Warman Pumps: Assembly, Operating and Maintenance Instructions
Warman Pumps: Assembly, Operating and Maintenance Instructions
Warman Pumps: Assembly, Operating and Maintenance Instructions
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WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS
PART 2D
TYPE ‘TV’
PC2D
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2D
WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS
PART 2D
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.
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.
CONTENTS - PART 2D
Page
1. INTRODUCTION
This publication, Part 2D, forms part of a set which together comprise the Assembly,
Operating, and Maintenance Instruction Manual for the 3DTV Warman Unlined Sump Pump,
Type 'TV'.
Other publications in the set comprise the following:
Part 1: Assembly, Operating and Maintenance Instructions - General Instructions for all
Types of Warman Pumps.
Both of these publications have been written to more specifically describe the horizontal
Type AH pump, and hence sections not relevant to vertical sump pumps should be
disregarded. Section 5.1 of this publication describes variations from Part 3A which apply
specifically to the Type 'TV' Sump Pump.
These pumps are of heavy-duty construction, designed for continuous pumping of highly
abrasive and corrosive slurries. They feature an unlined casing design, characterised by
design simplicity, minimum number of parts, and light overall weight. A principal feature of
this pump is the twin volute design of the casing, which results in reduced radial loading
applied to the impeller. A consequence of this design is that the pumps can operate with
greater casing submergence without the need for a lower bearing support, compared with
equivalent single volute 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 DTV3092 identifies the Casing to fit the 3DTV Warman Sump
Pump. Refer to the Component Diagram of the appropriate size of Warman Pump for
complete identification and description of component parts. Part names and Part Numbers
are used in assembly instructions throughout this instruction manual. Warman Part Numbers
are listed in the Appendix of this publication for all component parts of the Type 'TV' Sump
Pump.
In all communications with the C.H. Warman Pump 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.
The Bearing Assembly is assembled and maintained generally as described in the separate
publication, Part 3A of the Instruction Manual, as listed in Section 1 of this publication.
Part 3A describes the Basic Bearing Assembly which fits a range of different types of
Warman Pumps, including the Type 'TV' Sump Pump.
Variations from assembly instructions which are specific to the Type 'TV' Sump Pump are
described in Section 5.1 of this publication.
It is recommended that grease used for lubricating the rolling bearings should have the
following characteristics:
For a detailed description of lubrication requirements for the rolling bearings, refer to the
separate publication, Part 3A of the Instruction Manual.
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.
Fig 1 shows a cross section through the Bearing Assembly of a 3DTV Warman Sump
Pump, Type 'TV'.
DTV061
D004M DTV108
DTV073-nnnn
DTV046 D062-10
The completed Bearing Assembly, shown in Fig 1, has Part Number DTV005-nnnn. Note
that 'nnnn' defines the characteristic depth dimension (refer Fig 7) of the sump pump
where it appears in the part numbers of the Shaft and Bearing Assembly, and in the
pump size.
DTV003
D001M
(i) Place BASE (DTV003) on floor, with Shaft axis approximately horizontal, and
machined concave Bearing Housing support cradle facing upwards
(ii) Insert ADJUSTING SCREW (D001) in Base from end face. Fix to Base by
fitting one nut and fully tighten. Fit two additional nuts separated by two flat washers.
These nuts should be loose on Adjusting Screw and spaced well apart.
(v) Fit four HEX HEAD BOLTS through Base from below. Mount CLAMP
WASHER (D011) on each bolt (domed side up) and screw on nuts.
Fully tighten Bolts on side 'A', i.e. on left hand side of Base as viewed from the
Impeller end (refer Figs 2 and 5). Bolts on the other side (i.e. Side 'B') should not be
tightened at this stage. Leave finger tight only, to maintain alignment but allow axial
movement of the Bearing Assembly.
DTV3153
DTV3013 DTV3092
DTV3IO2-nnnn
DTV3116
DTV003 IMPELLER
DTV3159
DTV3085
C109 C064
DTV075
DTV3124
(i) With pump resting on floor or bench, with Shaft horizontal, provide support
under Shaft towards Impeller-end, as required, to prevent pump toppling over
towards the Impeller-end as the wet-end is assembled. Alternatively, the pump may
be supported vertically, from the drive-end, on a hoist.
(ii) Apply anti seize compound to inner edges of recesses in two openings in
mounting flange of BASE (DTV003).
(iii) Fit small plain flanged end of each COLUMN (DTV3102-nnnn), in turn, through
holes in Base, from drive-end, and move through until spigot of large support flange
at other end engages matching recess in Base.
(iv) Fit four Column Bolts (M16 x 75 + nut + washer) through matching holes in
each support flange of Columns, and fully tighten to fasten Columns firmly to Base.
(v) For 3DTV-1830 and 3DTV-2740 pump sizes only - Fit CUTLESS BEARING
RUBBER (DTV3159) over screwed end of Shaft, and slide along maximum diameter
section of Shaft.
(vi) Fit STRAINER (DTV3116), small end first, over screwed end of Shaft, and slide
over maximum diameter section of Shaft.
(vii) Fit COVER PLATE (DTV3013), smooth face outwards, over screwed end of
Shaft, and slide along Shaft to rear of Strainer.
(viii) Place O-RING (C109) over screwed end of Shaft, and slide along to shoulder.
(ix) Fit SHAFT SLEEVE (DTV075) to end of Shaft, over thread, and slide along until
it contacts the shoulder.
(x) Fit O-RING (C064) to groove in rear face of Shaft Sleeve. Apply heavy grease
to the O-Ring groove to assist in holding the O-Ring which seals against the back
face of the Impeller.
DTV3159
(xi) Fit SHAFT KEY (D070) in Shaft keyway, and bolt SHAFT WRENCH (D306X) to
Shaft, over key.
(a) Ensure that the O-Ring (C064) at the end of the Shaft Sleeve is positioned
in its locating groove.
(b) Select IMPELLER, and apply grease to thread. Lift Impeller, and screw to
Shaft. While restraining Impeller, turn Shaft with Wrench to engage Impeller and
Shaft threads. Tighten Impeller on Shaft with bar between Impeller vanes, and
flogging Shaft Wrench.
(c) Ensure that the two O-Rings on the Shaft are not damaged, and are
covered by adjacent parts.
HEXD012M
HEAD BOLT
D011
(a) Place VOLUTE COVER SEAL (DTV3124) over Impeller, and position in
peripheral recess of Cover Plate.
(b) Place Casing around Impeller, and rotate until discharge flanges are
adjacent corresponding flanges on ends of Columns.
(xiv) With the Casing securely fitted to the Columns, move the Bearing Assembly
towards the Impeller-end until the Impeller contacts the Casing surface. This is done
by loosening the Impeller-end nut on the Adjusting Screw, and tightening the drive-
end nut, to drive the Bearing Assembly towards the Impeller-end.
(xv) Fit STRAINER (DTV3116) and COVER PLATE (DTV3013) to CASING (DTV3092)
as follows:
(a) Move Strainer into contact with back face of Cover Plate, engaging
projections on Cover Plate with corresponding recesses in Strainer.
(b) Rotate Strainer and Cover Plate about Shaft axis, so that peripheral lips on
Strainer clear matching recesses in Casing, and move Strainer and Cover Plate
towards Impeller to engage opening in Casing. Ensure that Volute Cover Seal is
contained within recess formed between Cover Plate and Casing.
(c) Rotate Strainer and Cover Plate about Shaft axis until peripheral lips on
Strainer engage localised recesses in Casing.
(xvi) Fit two COTTERS (DTV3085) to rectangular slots in Strainer, ensuring that
Cotters enter to engage surfaces of Cover Plate and Strainer with matching surfaces.
Fasten Cotters by applying hammer blows to ends to bring Strainer and Cover Plate
firmly into engagement with the Casing.
The Lower Support Bearing is fitted only to pumps of length 1830 mms and longer, to
provide additional support for the long shafts on these pumps.
3DTV-1830 1160
3DTV-2200 1310
3DTV-2740 1800
3DTV-3050 2000
3DTV-3450 2500
3DTV-4000 1195 and 2940
ie 2 Support Bearings required
(ii) Position cavity of one BEARING BRACKET (DTV3368) around Cutless Bearing
Rubber, so that recess at other end engages COLUMN (DTV3102-nnnn).
(iii) Fit U-BOLT (DTV3199) around Column, and through holes in Bearing Bracket.
Fit Washers and Nuts to U-Bolt, and screw up finger tight .
(iv) Fit second Bearing Bracket as described in items (ii) and (iii).
(v) Place two Bolts through matching holes in Bearing Brackets across the
bearing cavity. Fit Washers and Nuts, and firmly tighten.
(vi) Align Bearing Brackets to be square to the axes of the Shaft and Columns.
Firmly tighten Nuts on U-Bolts to fix Bearing Brackets to Columns.
DTV003
DTV3368 DTV3159
DTV3199 DTV3368
DTV3154
50SJ
430
'nnnn'
The pump assembly is now substantially complete, and requires only fitting of
miscellaneous external components.
(ii) Fit elastomer NUT COVERS (430) to all external nuts to prevent fouling of
threads with slurry.
6. IMPELLER ADJUSTMENT
- Refer Fig 8
D001M
The pump should be adjusted to operate with the Impeller having minimum axial clearance
with the casing surfaces adjacent the drive-end face of the Impeller.
Adjustment of Impeller axial clearance is carried out as follows:
(i) Rotate the Shaft clockwise (as viewed from the drive-end) by hand, and move the
Bearing Assembly rearward (towards the drive-end) by adjusting the Impeller-end nut on
the ADJUSTING SCREW (D001) until the Impeller contacts the drive-end casing surface.
(ii) Unscrew the Impeller-end nut, and move the Bearing Assembly towards the
Impeller-end by adjustment of the drive-end nut on the Adjusting Screw by one turn.
Fully tighten the Impeller-end nut to secure the Bearing Assembly in position.
(iii) Ensure that the Shaft can now rotate freely without contact of the Impeller with
the casing surface. If contact occurs, repeat from step (i).
After Impeller adjustment is completed, the four Bearing Housing CLAMP BOLTS
must be tightened to a torque value of 45 N m, to firmly lock the Bearing Assembly in
position.
The procedure for dismantling the pump is generally the reverse of that described for pump
assembly.
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.
APPENDIX
NOTE - Refer to Appendix B of Part 1 of the Instruction Manual for details of Warman
Material Codes.
Egypt Ghana
TEL: +202 575 1544 TEL: +233 21 77 3444
FAX: +202 575 1702\575 1383 FAX: +233 21 77 0588
EMAIL: sonfarid@sonfarid.com EMAIL: chwarman@idngh.com
Kenya Morocco
TEL: +254 2 60 7021\60 0328 TEL: +212 22 39 5223\39 5237
FAX: +254 2 60 5468 FAX: +212 22 39 5113
EMAIL: sitelog@swiftkenya.com EMAIL: pumps@warman-na.com
Zambia Zimbabwe
TEL: +260 2 21 7743\0114 TEL: +263 9 78840\76853
FAX: +260 2 21 7762 FAX: +263 9 63565
EMAIL: warman@coppernet.zm EMAIL: warman@mweb.co.zw
For Alrode
Manufacturing
3 - 5 CLARKE STREET SOUTH, ALRODE 1449, ALBERTON (PO BOX 17872 RANDHART 1457) REPUBLIC OF SOUTH AFRICA
PHONE: +2711 617-0700 FACSIMILE: +2711 617-0791 EMAIL: warmpump@warman.co.za WEBSITE: www.warman.co.za
DIRECTORS: C.H. WARMAN*, V.H. KING*, W.A. KING* (* AUSTRALIAN)
BC/0903