ISSUED: MAY 1993
WARMAN INTERNATIONAL LTD
WARMAN PUMPS
ASSEMBLY AND MAINTENANCE
INSTRUCTIONS
SUPPLEMENT ‘P34’
Warman International Ltd. is the owner of the Copyright subsisting in this
Manual. The Manual may not be reproduced or copied in whole or in part in any
form or by any means without the prior consent in writing of Warman
International Ltd.
Copyright © WARMAN INTERNATIONAL LTD.
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993
WARNINGS
WARMAN PUMPS - ASSEMBLY AND MAINTENANCE
INSTRUCTION MANUALS AND SUPPLEMENTS
IMPORTANT SAFETY INFORMATION
•
The WARMAN PUMP is both a PRESSURE VESSEL and a piece of ROTATING
EQUIPMENT. All standard safety precautions for such equipment should be followed
before and during installation, operation and maintenance.
•
For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable
speed drives, etc.) standard safety precautions should be followed and appropriate
instruction manuals consulted before and during installation, operation and maintenance.
•
DRIVER ROTATION MUST BE CHECKED before belts or couplings are connected.
Personnel injury and damage could result from operating the pump in the wrong
direction.
•
DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS FOR
PROLONGED PERIODS, OR UNDER ANY CIRCUMSTANCES THAT COULD
CAUSE THE PUMPING LIQUID TO VAPORISE. Personnel injury and equipment
damage could result from the pressure created.
•
DO NOT APPLY HEAT TO IMPELLER BOSS OR NOSE in an effort to loosen the
impeller thread prior to impeller removal. Personnel injury and equipment damage could
result from the impeller shattering or exploding when the heat is applied.
•
DO NOT FEED VERY HOT OR VERY COLD LIQUID into a pump which is at
ambient temperature. Thermal shock may cause the pump casing to crack.
•
FOR THE SAFETY OF OPERATING PERSONNEL, please note that the
information supplied in this Manual only applies to the fitting of genuine Warman parts
and Warman recommended bearings to Warman pumps.
•
Tapped Holes (for Eye Bolts) and Lugs (for Shackles) on Warman Parts are for lifting
Individual Parts Only.
•
FULLY ISOLATE THE PUMP before any maintenance, inspection or troubleshooting
involving work on sections which are potentially pressurised (eg casing, gland, connected
pipework) or involving work on the mechanical drive system (eg shaft, bearing assembly,
coupling):-
• Power to the electric motor must be isolated and tagged out.
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993
• It must be proven that the intake and discharge openings are totally isolated from all
potentially pressurised connections and that they are and can only be exposed to
atmospheric pressure.
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993
ISSUED: MAY 1993
LAST ISSUE: JANUARY 1985
WARMAN PUMPS
ASSEMBLY AND MAINTENANCE INSTRUCTIONS
SUPPLEMENT ‘P34’
SUMP PUMPS
CYKLO
CONTENT
WARNINGS
CONTENT
INTRODUCTION ......................................................................................................... 1
VERTICAL TYPE ‘V’ BEARING ASSEMBLY - MAINTENANCE AND ASSEMBLY
INSTRUCTIONS .......................................................................................................... 1
PUMP PARTS IDENTIFICATION ................................................................................ 1
IMPELLER ADJUSTMENT .......................................................................................... 1
PUMP ASSEMBLY ...................................................................................................... 2
Fitting of Column to Bearing Assembly ........................................................................ 2
Fitting Frame Plate, Stuffing Box, Back Liner and Impellers ........................................ 5
Fitting Cover Plate Bolts, Volute Liner, Throatbush and Cover Plate ........................... 7
PRODUCT MODIFICATION ADVICE SHEETS (PMA) ................................................ 7
WARMAN BASIC NUMBERS AND PARTS LIST ........................................................ 8
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 1
INTRODUCTION
Supplement ‘P34’ should be read in conjunction with the following Warman Assembly
and Maintenance Instruction Supplements:
M1 – General Instructions applicable to All Types of Warman Pumps
BA5 – Vertical Type ‘V’ Bearing Assemblies
This supplement contains step by step illustrated instructions for complete and correct
assembly of the Warman Sump Pump.
VERTICAL TYPE ‘V’ BEARING ASSEMBLY - MAINTENANCE AND
ASSEMBLY INSTRUCTIONS
The bearing assembly is assembled according to the instructions contained in Warman
Supplement ‘BA5’. Maintenance instructions including lubrication are also included in
‘BA5’.
PUMP PARTS IDENTIFICATION
The comments in Warman Supplement ‘BA5’ regarding Warman basic numbers
incorporated in Warman part numbers applies equally to Warman pump components.
For full description and part number identification refer to the appropriate Warman
components diagram.
Names and basic numbers are used in assembly instructions in this supplement. All
relevant Warman basic numbers are listed at the end of this supplement.
IMPELLER ADJUSTMENT
Pump performance changes with the clearance existing between the impeller and casing.
For best performance, it is necessary therefore, to adjust the impeller close to the casing.
This adjustment can be carried out in a few minutes without any dismantling.
The method of impeller adjustment is to loosen COLUMN BOLTS (-) and remove or
add sufficient SPACERS (290) so the impeller is clear of the BACKLINER (041).
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 2
PUMP ASSEMBLY
Figure 1
FITTING OF COLUMN TO BEARING ASSEMBLY
When pumps have been dismantled for complete overhaul, all parts should be closely
inspected and new parts checked for correct identification
Used parts being replaced should be thoroughly cleaned and painted. Mating faces
should be free of rust, dirt and burrs and given a coat of grease before they are fitted
together.
It is preferable to renew small bolts and set screws during overhaul and all threads
should be coated with graphite grease before assembly.
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 3
Mating faces and spigots should be greased to assist future removal.
It is recommended that all rubber seals should be replaced during major overhauls as
rubber tends to harden and seals lose their effectiveness.
1. Completely assemble BEARING ASSEMBLY (005) according to assembly
instructions in Warman Supplement ‘BA5’.
2. Fit BEARING ASSEMBLY (005) into COLUMN (102).
3. Place SPACERS (290) between bearing assembly and column - four spacers to
each of the feet on hearing housing. Fit COLUMN BOLTS (-) and lightly tighten.
Note:
(a) These bolts will require to be fully tightened once the impeller adjustment is
completed.
(b) Orientate column such that grease nipples can be greased once pump is
installed.
4. Screw COLUMN STUDS (-) into MOUNTING PLATE (019).
5. Fit the two halves of the split MOUNTING PLATE (019) around the column and
orientate such that the grease nipples in the bearing assembly are on the opposite
side to the discharge pipe.
Fit nuts to COLUMN STUDS (-) and fully tighten.
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 4
Figure 2
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 5
FITTING FRAME PLATE, STUFFING BOX, BACK LINER AND IMPELLERS
Assembly of the pump components is best done by turning the unit sideways so the shaft
is horizontal or if sufficient head room is available, invert the unit so that it is supported
vertically with the impeller end of the shaft facing upwards.
1. Fit BACKLINER (041) on COLUMN (102) and check it fully engages in spigot.
2. Lift CASING O-RING (124) around backliner and up against flange on column.
It is advisable to use a rubber contact cement to hold this part in position during
rest of assembly.
3. Liberally grease shaft thread with graphite grease. Note that too much grease may
prevent the impeller from screwing hard home to lock against the shaft shoulder.
4. Slide IMPELLER O-RING (109) over thread and against shaft shoulder.
5. Using a rope sling or other appropriate method, lift IMPELLER (191) and screw
onto shaft. While screwing on the impeller check that the back of the impeller
does not rub on the backliner - SPACERS (290) may be required to be added or
removed to suit. The shaft wrench can be used to screw the shaft into the
impeller. Check the impeller is hard up onto the shaft shoulder.
6. Lift CASING (092) and position on end of column. Check that the casing O-ring
is not dislodged during this operation. The taper on the backliner will guide the
casing into the correct position. Check discharge flange is orientated to line up
with discharge pipe.
7. Insert CASING BOLTS (189) and tighten evenly to compress O-ring. Check that
all bolts are tensioned evenly and casing is pulled up against the column. Do not
over tighten casing bolts as this could cause flange on casing to break as the
casing is normally manufactured from a brittle material.
8. Fit second CASING O-RING (124) over SUCTION COVER (190) and locate in
the radiused corner. It is advisable to use a rubber contact cement to hold this part
in position during assembly.
In the case of 2/2TC, 3/3TC and 4/4TC the casing and the suction cover have been
combined to form one integral part, and no casing O-ring is required.
9. Lift up SUCTION COVER (190) and position in casing. Taper on casing and
suction cover will ensure alignment.
10. Insert CASING BOLTS (189) and tighten evenly to compress O-Ring. Check that
all bolts are tensioned evenly and suction cover is pulled up against the casing.
Do not over tighten casing bolts.
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 6
Figure 3
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 7
FITTING COVER PLATE BOLTS, VOLUTE LINER, THROATBUSH AND COVER PLATE
The discharge pipe is best assembled by laying the pump horizontally such that the
clamp for the discharge pipe is uppermost. Place support beneath the column to allow
free access and working space at pump end of the column.
1. Fit JOINT RING (060) to pump discharge. A smear of rubber contact cement will
keep joint in place during assembly.
2. Position DISCHARGE PIPE (154) on pump and such that the lugs on side of pipe
align with bracket on mounting plate. Fit DISCHARGE PIPE BOLTS (-) and
tighten evenly.
3. Fit DISCHARGE PIPE CLAMP BOLTS (-) and tighten to fix discharge pipe to
mounting plate.
The pump is now complete and ready for assembly of drive components and
then installation.
PRODUCT MODIFICATION ADVICE SHEETS (PMA)
This manual has been compiled from the latest information and revisions regarding
Warman Cyklo type pump fit-up. Over time improvements have been incorporated into
certain pumps and advice distributed in the form of Product Modification Advice
(PMA) sheets. Listed below are the relevant PMA’s for the cyklo type pumps. If further
information is required on any of these topics please contact your local Warman
International Office.
PMA No. ISSUED DATE DESCRIPTION
PMA-110-54 Apr 93 Casing and suction cover integration.
PMA-110-89 Jan 93 3/3 VD-TC dual lip seal
Copyright © WARMAN INTERNATIONAL LTD
MANUAL SUPPLEMENT ‘P34’ ISSUED: MAY 1993 8
WARMAN BASIC NUMBERS AND PARTS LIST
B I
BACKLINER (041)..................................................... 1, 5
IMPELLER (191) ........................................................... 5
BEARING ASSEMBLY (005)........................................ 3
IMPELLER O-RING (109)............................................. 5
C J
CASING (092) ................................................................ 5
JOINT RING (060) ......................................................... 7
CASING BOLTS (189) ................................................... 5
CASING O-RING (124).................................................. 5
COLUMN (102) .......................................................... 3, 5 M
COLUMN BOLTS (-) ................................................. 1, 3
MOUNTING PLATE (019) ............................................ 3
COLUMN STUDS (-) ..................................................... 3
D S
SPACERS (290)...................................................... 1, 3, 5
DISCHARGE PIPE (154) ............................................... 7
SUCTION COVER (190) ............................................... 5
DISCHARGE PIPE BOLTS (-)....................................... 7
DISCHARGE PIPE CLAMP BOLTS (-) ........................ 7
Copyright © WARMAN INTERNATIONAL LTD
