute body, impellers and cover plate (Sections 6,7,3 and 4) 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 head 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.

  • Page 29: Hale Products Europe Ltd, Warwick

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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.

  • Page 30: Rear End Oil Seal & Wear Ring

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 11 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.

  • Page 31: Bearing Housing

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 12 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.

  • Page 32: Gearbox (Optional

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 13 GEARBOX (Optional) The gearbox incorporates a cooling system, which utilises cold water diverted from the main pump body to flow around the gearbox outer housing and then return to the pump. The water is always flowing around the gearbox whenever the pump is operating and pumping water.

  • Page 33: Hale Products Europe Ltd, Warwick

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 The oil level can be checked by removing one of the oil level check point plugs, located on both sides of the gearbox, see the photograph above. The oil should be just up to the lower rim of the hole, which indicates the capacity is 1.5 litres. Replace plug hand...

  • Page 34: Pump Tests

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 14 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.

  • Page 35: Delivery Valves

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Section 15 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.

  • Page 36: Hale Products Europe Ltd, Warwick

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 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. A Item Description Item Description Main Body...

  • Page 37: Hale Products Europe Ltd, Warwick

    MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Instantaneous Outlet Servicing Procedure: Knob Closure Disc Twist Release Knob Twist Release Cam Twist Release Bolt 2 1/2" Inst Seal 2 1/2" Twist Release Body Coil Spring Sel-Lock Pin Dia.B Inspection A. Flush out equipment with clean water after use B.

  • Page 38: Hale Products Europe Ltd, Warwick

    World Series MAINTENANCE MANUAL GP/146/99. Issue 9. October 2005 Servicing Procedures - Continental Delivery Valves Item 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...

  • Page 39: Special Tools

    GP/146/99. Issue 9. October 2005 Section 16 Special Tools available for servicing World Series Pumps DESCRIPTION Part Numbers WTA2010 WTB2010 WTA4010 WTB4010 WTA3010 WTB3010 WTA6010 WTB6010 ASSY TOOL - BRG TO SHAFT 60275 60275 60275 60275 ASSY TOOL - BRG TO SHAFT...

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