HALE Godiva KP1 User manual

KP1 and KP2
Vehicle Mounted Fire Pump


Installaon and Operaon Manual

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Amendment Record

 Date   
- - - 
   


   


   


4  


   

4
  











Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
CONTENTS
Amendment Record 2
Contents 3
Introduction 4
Safety 5
Technical Data 8
Installation 13
Commissioning 27
Operation 28
Maintenance 31
Fault Finding 34
Operator Maintenance Log 37
RTP - Round the Pump Foam System 38

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

INTRODUCTION








Important Notes
Spares



Ordering

 




 
 
 


Pump



Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
SAFETY



!
 
 
 
Installation and Commissioning
Once packaging has been removed, installer should ensure rotating parts are not accessible.
In operation
Rotating parts must be guarded against accidental contact.
Do not insert items into the suction tube when pump is running.
Discharge hoses must not be disconnected when the unit is running.
No components must be unfastened when the unit is running.
When installing or removing the pump, suitable lifting equipment must be used.
Suitable ear protection must be worn when pump is running – if necessary.
When lling the gearbox - avoid spilling oil onto the oor to prevent the danger of slipping.
Maximum allowable inlet pressure is 12 bar
Do not run the pump without water for more than one minute as dry running will damage the seal
Training

Maintenance


Environmental Protection

Risk Assessment


Transportation and Storage







Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Post-production Cleaning Fluid



Warranty


Associated Publications
Publicaon Part No
   
   
Pump specicaon numbering

   
 






Cleaning uid deposit
– will be ushed away
when pump is used

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
KP1_1510 and KP2_1510 Spares



Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Technical Data
Features unique to KP1 or KP2 model only are indicated, other parts are common
Description
Pump type KP1 Single stage - centrifugal
Pump type KP2 Two stage. 1st stage centrifugal, 2nd stage regenerative
Shaft Stainless steel
Seal Self-adjusting mechanical type
Material Aluminium or bronze (applies to main castings)
See Materials of Construction list for details
Direction of rotation Clockwise and Counter Clockwise available (when viewed on drive ange)
(impeller)
Priming system Reciprocating, positive displacement piston
Temperature range -15°C to +40° ambient (ref: EN1028-1)
Lubrication - 1.1 litre. Use fully synthetic ISO VG 220 oil, to ensure ve years running with no
Gearbox oil change. If not available use gear oil EP80/90 (to be changed every year)
See recommended oil list below.
Recommended Oil Suppliers for the ISO VG 220 oil - for 5 year period
Manufacturer Specicaon Contact informaon
  
  
Safety devices 42°C Thermal relief valve (74°C option).
Fitted as standard on KP2, optional on KP1
KP2 only - Suction pressure relief valve opens at 13 Bar
Angle of inclination 15° in any plane
Maximum inlet pressure 12 bar
Accessories Foam systems
Mass moment of inertia -
 
    
    
    
    

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
EN Designation (EN 1028:-1:2002)
Godiva Descripon
and specicaon
European
standard Classicaon Limit pressure pa lim bar


 







 





Materials of construction
Material Material
Component Aluminium alloy pump Gunmetal pump
Volute casing Aluminium alloy Gunmetal
Pump head - KP1 Aluminium alloy Gunmetal
Pump head - KP2 Stainless steel Stainless steel
Suction cover Aluminium Alloy Gunmetal
L.P. Impeller Aluminium Alloy Gunmetal
Front wear ring Acetal copolymer Acetal copolymer
Rear rear wing Acetal copolymer Acetal copolymer
Gearbox Aluminium alloy Aluminium alloy
Input shaft Stainless steel Stainless steel
Pump shaft Stainless steel Stainless steel
Mechanical seal Silicon carbide / Carbon Silicon carbide / Carbon
Other mechanical seal
components Stainless steel Stainless steel
H.P. Impeller – KP2 only Stainless steel Stainless steel
Cover Plate – KP2 only Stainless steel Stainless steel

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Figure 1. Cross Section of Prima KP1 Pump – Typical



 











Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
Figure 2. Cross Section of Prima KP2 Pump – Typical








seal












Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Essenal installaon data
Fastening bolts, pump to chassis
cross-member
8 o󰀨 M8 x 1.25, Grade 8.8, Minimum 12mm
Engagement. Torque to 14Nm
Alignment of pump drive lines 7° Equivalent single joint angle - maximum
Tank to suction pipework Ø 100mm
Must incorporate a pliable element for exibility.
Pump speed sensor Electronic.
Please see diagram DS651 for the wiring
connection details (page xx).
Fasteners ISO specication
Utility requirements Water supply to pump inlet
Electricity supply to clutch, 24V/5A or 12V/10A
Special assembly tools for installation Connector tool for attaching plugs (where
supplied)
Angle of installation (in any plane) ±15°

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
INSTALLATION
1. Before installation check the pump for any transit damage.
2. Mounting - Securing pump
The pump is secured to the vehicle chassis by eight M8 bolts, the corresponding bolt holes on the
pump will be located on the gearbox. Note: the gearbox can be supplied in three positions - left, right
and down, so the location of the xing holes will vary according to the gearbox position.
The full bolt specication is M8 x 1.25, Grade 8.8, Minimum 12mm Engagement. Torque to 14Nm.
This photograph shows the gearbox in the down position.
For mounting gearbox in down position
Pump mounting points - Use 8 x M8 Bolts
3. Mounting - Provision for external pipes
Provision must be made for the oil drain plug and the cooling pipes in left and right position
gearboxes. Refer to the KP1 and KP2 installation drawing for further installation information.
Oil drain plug
For pump mounting
with gearbox to right
side. The same holes
are provided on the
left side for left side
mounting

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

4. Priming System
Connect a exible pipe (32mm, 1¼inch internal dia.) to the discharge port on the side of the primer.
The discharge options for the primer are -
Discharge can be piped to the ground. Point discharge away from the operator.
Discharge can be piped to a separate holding tank.
Discharge can be piped back to main tank – if no foam system is used.
5. Wiring connections - Primer disengagement and Tachometer
The pump is supplied with the main disengaging components connected. It is the external power
supply that needs to be connected to the pressure switch and tachometer.
Connect discharge
pipe to primer here
- 32mm, 1¼inch
internal diameter
exible pipe.
Tachometer
Connect these wires
to -
Green = 12/24V
Pos(+)
White/Black = Signal
to tacho
Black = 12/24V Neg(-)
ground
Also see page 25 for
wiring diagram.
Pressure Switch
Connect these wires
to -
Red = 12/24V Pos(+)
Red/White = to earth
Black = 12/24V(-)
ground
Also see page 24 for
wiring diagram.

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
6. Pump Draining
The volute and gearbox drain point must be connected to suitable drain taps.
This photograph shows the pump drain and gearbox cooling circuit connected to a drain point at the
front of the pump.
7. Gearbox Draining
Volute drain port -
This connection is a
G3/8 inch, for a tap
or tting to attach a
minimum Ø9.5mm
hose.
The gearbox cooling
circuit is also drained
at this point

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

8. Suction – Sideline Connection
A tank to suction line can be accommodated if the special adaptor is tted to the suction ange. The
tank to pump line must incorporate a exible coupling to allow for any movement.
The adaptor can be rotated to suit di󰀨erent tank to suction line congurations.
9. Filter – KP2 model only
The high pressure lter limits particles entering the high pressure stage.
It should be regularly removed, ushed with clean water and replaced. This should be carried out
when pump is not in operation
10. High pressure selector valve – KP2 model only
The position of this valve allows the handle to project through an instrument panel attached to the
front of the pump. When the handle is down, low pressure is available in the hose reels. With the
handle up high pressure is available in the hose reels. Note: Low pressure water is available on the
high pressure outlet when high pressure is not selected.
High pressure lter.
Remove with 38mm
A/F (1½in) spanner
High pressure / Low
pressure selector lever
High
Low

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
11. Pipework for Instrumentation and Safety Devices
Vacuum and pressure gauge connection points are indicated in the pictures below. All connections
and tubing must have a minimum working pressure rating of 19 bar.
KP1 and KP2 models - low pressure gauge connection – on side of volute.
KP2 model - High pressure gauge connection – on side of high pressure discharge manifold
Low pressure gauge
connection, Rp ¼”
High pressure outlet
connection Rp 1¼
High pressure gauge
connection, Rp ¼”

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

Vacuum gauge connection – on suction tube
Thermal Relief Valve (TRV)
Elbow accepts 12mm (1/2 in) bore exible hose
DO NOT PLUG THIS VALVE. FEED DISCHARGE AWAY FROM OPERATOR.
MAY BE FED INTO TANK IF FOAM IS NOT USED – available in two ratings, 42°C and 74°C.
Vacuum gauge
connection, Rp ¼”
Note: TRV is shown on
a KP2 model, located
on high/low pressure
transfer module.
KP1 model - TRV
is located on low
pressure discharge
manifold (which is an
optional item) or if no
manifold tted the TRV
is provided loose.

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon. 
Suction Pressure Relief Valve
Pressure relief valve is tted to relieve high pressure in hose reels when discharge nozzles are
closed.
The valve must discharge to atmosphere.

Godiva Ltd. policy is one of connuous development.
We therefore reserve the right to amend specicaons without noce or obligaon.

157.1
91.0
369.5
Ø104.0
Ø180.0
Ø175.0
4x
R8.5
457.0
160.0
189.8
OIL LEVEL
SIGHT GLASS
General Arrangement Drawing - KP1, Part 1
118.8
119.2
138.0
323.8
488.3
98.0
98.0
1410 DRIVE FLANGE
P
PRESSURE
GAUGE
CONNECTION
- Rp ¼
DIN 175
FLANGE
PUMP
DRAIN
Rp 3/8