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WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS

PART 2G

ELASTOMER LINED
SUMP PUMP

TYPE ‘SPR’

PC2G
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS

PART 2G

ELASTOMER LINED SUMP PUMP

TYPE ‘SPR’

Issue Date: 4 January 2000

Information in this publication is subject to change without notice.

This publication may not be reproduced in whole or in part by any process, electronic or otherwise,
without the specific written consent of Research and Development Pty Limited.

Copyright © Research and Development Pty Limited 2000

WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

SAFETY INFORMATION

The following safety information relating to pump operation and maintenance should be
carefully observed, and correct procedures followed, to avoid injuries to personnel, and
damage to equipment. All statutory requirements relating to this equipment must be complied
with at all times.

DO NOT APPLY HEAT TO THE IMPELLER HUB OR INLET EYE TO ASSIST IMPELLER
REMOVAL. APPLICATION OF HEAT MAY RESULT IN SHATTERING OF THE IMPELLER ,
RESULTING IN INJURY OR EQUIPMENT DAMAGE.

DO NOT OPERATE THE PUMP FOR AN EXTENDED TIME WITH ZERO OR VERY LOW
FLOWRATE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OVERHEATING OF
THE PUMP, AND VAPORISATION OF THE PUMPED FLUID, WITH GENERATION OF VERY
HIGH PRESSURES. SERIOUS INJURY TO PERSONNEL, OR DAMAGE TO EQUIPMENT MAY
RESULT FROM SUCH ACTION.

CHECK DRIVE MOTOR ROTATION PRIOR TO FITTING OF DRIVE BELTS OR

COUPLINGS. INCORRECT MOTOR ROTATION MAY CAUSE PERSONNEL INJURY OR
EQUIPMENT DAMAGE.

DO NOT FEED VERY HOT OR VERY COLD FLUID INTO A PUMP AT AMBIENT
TEMPERATURE. THERMAL SHOCK MAY RESULT IN FRACTURE OF PUMP WET-END
PARTS.

A WARMAN PUMP MUST BE REGARDED AS BOTH AN ITEM OF ROTATING

MACHINERY, AND A PRESSURE VESSEL. ALL RELEVANT SAFETY PRECAUTIONS AND
PROCEDURES FOR SUCH EQUIPMENT SHOULD BE OBSERVED DURING PUMP
INSTALLATION, OPERATION AND MAINTENANCE.

WHERE AUXILIARY EQUIPMENT IS ASSOCIATED WITH A PUMP (eg MOTORS, DRIVE

BELTS, DRIVE COUPLINGS, SPEED REDUCERS, VARIABLE SPEED DRIVES, ETC), ALL
RELEVANT INSTRUCTION MANUALS SHOULD BE CONSULTED, AND RECOMMENDED
PROCEDURES IMPLEMENTED, DURING INSTALLATION, OPERATION AND MAINTENANCE
OF THE PUMP SYSTEM.

ISSUE DATE : 4 January 2000

WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

CONTENTS - PART 2G

Page

1. INTRODUCTION .............................................................................................................................................................. 2 - 1

2. APPLICATION AND FEATURES OF ELASTOMER LINED

TYPE ‘SPR’ SUMP PUMPS ................................................................................................................................ 2-1

3. IDENTIFICATION OF PARTS ................................................................................................................................ 2-2

4. BEARING ASSEMBLY – ASSEMBLY, MAINTENANCE AND LUBRICATION .............. 2 - 2

5. PUMP ASSEMBLY INSTRUCTIONS .............................................................................................................. 2 - 3

5.1 Frame Assembly ............................................................................................................................................ 2 - 3

5.1.1 Standard Duty Bearing Assembly ................................................................................ 2 -3

5.1.2 Heavy Duty Bearing Assembly ........................................................................................ 2 - 5

5.2 Casing Assembly .......................................................................................................................................... 2-8

5.2.1 40 SPR and 65 SPR Pumps .............................................................................................. 2 - 8

5.2.2 100 SPR and larger Pumps ................................................................................................ 2 - 10

5.3 Miscellaneous Fittings .............................................................................................................................. 2 - 13

6. IMPELLER ADJUSTMENT ...................................................................................................................................... 2 - 15

7. DISMANTLING PUMP AND REMOVAL OF IMPELLER ................................................................ 2 - 15

APPENDIX - WARMAN BASIC PART NUMBERS .......................................................................... 2 - 16

ISSUE DATE : 4 January 2000

WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

1. INTRODUCTION

This publication, Part 2G, forms part of a set which together comprise the Assembly,
Operating, and Maintenance Instruction Manual for the Warman Elastomer Lined Sump
Pump, Type ‘SPR’. Other publications in the set comprise the following:

Part 1: Assembly, Operating and Maintenance Instructions – General Instructions for

all Types of Warman Pumps.

Part 3E: Vertical Bearing Assembly, Type ‘V’, Heavy Duty.

Part 3F: Vertical Bearing Assembly, Type ‘V’, Standard Duty.

Part 1 has been written to more specifically describe the horizontal Type AH pump, and
hence sections not relevant to vertical sump pumps should be disregarded.

Part 2G applies to Type ‘SPR’ Warman Elastomer Lined Sump Pumps.

2. APPLICATION AND FEATURES OF ELASTOMER LINED TYPE ‘SPR’

SUMP PUMPS

These pumps are of heavy-duty construction, designed for submerged mounting in pits or
sumps. They are particularly suited to continuous pumping of highly abrasive, and corrosive
slurries in the Mining, Chemical, and General Process Industries. They feature an elastomer
lined casing design, characterised by design simplicity, minimum number of parts, and light
overall weight.
Important design features of this range of Warman Slurry Pumps include:

• Robust shafts
• Optional Standard or Heavy duty bearing assemblies
• Heavy duty screw thread Impeller attachment
• Through-bolt design throughout
• Replaceable casing components
• No submerged bearings

Type ‘SPR’ Sump Pumps may be supplied with either Standard Duty or Heavy Duty Bearing
Assemblies. Standard Duty Bearing Assemblies are satisfactory for the bulk of sump pump
applications. However for extreme operating conditions, involving high bearing loading, the
longer bearing life yielded by the Heavy Duty Bearing Assemblies will often justify their use.

Pumps fitted with Standard Duty Bearing Assemblies are characterized by a numeral
representing PUMP SIZE (ie discharge pipe size in mms), immediately followed by FRAME
TYPE (ie ‘V’), FRAME SIZE, and an optional IDENTIFIER for High Head models (ie ‘H’),
followed by - PUMP TYPE (ie ‘- SPR’), eg 100VE-SPR, 65VDH-SPR Sump Pumps.
High head Sump Pumps (eg 65VDH-SPR) are fitted with large diameter shafts for increased
stiffness, which results in increase of the critical vibration speeds, and corresponding
maximum pump speeds, to higher values than for the equivalent standard Bearing
Assembly.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

Pumps fitted with Heavy-Duty Bearing Assemblies are characterized by a numeral

representing PUMP SIZE (ie discharge pipe size in mms), immediately followed by FRAME
SIZE, FRAME TYPE (ie ‘V’), and an optional IDENTIFIER for High Head models (ie ‘H’),
followed by - PUMP TYPE (ie ‘- SPR’), eg 100RV-SPR, 150SVH-SPR Sump Pumps.

3. IDENTIFICATION OF PARTS

Each Warman pump part has a unique name and a three-digit Basic Part Number. Parts
with the same name have the same Basic Part Number, regardless of pump size. For
example, the Shaft of every Warman pump has the Basic Part Number 073.

Additional letters and numbers are added before and after the Basic Part Number to further
define a component part of a particular pump, as described in Part 1 of the Assembly,
Operating, and Maintenance Instruction Manual. This expanded marking is identified as the
Part Number, and represents a unique identification for each component part. The Part
Number is normally cast or otherwise prominently marked on each part.

For example, Part Number SPR10092 identifies the Casing to fit the 100RV-SPR, 100VE-
SPR, and 100VEH-SPR Warman Sump Pumps. Refer to the Component Diagram of the
appropriate size of Warman Pump for complete identification and description of component
parts. Part names and Basic Part Numbers are used in assembly instructions throughout
this instruction manual. Warman Basic Part Numbers for all component parts of Type ‘SPR’
pumps are listed in the Appendix of this publication.

In all communications with the C.H. Warman Group, or its representatives, and particularly
when ordering spare parts, it is recommended that the correct component names and Part
Numbers be used at all times to avoid supply of incorrect parts. The pump serial number
should also be quoted if any doubt exists as to part identification.

4. BEARING ASSEMBLY – ASSEMBLY, MAINTENANCE AND

LUBRICATION

The Bearing Assembly is assembled and maintained, generally as described in the separate
publications, Part 3E or 3F of the Instruction Manual as listed in Section 1, depending on
the particular Bearing Assembly fitted. It is recommended that grease used for lubricating
the rolling bearings should have the following characteristics:

Lithium soap base grease with EP additives and oxidation inhibitors.

N.L.G.I. Consistency No: 2

Drop Point > 170° C
Work penetration 25°C A.S.T.M. 265 – 295

RECOMMENDED GREASE: SHELL ALVANIA EP GREASE 2,

CASTROL EPL2, or equivalent.

For detailed description of lubrication requirements for the rolling bearings, refer to the
separate publications, Part 3E or 3F of the Instruction Manual as listed in Section 1.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

5. PUMP ASSEMBLY INSTRUCTIONS

Reference to a Component Diagram for the particular pump being assembled will be of
assistance in following the instructions outlined in the following sections.

All parts dismantled during pump overhaul should be inspected to assess suitability for re-
use, and identification of new parts should be checked.

Parts suitable for re-use should be cleaned and painted. Matching faces should be free of
rust, dirt, and burrs, and have a coating of anti-seize compound applied prior to assembly.

Small fasteners should preferably be replaced, and all threads coated with graphite grease
before assembly. Replacement of all elastomer seals is recommended at major overhauls,
as these materials tend to deteriorate with use. Exposure to direct and continuous sunlight
will accelerate material degradation.

5.1 FRAME ASSEMBLY

5.1.1 Standard Duty Bearing Assembly - Fitting of Column and Mounting Plate
- Refer Figs 1 and 2

For Pump Sizes: 40VC-SPR, 40VCH-SPR, 65VD-SPR, 65VDH-SPR,

100VE-SPR, 100VEH-SPR

(i) Fully assemble BEARING ASSEMBLY (005) in accordance with instructions

in Warman Manual Part 3F.

(ii) With Bearing Assembly mounted horizontally, and lubrication block

uppermost, fit MOUNTING PLATE (019) to Bearing Assembly, ensuring that they
are aligned as indicated in Figs 1 and 2. Carefully note orientation of Grease
Nipples, and Grease Tubes. Take particular care during pump assembly to avoid
damage to the exposed Grease Tubes.

(iii) Fit four SPACERS (290) between Bearing Assembly mounting flange, and
top of Mounting Plate flange at each bolt hole. Fit BEARING HOUSING BOLTS
and tighten evenly.

(iv) Fit DISCHARGE PIPE SUPPORT (293) angle bar to Mounting Plate channel
members, aligning corresponding holes in each. Upturned flange of Discharge
Pipe Support should be positioned remote from Bearing Assembly, as shown in
Fig 1. Fit two DISCHARGE PIPE SUPPORT SCREWS to fasten Discharge Pipe
Support to Mounting Plate, and tighten firmly.

(v) Fit COLUMN (102) around Shaft and engage with lower flanges of
Mounting Plate, ensuring that bolt holes are aligned.

(vi) Fit four COLUMN BOLTS to fasten Column to Mounting Plate, and firmly
tighten.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

5.1.2 Heavy Duty Bearing Assembly - Fitting of Column and Mounting Plate
- Refer Figs 3, 4 and 5

For Pump Sizes: 40PV-SPR, 65QV-SPR, 100RV-SPR, 150SV-SPR, 300TV-SPR,

150SVH-SPR

(i) Fully assemble BEARING ASSEMBLY (005) in accordance with instructions

in Warman Manual Part 3E.

(ii) Position Bearing Assembly and COLUMN (102) with axes horizontal.

(iii) Fit Bearing Assembly to COLUMN (102), ensuring that they are aligned as
indicated below:

(a) 40 SPR and 65 SPR Pumps – orient components as indicated in Fig 4.

(b) 100 SPR and larger Pump sizes – orient components as indicated in
Fig 5.

(iv) Fit four SPACERS (290) between Bearing Assembly feet, and top flange of
Column. Fit Column Bolts and tighten evenly.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

(v) Screw COLUMN STUDS into tapped holes in two sections of MOUNTING
PLATE (019)

(vi) Place two sections of split Mounting Plate around Column, below top
flange, orienting to suit discharge pipe position, and engage studs with holes in
flange, as shown in Fig 3.

(vii) Fit Nuts to Studs, and firmly tighten to fix Mounting Plate to Column.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

Note positon of hole

in top of column flange Discharge Pipe
relative to cut-out in side
of column.

3 Grease nipples
in Bearing Assembly
in line as shown.
STANDARD COMPONENTS ORIENATION
VIEWED FROM DRIVE END
TYPE 40 SPR AND 65 SPR PUMPS

Fig. 4

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

5.2 CASING ASSEMBLY

Fitting Back Liner, Impeller, Casing and Suction Strainer

5.2.1 40 SPR and 65 SPR Pumps

- Refer Figs 4 and 6

(i) Position pump with shaft horizontal, and with discharge pipe clamp
upwards. Place support beneath COLUMN (102) to allow access to end for
assembly of pump casing.

(ii) Fit BACK LINER (041) to end of Column, adjusting orientation of Liner as
shown in Fig 4 to suit discharge pipe position.

(iii) Fit IMPELLER O-Ring (064) to groove on end of Shaft. Apply heavy grease
to O-Ring groove to hold the O-Ring which seals against the back face of the
Impeller.

(iv) Apply anti-seize compound liberally to Shaft thread.

(v) Select the appropriate IMPELLER required for the pump assembly, and fit
as follows:

(a) Place impeller (thread up) on a flat surface, apply anti-seize compound
to thread, and screw Impeller to Shaft.

(b) Fit SHAFT KEY (070) in Shaft keyway at drive-end, and bolt SHAFT
WRENCH (306) to Shaft over key. While restraining Shaft with Wrench, and
turning Impeller with a bar between vanes, firmly screw Impeller to Shaft, but
do not overtighten. Exercise care when tightening elastomer Impellers to
avoid damage to elastomer surfaces.

(vi) Fit DISCHARGE PIPE (154) to Back Liner so that shoulder on pipe fits
against top surface of Liner.

(vii) Lift CASING (092) and place against Back Liner, aligning discharge of
Casing to match discharge pipe. Check that Impeller turns freely, without fouling
faces of Back Liner or Casing. If necessary adjust axial position of Impeller by
adding or removing SPACERS (290) between the Bearing Assembly feet, and the
Column end flange.

(viii) Fit two halves of COLUMN CLAMP (153) around Column and Discharge
pipe.

(ix) Fit COLUMN CLAMP SOCKET HEAD CAP SCREWS to the SOCKET
HEAD PROTECTORS (291). Fit Cap Screws through Column Clamp and Back
Liner, and screw into threaded holes in CASING (092).

NOTE: Tighten all Cap Screws evenly and in sequence to ensure even
compression of the elastomer.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

(x) Check again that the Impeller turns freely, without fouling faces of Back
Liner or Casing. If necessary adjust axial position of Impeller by adding or
removing SPACERS (290) between the Bearing Assembly feet, and the Column
end flange.

(xi) Ensure that the Casing assembly is firmly secured to the Column.

(xii) Fit ‘snap-on’ caps to all SOCKET HEAD PROTECTORS (291), to cover Cap
Screw heads.

5.2.2 100 SPR and larger Pump sizes

- Refer Figs 5 and 7

(i) It is recommended that the partly assembled unit be inverted for assembly
of pump casing components, by supporting the assembly on a hoist with the
impeller-end upwards.

(ii) Lower BACK LINER (041) over Shaft on to the end of the COLUMN (102),
aligning it as shown in Fig 5.

(iii) Fit COLUMN SOCKET HEAD CAP SCREWS to the SOCKET HEAD
PROTECTORS (291). Fit Cap Screws through end flange of Column Clamp, and
screw into threaded holes in BACK LINER (041).

NOTE: Tighten all Cap Screws evenly and in sequence to ensure even
compression of the elastomer.

(iv) Fit IMPELLER O-Ring (064) to groove on end of Shaft. Apply heavy grease
to O-Ring groove to hold the O-Ring which seals against the back face of the
Impeller.

(v) Apply anti-seize compound liberally to Shaft thread.

(vi) Select the appropriate IMPELLER required for the pump assembly, and fit
as follows:

(a) Place impeller (thread up) on a flat surface, apply anti-seize compound
to thread, and screw Impeller to Shaft.

(b) Fit SHAFT KEY (070) in Shaft keyway at drive-end, and bolt SHAFT
WRENCH (306) to Shaft over key. While restraining Shaft with Wrench, and
turning Impeller with a bar between vanes, firmly screw Impeller to Shaft, but
do not overtighten. Exercise care when tightening elastomer Impellers to
avoid damage to elastomer surfaces.

(vii) Lift CASING (092) on a hoist, and position on Back Liner with alignment as
shown in Fig 5. Check that Impeller turns freely, without fouling faces of Back
Liner or Casing. If necessary adjust axial position of Impeller by adding or
removing SPACERS (290) between the Bearing Assembly feet, and the Column
end flange.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

(viii) Fit CASING SOCKET HEAD CAP SCREWS to the SOCKET HEAD
PROTECTORS (291). Fit Cap Screws through end flange of Column Clamp, and
screw into threaded holes in CASING (092).

NOTE: Tighten all Cap Screws evenly and in sequence to ensure even
compression of the elastomer.

(ix) Check again that the Impeller turns freely, without fouling faces of Back
Liner or Casing. If necessary adjust axial position of Impeller by adding or
removing SPACERS (290) between the Bearing Assembly feet, and the Column
end flange.

(x) Position pump with shaft horizontal, and with casing discharge upwards.

(xi) Fit end of DISCHARGE PIPE (154) into Back Liner. Fasten end of Discharge
Pipe to Casing by fitting CASING SOCKET HEAD CAP SCREWS and SOCKET
HEAD PROTECTORS. Tighten Cap screws evenly.

(xii) Fit ‘snap-on’ caps to all SOCKET HEAD PROTECTORS (291) to cover Cap
Screw heads.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

5.3 MISCELLANEOUS FITTINGS

- Refer Figs 8 and 9

Ensure that pump is positioned with Shaft horizontal, and with discharge pipe upwards.

(i) Only Sump Pump with Standard Duty - Type ‘V’ - Bearing Assembly.
Refer Fig 8. Fit U-BOLT (421) around top end of DISCHARGE PIPE (154) with ends
projecting through matching holes in DISCHARGE PIPE SUPPORT (293). Fit two Nuts
and firmly tighten to secure Discharge Pipe to Discharge Pipe Support.

ISSUE DATE : 4 January 2000 2-13

WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

(ii) Only Sump Pump with Heavy Duty - Type ‘V’ - Bearing Assembly.
Refer Fig 9. Fit DISCHARGE PIPE RETAINING SCREW AND NUT to fasten top end of
Discharge Pipe to Mounting Plate. Firmly tighten Screws.

(iii) All Type ‘SPR’ Sump Pumps – Refer Figs 8 and 9.

(a) Fit three elastomer STRAINERS (116) to openings in COLUMN (102). Bend
Strainers slightly, and fit into openings in Column so that the four Strainer lugs
clip onto sides of Column opening, and hold Strainers firmly.

(b) Stretch top of STRAINER (LOWER) (116L) and clip over lower suction
opening in CASING (092).

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

(c) For suction option (not shown) comprising Suction Pipe Extension without
STRAINER (LOWER) (116L), fit pipe using SOCKET HEAD CAP SCREWS and
SOCKET HEAD PROTECTOR (291).

(d) For suction option (not shown) comprising Suction Pipe Extension with
STRAINER (LOWER) (116L), fit pipe, with Strainer (Lower), using SOCKET HEAD
CAP SCREWS and SOCKET HEAD PROTECTOR (291).

(e) Fit elastomer NUT COVERS (430) to all external nuts to prevent fouling of
threads with slurry.

The pump assembly is now substantially complete, and ready for fitting of drive
components.

6. IMPELLER ADJUSTMENT

No provision is made for periodic adjustment of Impeller end clearances in Type ‘SP’ Sump
Pumps, as is provided in horizontal Warman Pumps to compensate for effects of wear on
pump performance. During pump assembly, Spacers are fitted between the Bearing
Housing and Column upper flange to provide satisfactory Impeller end clearances in the
Casing, and compensate for manufacture tolerances.

When wear of the Impeller and casing progresses to the stage that pump performance is
reduced to an unsatisfactory level, the pump casing should be dismantled and worn parts
replaced.

7. DISMANTLING PUMP AND REMOVAL OF IMPELLER

The procedure for dismantling the pump is generally the reverse of that described for pump
assembly.

Access to the IMPELLER requires removal of the CASING (092). This may be removed after
hoisting the Pump from the sump to give access to the wet-end.

Impellers are fitted to Shafts with a right hand screw thread attachment on all Warman
pumps. Impeller removal generally involves applying an impulsive torque loading to the
Impeller, while separately restraining the Shaft from rotation.

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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2G

APPENDIX

WARMAN BASIC PART NUMBERS

WARMAN BASIC
PART No. PART NAME

005 Bearing Assembly

019 Mounting Plate
041 Back Liner
064 Impeller O-Ring
070 Shaft Key
092 Casing
102 Column
116 Strainer – Upper
116L Strainer – Lower
153 Column Clamp
154 Discharge Pipe
290 Spacer
291 Socket Head Protectors
293 Discharge Pipe Support
306 Shaft Wrench
421 U-Bolt
430 Nut Covers
- Bearing Housing Bolts
- Casing Socket Head Cap Screws
- Column Clamp Socket Head Cap Screws
- Column Socket Head Cap Screws
- Column Studs
- Discharge Pipe Support Screws
- Discharge Pipe Retaining Screw and Nut
- Impeller
- Socket Head Cap Screws

ISSUE DATE : 4 January 2000 2-16