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WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS

PART 2H

SUMP PUMP

TYPE ‘GPS’

PC2H
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions PART 2H

WARMAN PUMPS
ASSEMBLY, OPERATING
AND MAINTENANCE INSTRUCTIONS

PART 2H

SUMP PUMP
TYPE ‘GPS’

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 2H

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 2H

CONTENTS - PART 2H

Page

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

2. APPLICATION AND FEATURES OF UNLINED TYPE ‘GPS’ SUMP PUMPS ..... 2-1

3. IDENTIFICATION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

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

AND LUBRICATION

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

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

5.2 Pump Casing Assembly ......................................................... 2-5

5.3 Miscellaneous Fittings ........................................................... 2-8

6. IMPELLER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

7. DISMANTLING PUMP AND REMOVAL OF IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10

APPENDIX - WARMAN BASIC PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11

ISSUE DATE : 4 January 2000

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

1. INTRODUCTION

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

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

all Types of Warman Pumps.

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 2H applies to Type ‘GPS’ Warman Sump Pumps, which are available in both standard
and high-speed versions. The standard pump version is characterized by a numeral
representing PUMP SIZE (ie discharge pipe size in mms), immediately followed by FRAME
TYPE (ie ‘V’), and FRAME SIZE followed by PUMP TYPE (ie GPS), eg 100VE-GPS Sump
Pump.
The high-speed pump version is identified by an additional “H” immediately following the
FRAME SIZE, eg 100VEH-GPS Sump Pump.

2. APPLICATION AND FEATURES OF TYPE ‘GPS’ SUMP PUMPS

These pumps are of heavy-duty construction, designed for partially submerged mounting in
pits or sumps. They are particularly suited to continuous pumping of highly abrasive slurries
in the Mining, Chemical, and General Process Industries. They feature an unlined, or
elastomer lined, casing design, characterized by design simplicity, minimum number of
parts, and light overall weight. Each pump size may be supplied with a standard, or high-
speed shaft assembly. The high-speed shaft assemblies, with larger shaft diameters,
provide higher critical vibration frequencies, enabling operation to higher pump speeds, with
corresponding increased discharge pressures.
Important design features of this range of Warman Slurry Pumps include:

• Design simplicity
• Robust shafts
• High capacity bearing assemblies
• Heavy duty screw thread Impeller attachment
• Through-bolt design throughout
• Replaceable casing components
• No submerged bearings

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.

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

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 GPS65092 identifies the Casing to fit the 65VD-GPS and 65VDH-
GPS 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 ‘GPS’ Sump 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
publication, Part 3F of the Instruction Manual as listed in Section 1. Part 3F describes the
Standard Duty, Type ‘V’, Bearing Assembly which fits a range of different types of Warman
Series ‘A’ pumps.
It is recommended that grease used for lubricating the rolling bearings, and grease purged
lower bearing seal, 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 publication, Part 3F of the Instruction Manual as listed in Section 1.

ISSUE DATE : 4 January 2000 2-2

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

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

- Fitting Column, Mounting Plate, and Bearing Assembly
- Refer Figs 1 and 2

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

Warman Manual Part 3F. Support Bearing Assembly on a bench or on the floor, with
Shaft axis horizontal.

(ii) Fit beams of MOUNTING PLATE (019) to lower flange of Bearing Assembly
using four BEARING HOUSING BOLTS, with matching surfaces spaced apart by four
SPACERS (290) at each bolt, as shown in Fig 1. Carefully note the orientation of the
Bearing Assembly motor support mounting flange relative to the Discharge Pipe
Support Screw holes, shown in Fig 2. Evenly tighten all Bearing Housing Bolts.

(iii) Fit COLUMN (102) to Mounting Plate beams, ensuring that the discharge pipe
opening in the lower flange of the Column is positioned below the Discharge Pipe
Support Screw holes, as shown in Figures 1 and 2.

(iv) Secure Column to Mounting Plate beams with four COLUMN BOLTS, and
tighten evenly.

(v) Fit DISCHARGE PIPE SUPPORT (293) to Mounting Plate beams, with
orientation shown in Fig 1, and secure with two DISCHARGE PIPE SUPPORT
SCREWS.

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

ISSUE DATE : 4 January 2000 2-4

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

5.2 PUMP CASING ASSEMBLY

Fitting Back Liner, Impeller, Casing and Suction Strainer
- Refer Fig 3

(i) Fit SPIGOT RING (211) to matching spigot on face of BACK LINER (041). This
part is required only for the metal wet-end. In elastomer lined wet-ends this seal is
integral with the elastomer lining.

(ii) Place Back Liner, with Spigot Ring fitted, over impeller-end of Shaft, and
engage Spigot Ring with bore of Column end face, ensuring that the Back Liner
discharge outlet engages the corresponding opening in lower flange of Column.

(iii) Fit IMPELLER O-RING (064) to impeller-end of Shaft and move axially until it
occupies the O-Ring groove.

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

(v) Fit SHAFT KEY (070) to drive-end Shaft keyway, and bolt SHAFT WRENCH
(306) to Shaft, over key.

(vi) Fit IMPELLER to Shaft thread as follows:

ISSUE DATE : 4 January 2000 2-5

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

ISSUE DATE : 4 January 2000 2-6

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

(a) Ensure that Impeller O-Ring is positioned in the Shaft O-Ring groove.

(b) Select IMPELLER, and apply anti-seize compound to thread. Lift Impeller,
and screw to Shaft.

(c) While restraining Impeller, turn Shaft with Wrench to engage Impeller and
Shaft threads. Tighten Impeller on Shaft, with bar between between Impeller
vanes, and flogging Shaft Wrench.

(vii) Fit BACKLINER SEAL (125) to matching recess around inner edge of CASING
(092). This part is required only for the metal wet-end. In elastomer lined wet-ends
this seal is integral with the elastomer lining.

(viii) Place Casing, with Back Liner Seal fitted, over impeller-end of Shaft, and
engage periphery of Back Liner with matching recess in Back Liner Seal. Secure
Casing to end flange of Column by fitting Bolts from Casing side to holes around
periphery.

(ix) Fit Nuts to Bolts, and tighten evenly, checking that interference between the
Impeller and Casing is not occurring by rotating the drive-end of the Shaft in a
clockwise direction using the Shaft Wrench.

(x) If fouling of the Impeller with the Casing side walls occurs, add or remove
SPACERS (290) between Mounting Plate and Bearing Assembly, to adjust Impeller
end clearance. When Shaft rotates freely, tighten four Bolts at Casing periphery
evenly.

NOTE: These Bolts should be tightened only sufficiently to compress Back Liner
Seal and Spigot Ring, and bring Casing and end face of Column into contact.

(xi) Check again that Impeller turns freely, without contacting surfaces of Casing.
Adjust Spacers between Column flange and Bearing Assembly if required.

ISSUE DATE : 4 January 2000 2-7

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

5.3 MISCELLANEOUS FITTINGS

- Refer Fig 4

(i) Fit DISCHARGE PIPE (154) as follows:

(a) Ensure that pump is positioned horizontally, with Casing discharge opening
upwards.

ISSUE DATE : 4 January 2000 2-8

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

(b) Fit U-BOLT (421) to holes in DISCHARGE PIPE SUPPORT (293), with Bolt
positioned on side remote from Shaft axis. Loosely fit Nuts.

(c) Insert plain end of Discharge Pipe through loop of U-Bolt, and move
through to rest on matching opening in BACK LINER (041).

(d) Fit DISCHARGE CLAMP (153) over plain end of Discharge Pipe, with bolt
lugs adjacent end of pipe, and slide along pipe.

(e) Fit JOINT RING (372) over plain end of Discharge Pipe, with small diameter
end adjacent end of pipe, and slide along pipe.

(f) Place plain end of Discharge Pipe centrally into matching opening in Back
Liner, with end of pipe in contact with end face of Back Liner.

(g) Slide Joint Ring back along Discharge Pipe towards plain end, and fully
engage with annular opening between Pipe and Back Liner.

(h) Slide Discharge Clamp back along Discharge Pipe, and align bolt holes
with matching holes in Back Liner. Insert the two DISCHARGE CLAMP BOLTS
through holes in Back Liner and Discharge Clamp. Fit Nuts, and carefully tighten
evenly until Discharge Pipe is firmly clamped at Casing end.

(i) Tighten Nuts evenly on U-Bolt at free end of Discharge Pipe, until pipe is
firmly secured.

(ii) Fit STRAINER (LOWER) (116L), or SUCTION PIPE (231), with or without
Strainer, according to requirements.

(iii) 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 ‘GPS’
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.

ISSUE DATE : 4 January 2000 2-9

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

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.

ISSUE DATE : 4 January 2000 2-10

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

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
116L Strainer – Lower
125 Back Liner Seal
153 Discharge Clamp
154 Discharge Pipe
211 Spigot Ring
231 Suction Pipe
290 Spacer
293 Discharge Pipe Support
306 Shaft Wrench
372 Joint Ring
421 U-Bolt
430 Nut Covers
- Bearing Housing Bolts
- Column Bolts
- Discharge Pipe Support Screws
- Discharge Clamp Bolts
- Impeller

ISSUE DATE : 4 January 2000 2-11