WP04 Manual Braun

8/12/2019 WP04 Manual Braun

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INSTALLATION, OPERATIONAND MAINTENANCE MANUAL

WITH PARTS LIST

WP SERIES PUMP

MODEL

WP-04


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TABLE OF CONTENTS

INTRODUCTION............................................................................... Pg. 03

WARNING SECTION .................................................................... Pg. 04

INSTALLATION SECTION B......................................................... Pg. 05

Pump Dimensions............................................................ Pg. 05PREINSTALLATION INSPECTION......................................... Pg. 06POSITIONING PUMP............................................................ Pg. 06

Lifting................................................................................ Pg. 06Mounting........................................................................... Pg. 06Clearance......................................................................... Pg. 06

SUCTION AND DISCHARGE PIPING.................................. Pg. 06Materials........................................................................... Pg. 06Line Configuration............................................................ Pg. 07Connections to Pump....................................................... Pg. 07Gauges............................................................................. Pg. 07

SUCTION LINES................................................................... Pg. 07Fittings.............................................................................. Pg. 07Strainers........................................................................... Pg. 07Sealing.............................................................................. Pg. 07Suction Lines in Sumps.................................................... Pg. 07Suction Lines Positioning................................................. Pg. 08

DISCHARGE LINES.............................................................. Pg. 08Siphoning.......................................................................... Pg. 08Valves............................................................................... Pg. 08Bypass Lines..................................................................... Pg. 09

AUTOMATIC AIR RELEASE VALVE..................................... Pg. 10Theory of Operation........................................................... Pg. 10

Air Release Valve Installation........................................... Pg. 10ALIGNMENT.......................................................................... Pg. 11

Coupled Drivers................................................................ Pg. 12V-Belt Drives..................................................................... Pg. 12

OPERATION SECTION C............................................................... Pg. 14

PRIMING................................................................................ Pg. 14STARTING............................................................................. Pg. 14

Rotation............................................................................ Pg. 14OPERATION.......................................................................... Pg. 15

Lines With a Bypass......................................................... Pg. 15

Lines Without a Bypass.................................................... Pg. 15Leakage............................................................................ Pg. 15Liquids Temperature and Overheating............................. Pg. 15Strainer Check.................................................................. Pg. 16Pump Vacuum Check....................................................... Pg. 16

STOPPING............................................................................. Pg. 16Cold Weather Preservation............................................... Pg. 16

BEARING TEMPERATURE CHECK...................................... Pg. 16


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TABLE OF CONTENTS

(Continued)

TROUBLESHOOTING SECTION D .. Pg. 18

PUMP MAINTENANCE AND REPAIR SECTION E Pg. 21

PERFORMANCE CURVE Pg. 21Pump Model . Pg. 22

PARTS LISTS ......................................................................... Pg. 23Repair Rotating Assembly.. Pg. 24

PARTS LISTS ......................................................................... Pg. 25PUMP AND SEAL DISASSEMBLY AND REASSEMBLY. Pg. 26

Back Cover and Wear Plate Removal. Pg. 26

Suction Check Valve Removal.. Pg. 26Rotating Assembly Removal.. Pg. 26Impeller Removal. Pg. 27Seal Removal Pg. 28Shaft and Bearing Removal and Disassembly Pg. 28Shaft and Bearing Reassembly and Installation. Pg. 29Seal and Installation....................... Pg. 30Impeller Installation. Pg. 32Rotating Assembly Installation. Pg. 32Suction Check Valve Installation.. Pg. 33Back Cover Installation... Pg. 33

PRESSURE RELIEF VALVE MAINTENANCE Pg. 33

Final Pump Assembly Pg. 34LUBRIFICATION Pg. 34

Seal Assembly Pg. 34Bearings Pg. 34Power Source Pg. 34


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INTRODUCTION

If there are any questions regarding the pump or its applications which are not covered in this manual or in otherliterature accompanying this unit, please contact your WhalesPumps distributor, or write:

The WhalesPumps

For information or technical assistance on the power source, contact the power source manufactures locadealer or representative.

The following are used to alert maintenance personnel to procedures which require special attention, to thosewhich could damage equipment, and to those which could be dangerous to personnel:

This Installation, Operation, andMaintenance manual is designed to helpyou get the best performance and longestlife from your Whales pump.

This pump is a WP Series, semi-openimpeller, self priming centrifugal modelwith a suction check valve.

The pump is designed for handling mildindustrial corrosives, mud or slurriescontaining large entrained solids. The basicmaterial of construction is gray iron, with

ductile iron impeller and steel wearing parts.

DANGER!

Immediate hazards which WILL result insevere personal injury or death. Theseinstructions describe the procedure requiredand the injury which will result from failureto follow procedure.

CAUTION!

Hazards or unsafe practices which COULDresult in minor personal injury or product orproperty damage. These instructions describethe requirements and the possible damagewhich could result from failure to follow theprocedure.

NOTE

Instructions to aid in installation, operation,and maintenance or which clarify a procedure.


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SAFETY SECTION A

These warnings apply to WP Series basic pumps.Whales Pumps has no control over or particularknowledge of the power source which will beused. Refer to the manual accompanying thepower source before attempting to beginoperation.

WARNING!

After the pump has been positioned, makecertain that the pump and all pipingconnections are tight, properly supported andsecure before operation.

WARNING!

Do not operate the pump without the guardsin place over the rotating parts.Exposed rotating parts can catch clothing,fingers, or tools, causing severe injury to

personnel.

WARNING!

Do not operate the pump against a closeddischarge valve for long periods of time. Ifoperated against a closed discharge valve, pumpcomponents will deteriorate, and the liquid couldcome to a boil, pressure, and cause the pumpcasing to rupture or explode .

WARNING!

Before attempting to open or service thepump:

1. Familiarize yourself with this manual.

2. Disconnect or lock out the power source toensure that the pump will remain inoperative.

3. Allow the pump to cool if overheated.

4. Check the temperature before opening anycovers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump

WARNING!

This pump is designed to handle mildindustrial corrosives, mud or slurriescontaining large entrained solids. Do notattempt to pump volatile, corrosive, orflammable materials which may damage thepump or endanger personnel as result ofpump failure.

WARNING!

Do not remove plates, covers, gauges, pipeplugs, or fittings from an overheated pump.Vapor pressure within the pump can cause partsbeing disengaged to be ejected with great force.Allow the pump to cool before servicing.

WARNING!

Use lifting and moving equipment in good repairand with adequate capacity to prevent injuries topersonnel or damage to equipment. Suction anddischarge hoses and piping must be removedform the before lifting


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PREINSTALLATION INSPECTION POSITIONING PUMPThe pump assembly was inspected and testedbefore from the factory. Before installation, inspectthe pump for damage which may have occurred

during shipment. Check as follows:

a. inspect the pump for cracks, dents,damaged threads, and other obviousdamage.

b. Check for and tighten loose attachinghardware. Since gaskets tend to shrinkafter drying, check for loose hardware atmating surfaces.

c. Carefully read all warnings and cautionscontained in this manual or affixed to thepump, and perform all duties indicated.Note the direction of rotation indicated onthe pump. Check that the pump shaftrotates counterclockwise when facing theback cover plate assembly/impeller end ofthe pump.

Lifting

Use lifting equipment with a capacity of at least3.000 pounds (1360 Kg). This pump weighsapproximately 550 pounds (249,5 Kg), notincluding the weight of accessories and base.Customer installed equipment such as suction anddischarge piping must be removed beforeattempting to lift.

CAUTION!

The pump assembly can be seriouslydamaged if the cables or chains used to liftand move the unit are improperly wrapped

around the pump.

CAUTION!

Only operate this pump in the directionindicate by the arrow on the pump body and

on the accompanying decal. Refer toROTATION in OPERATION, Section C.

d. Check levels and lubricate asnecessary. Refer to LUBRICATION in theMAINTENANCE AND REPAIR section ofthis manual and perform duties asinstructed.

e. If the pump and power source havebeen stored for more than 12 months,some of the components or lubricants mayhave exceeded their maximum shelf life.

These must be inspected or replaced toensure maximum pump service.

If the maximum shelf life has been exceeded,or if anything appears to be abnormal, contactyour Whales Pumpsdistributor or the factory todetermine the repair or updating policy. Do notput the pump into service until appropriateaction has been taken.

Mounting

Locate the pump in an accessible place as close aspractical to the liquid being pumped. Level mountingis essential for proper operation.

The pump may have to be supported or shimmed toprovide for level operation or to eliminate vibration.

Clearance

When positioning the pump, allow a minimumclearance of 18 inches (457mm) in front of the backcover to permit removal of the cover and easyaccess to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected byincrease suction lift, discharge elevation. And frictionlosses. See the performance curve and operating

range shown on Page 21 to be sure your overallapplication allows pump to operate within the safeoperation range.

Materials

Either pipe or hose maybe used for suction anddischarge lines: however, the materials must becompatible with liquid being pumped.


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If hose is used in suction lines, it must be therigid-wall, reinforced type to prevent collapseunder suction. Using piping couplings in suctionlines is not recommended.

Line Configuration

Keep suction and discharge lines as straight aspossible to minimize friction losses. Makeminimum use of elbows and fittings, whichsubstantially increase friction loss. If elbows arenecessary, use the long radius type to minimizefriction loss.

Connections to Pump

Before tightening a connecting flange, align itexactly with the pump port. Never pull a pipe lineinto place by tightening the flange bolts and/orcouplings.

Lines near the pump must be independentlysupported to avoid strain on the pump whichcould cause excessive vibration, decreasebearing life, and increased shaft and seal wear. Ifhose-type lines are used, they should haveadequate support to secure them when filled withliquid and under pressure.

Gauges

Most pumps are drilled and tapped for installingdischarge pressure and vacuum suction gauges.If these gauges are desired for pumps that arenot tapped, drill and tap the suction anddischarge lines not less than 18 inches(457,2mm) from the suction and discharge portsand install the lines. Installation closer to thepump may result in erratic readings.

SUCTION LINES

To avoid air pockets which could affect pumppriming, the suction line must be as short and

direct as possible. When operation pumped: if theline slopes down to the pump at any point alongthe suction run, air involves a suction lift, the linemust always slope upward to the pump from thesource of the liquid being pockets will be created.

Fittings

Suction lines should be the same size as the pumpinlet. If reducers are used in suction lines, they shouldbe the eccentric type, and should be installed with the

flat part of the reducers uppermost to avoid creatingair pockets. Valves are not normally used in suctionlines, but if a valve is used, install it with the horizontalto avoid air pockets.

Strainers

If a strainer is furnished with the pump, be certain touse it; any spherical solids which pass through astrainer furnished with the pump will also passthrough the pump itself.

If a strainer is not furnished with the pump, but isinstalled by the pump user, make certain that the totalarea of the openings in the strainer is at least three orfour times the cross section of the suction line, andthat the openings will not permit passage of solidslarger than the solids handling capability of the pump.

This pump is designed to handle up to 1.3/4 inch (44mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head, andcapacity, especially when operating with a highsuction lift, all connections in the suction line shouldbe sealed with pipe dope to ensure an airtight seal.Follow the sealant manufacturers recommendationswhen selecting and applying the pipe dope. The pipedope should be compatible with the liquid beingpumped.

Suction Lines in Sumps

If a single suction line is installed in a sump, it shouldbe positioned away from the wall of the sump at a

distance equal to 1 times the diameter of thesuction line.

If there is a liquid flow from an open pipe into thesump, the flow should be kept away from the suctioninlet because the inflow will carry air down into thesump, and air entering the suction line will reducepump efficiency.


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VELOCITY (FT./SEC.)= QUANT. (G.P.M)x.321 OR G.P.M. x 4085AREA D

VELOCITY (M./SEC.)= FLOW (M./MIN)x21.22 OR FLOW (M/SEC.)DIAMETER IN MM AREA IN M

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

If it is necessary to position inflow close to the suctioninlet, install a baffle between the inflow and the insuction lines, it must be the rigid-wall, reinforced typeto prevent collapse under suction. Using pipingcouplings in suction lines is not recommended.Suction inlet at a distance 1 times the diameter ofthe suction pipe. The baffle will allow entrained air toescape from the liquid before it is drawn into thesuction inlet.

If two suction lines are installed a single sump, theflow paths may interact, reducing the efficiency of oneor both pumps. To avoid this, position the suctioninlets so that they are separated by a distance equalto at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line iscritical to efficient pump operation. Figure 2 showsRecommended minimum submergence vs. velocity.

NOTE

The pipe submergence required may be reducedby installing a standard pipe increaser fitting atthe end of the suction line. The larger openingsize will reduce the inlet velocity. Calculate therequired submergence using the followingformula based on the increased opening size(area or diameter).

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lowerthan of the liquid being pumped unless a siphonbreaker is used in the line. Otherwise, a siphoningaction causing damage to the pump could result.

Valves

If a throttling valve is desired in the discharge line,

use a valve as large as the largest pipe to minimizefriction losses. Never install a throttling valve in asuction line.

With high discharge heads, it is recommended that athrottling valve and a system check valve be installedin the discharge line to protect the pump fromexcessive shock pressure and reverse rotation whenit is stopped.


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In high discharge head applications (more than30 feet), an excessive amount of liquid may bebypassed and forced back to the wet well underthe full working pressure of the pump; this willreduce overall pumping efficiency. Therefore, it is

recommended that a Whales Pumps AutomaticAir Release Valve be installed in the bypassline.

Whales Pumps Automatic Air Release Valves arereliable, and require minimum maintenance. SeeAUTOMATIC AIR RELEASE VALVE in thissection for installation and theory of operation ofthe Automatic Air Release Valve. Contact theWhales Pumps Company for selection of anAutomatic Air Release Valve to fit your application.

If the installation involves a flooded suction such as

below-ground lift station. A pipe union and manualshut-off valve may be installed in the bleed line toallow service of the valve without shutting down thestation, and to eliminate the possibility of flooding.If a manual shut-off valve is installed anywhere inthe air release piping, it must be a full-opening balltype valve to prevent plugging by solids.

DANGER!

If a manual shut-off valve is installed in abypass line, it must not be left closed during

operation. A closed manual shut-off valve maycause a pump which has lost prime to continueto operate without reaching prime, causingdangerous overheating and possible explosiverupture of the pump casing. Personnel couldbe severely injured.

Allow an over-heated pump to cool beforeservicing. Do not remove plates, covers,gauges, or fittings from an overheated pump.Liquid within the pump can reach boilingtemperatures, and vapor pressure within the

pump can cause parts being disengaged to beejected with great force. After the pump cools,drain the liquid from the pump by removing thecasing drain plug. Use caution when removingthe plug to prevent injury to personnel from hotliquid.

CAUTION!

If the application involves a high discharge head,gradually close the discharge throttling valve before

stopping the pump.

Bypass Lines

Self-priming pumps are not air compressors. Duringthe priming cycle, air from the suction line must bevented to atmosphere on the discharge side. If thedischarge line is open, this air a check valve hasbeen installed in the discharge line, the dischargeside of the pump must be opened to atmosphericpressure through a bypass line installed betweenthe pump discharge an the check valve. A self-

priming centrifugal pump will not prime if there issufficient static liquid head to hold the dischargecheck valve closed.

NOTEThe bypass line should be sized so that it doesnot affect pump discharge capacity; however,the bypass line should be at least 1 inch indiameter to minimize the chance of plugging.

In low discharge head applications(less than 30feet or 9 meters), it is recommended that the bypassline be run back to the wet well, and locate 6 inches

below the water level or cut-off point of the levelpump. In some installations, this bypass line may beterminated with a six-to-eight foot length of 1 inchID. smooth-borehose; air and liquid vented duringthe priming process will then agitate the hose andbreak up any solids, grease, or other substanceslikely to cause clogging.

CAUTION!

A bypass line that is returned to a wet well mustbe secured against being drawn into the pumpsuction inlet.It is also recommended that pipe unions be installedat each 90 elbow in a bypass line to easedisassembly and maintenance.


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WARNING!

Some leakage (1 to 5 gallons [3.8 to 19 liters] perminute) will occur when the valve is fully closed.Be sure the bypass line is directed back to the

wet well or tank to prevent hazardous spills.

When the pump shuts down, the spring returns thediaphragm to its original position. Any solids thatmay have accumulated in the diaphragm chambersettle to the bottom and are flushed out during thenext priming cycle.

NOTE

The valve will remain open if the pump does notreach its designed capacity or head. Valve

closing pressure is dependent upon thedischarge head of the pump at full capacity. Therange of the valve closing pressure isestablished by the tension rate of the spring asordered from the factory. Valve closing pressurecan be further adjusted to the exact systemrequirements by moving the spring retaining pinup or down the plunger rod to increase ordecrease tension on the spring. Contact yourWhales Pumps distributor orwww.whalespumps.com Company forinformation about an Automatic Air ReleaseValve for your specific application.

Air Release Valve installation

The Automatic Air Release Valve must beindependently mounted in a horizontal position andconnected to the discharge line of the self-primingcentrifugal pump (see Figure 5).

NOTE

If the Air Release Valve is to be installed on astaged pump application, contact the factory forspecific installation instructions.

AUTOMATIC AIR RELEASE VALVE

When properly installed and correctly adjusted to thespecific hydraulic operating conditions of theapplication, the Whales Pumps Automatic Air ReleaseValve will permit air to escape through the bypass line,

and then close automatically when the pump is fullyprimed and pumping at full capacity.

Theory of Operation

Figures 3 and 4 show a cross-sectional view of theAutomatic Air Release Valve, and a correspondingdescription of operation.

Figure 3. Valve in Open Position

During the priming cycle, air from the pump casingflows through the bypass line, and passes through theAir Release valve to the wet well (Figure 3).

Figure 4. Valve in Closed Position

When the pump is fully primed, pressure resulting fromflow against the valve diaphragm compresses thespring and closes the valve (Figure 4). The valve willremain closed, reducing the bypass of liquid to 1 to 5gallons (3.8 to 19 liters) per minute, until the pumploses its prime or stops.


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Figure 5. Typical Automatic Air ReleaseValve Installation

The valve inlet must be installed between the pumpdischarge port and the non-pressurized side of thedischarge check valve. The valve inlet is it at thelarge end of the valve body, and is provided withstandard 1-inch NPT pipe threads.

The valve outlet is located at the opposite end of thevalve, and is also equipped with standard 1-inch NPTpipe threads. The outlet should be connected to ableed line which slopes back to the wet well or sump.The bleed line must be the same size as the inletpiping, or larger. If piping is used for the bleed line,avoid the use of elbows whenever possible.

NOTE

It is recommended that each Air Release Valve befitted with an independent bleeder line directedback to the wet well. However, if multiple airRelease Valves are installed in a system, thebleeder lines may be directed to a commonmanifold pipe. Contact your Whales Pumpsdistributor or the Whales Pumps company forinformation about installation of an Automatic AirRelease Valve for your specific application.

ALIGNMENT

The alignment of the pump and its power source iscritical for trouble-free mechanical operation. Ineither a flexible coupling or V-belt driven system, thedriver and pump must be mounted so that theirshafts are aligned with and parallel to each other. Itis imperative that alignment be checked after thepump and piping are installed, and before operation.

NOTE

Check Rotation, Section C, before alignment of thepump.

When mounted at the Whales Pumps factory, driverand pump are aligned before shipment.Misalignment will occur in transit and handling.Pumps must be checking alignment, tighten thefoundation bolts. The pump casing feet and/orpedestal feet, and the driver mounting bolts shouldalso be tightly secured.

SUCTION LINE

WET WELL OR SUMP

BLEED LINE 1"

(25,4MM) DIA. MIN.(CUSTOMERFURNISHED)

EXTEND 6"(152,4MM)BELOW LIQUIDLEVEL SURFACE

90 LONGRADIUS

ELBOW

INSTALL AIR RELEASE VALVEIN HORIZONTAL POSITION

CLEAN-OUTCOVER

DISCHARGE PIPE

DISCHARGE PIPE

SUPPORTBRACKET

SELF-PRININGCENTRIFUGALPUMP

DRAIN LINE


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Figure 6A. Aligning Spider Type Couplings

F

Figure 6B. Aligning Non-Spider Type Couplings

WARNING!

When checking alignment, disconnect the power sourceto ensure that the pump will remain inoperative.

CAUTION!

Adjusting the alignment in one direction may alter thealignment in another direction. Check each procedureafter altering alignment.

Coupled Drives

When using couplings, the axis of the power sourcemust be aligned the axis of the pump shaft in boththe horizontal and vertical planes. Most couplingsrequire a specific gap or clearance between the

driving and the driven shafts. Refer to the couplingmanufacturers service literature.

Align spider insert type couplings by using calipersto measure the dimensions on the circumference ofthe outer ends of the coupling hub every 90degrees. The coupling is in alignment when the hubends are the same distance apart at all points (seeFigure 6A).

Align non-spider type couplings by using a feelergauge or taper gauge between the coupling halvesevery 90 degrees. The coupling is in alignment whenthe hubs are the same distance apart at all points

(see Figure 6B).

Check parallel adjustment by laying a straightedgeacross both coupling rims at the top, bottom, andside. When the straightedge rests evenly on bothhalves of the coupling, the coupling is in horizontalparallel alignment. If the coupling is misaligned use afeeler gauge between the coupling and thestraightedge to measure the amount of misalignment.

V-Belt Drives

When using V-belt drives, the power source andthe pump must be parallel. Use a straightedgealong the sides of the pulleys to ensure that thepulleys are properly aligned (see Figure 6C). Indrive systems using two pr more belts, makecertain that the belts are a matched set;unmatched sets will cause accelerated belt wear.


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MISALIGNED: SHAFTS MISALIGNED: SHAFTS ALIGNED: SHAFTS PARALLELNOT PARALLEL NOT IN LINE AND SHEAVES IN LINE

Figure 6C. Alignment of V-Belt Driven Pumps

F

Tighten the belts in accordance with the beltmanufacturers instructions. If the belts are too loose,

they will slip; if the belts are too tight, there will beexcessive power loss and possible bearing failure.Select pulleys that will match the proper speed ratio;over speeding the pump may damage both pump andpower source.

DANGER!

Do not operate the pump without the guard inplace over the rotating parts. Exposed rotatingparts can catch clothing, fingers, or tools,

causing severe injury to personnel.


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OPERATION SECTION C

Review all SAFETY information in Section A.

Follow instructions on all tags, labels and decals

attached to the pump.

WARNING!

This pump is designed to handle mildindustrial corrosives, mud or slurriescontaining large entrained solids. Do notattempt to pump volatile; corrosive, orflammable liquids which may damage thepump or endanger personnel as a result ofpump failure.

CAUTION!

Pump speed and operating conditions must bewithin the performance range shown on page21.

PRIMING

Install the pump and piping as describe inINSTALLATION. Make sure that the piping

connections are tight, and that the pump issecurely mounted. Check that the pump isproperly lubricated (see LUBRICATION inMAINTENANCE AND REPAIR).

This pump is self-priming, but the pump shouldnever be operated unless there is liquid in thepump casing.

CAUTION!

Never operate this pump unless there is liquidin the pump casing. The pump will not primewhen dry. Extend operation of a dry pump willdestroy the seal assembly.

Add liquid to the pump casing when:

1. The pump is being put into service for thefirst time.

2. The pump has not been used for a

considerable length of time.3. The liquid in the pump casing hasevaporated.

Once the pump casing has been filled, the pumpwill prime and reprime as necessary.

WARNING!

After filling the pump casing, reinstall andtighten the fill plug. Do not attempt to operate

the pump unless all connecting piping issecurely installed. Otherwise, liquid in thepump forced out under pressure could causeinjury to personnel.

To fill the pump, remove the pump casing fill coveror fill plug in the top of the casing, and add cleanliquid until the casing is filled. Replace the fill coveror fill plug before operating the pump.

STARTING

Consult the operations manual furnished with thepower source.

Rotation

The correct direction of pump rotation iscounterclockwise when facing the impeller. Thepump could be damaged and performanceadversely affected by incorrect rotation. If pumpperformance is not within the specified limits (seethe curve on page 21), check the direction ofpower source rotation before furthertroubleshooting.

If an electric motor is used to drive the pump,remove V-belts, couplings, or otherwise disconnectthe pump from the motor before checking motorrotation. Operate the motor independently whileobserving the direction of the motor shaft, orcooling fan.


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If rotation is incorrect on a three-phase motor,have a qualified electrician interchange any of thePhase wires to change direction. If rotation isincorrect on a single-phase motor, consult the

literature supplied with the motor for specificinstructions.

OPERATION

Lines With a Bypass

If a Whales Pumps Automatic Air Release Valvehas been installed, the valve will automaticallyopen to allow the pump to prime, andautomatically close after priming is complete (seeINSTALLATIONfor Air Release Valve operation.

Lines without a Bypass

Open all valves in the discharge line and start thepower source. Priming is indicated by a positivereading on the o the discharge pressure gauge orby a quieter operation. The pump may not primeimmediately because the suction line must first fillwith liquid. If the pump fails to prime within fiveminutes, stop it and check the suction line forleaks.

After the pump has been primed, partially close

the discharge line throttling valve in order to fill theline slowly and guard against excessive shockpressure which could damage pipe ends, gaskets,sprinkler heads, and any other fixtures connectedto the line. When the discharge line is completelyfilled, adjust the throttling valve to the requiredflow rate.

WARNING!

Do not operate the pump against a closeddischarge throttling valve for long periods oftime. If operated against a closed dischargethrottling valve, pump components willdeteriorate, and the liquid could come to aboil, build pressure, and cause the pumpcasing to rupture or explode.

Leakage

No leakage should be visible at pump matingsurfaces, or at pump connections or fittings. Keepall line connections and fittings tight to maintainmaximum pump efficiency.

Liquid Temperature and Overheating

The maximum liquid temperature for this pump is160 F(71 C). Do not apply it at a higher operatingtemperature.Overheating can occur if operated with the valvesin the suction or discharge lines closed. Operatingagainst closed valves could bring the liquid to aboil, build pressure, and cause the pump to ruptureor explode. If overheating occurs, stop the pump

and allow it to cool before servicing it. Refill thepump casing with cool liquid.

DANGER!

Allow an over-heath pump to cool beforeservicing. Do not remove plates, covers,gauges, or fittings from an overheated pump.Liquid within the pump can reach boilingtemperatures, and vapor pressure within thepump can cause parts being disengaged to be

ejected, with great force. After the pump cools,drain the liquid from the pump by removing thecasing drain plug. Use caution when removingthe plug to prevent injury to personnel from hotliquid.

As safeguard against rupture or explosion due toheat, this pump is equipped with a pressure reliefvalve which will open if vapor pressure within thepump casing reaches a critical point. If overheatingdoes occur, stop the pump immediately and allow itto cool before servicing it. Approach any

overheated pump cautiously. It is recommendedthat the pressure relief valve assembly be replacedat each overhaul, or any time the pump casingoverheats and activates the valve. Never replacethis valve with a substitute which has not been

specified or provided by the Whales PumpsInc.


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Strainer Check

If s suction strainer has been shipped with thepump or installed by the user, check the strainerregularly, and clean it as necessary. The strainershould also be checked if pump flow rate begins

to drop. If a vacuum suction gauge has beeninstalled, monitor and record the readingsregularly to detect strainer blockage.

Never introduce air or steam pressure into thepump casing or piping to remove a blockage. Thiscould result in personal injury or damage to theequipment. If back flushing is absolutelynecessary, liquid pressure mustbe limited to 50%of the maximum permissible operating pressureshow on the pump performance curve.

Pump Vacuum Check

With the pump inoperative, install a vacuumgauge in the system, using pipe dope on thethreads. Block the suction line and start the pump.At operating speed the pump should pull avacuum of 20 inches (508,0mm) or more ofmercury. If it does not, check for air leaks in theseal, gasket, or discharge valve.

Open the suction line, and read the vacuumgauge with the pump primed and at operation

speed. Shut off the pump. The vacuum gaugereading will immediately drop proportionate tostatic suction lift, and should then stabilize. If thevacuum reading falls off rapidly after stabilization,an air leak exists. Before checking for the sourceof the leak, check the point of installation of thevacuum gauge.

STOPPING

Never halt the flow of liquid suddenly. If the liquidbeing pumped is stopped abruptly, damagingshock waves can be transmitted to the pump andpiping system. Close all connecting valves slowly.

On engine driven pumps, reduce the throttlespeed slowly and allow the engine to idle brieflybefore stopping.

CAUTION!

If the application involves a high discharge head,gradually close the discharge throttling valvebefore stopping the pump.

After stopping the pump, lock out or disconnect thepower source to ensure that the pump will remaininoperative.

WARNING!

Do not operate the pump against a closeddischarge throttling valve for long periods of

time. If operated against a closed dischargethrottling valve, pump components willdeteriorate, and the liquid could come to a boil,build pressure, and cause the pump casing torupture or explode.

Cold Weather Preservation

In below freezing conditions, drain the pump toprevent damage from freezing. Also, clean out anysolids by flushing with a hose. Operate the pumpfor approximately one minute; this will remove anyremaining liquid that could freeze the pump

rotating parts. If the pump will be idle for more thana few hours, or if it has been pumping liquidscontaining a large amount of solids, drain thepump, and flush it thoroughly with clean water. Toprevent large solids from clogging the drain portand preventing the pump from completely draining,insert a rod or stiff wire in the drain port, andagitate the liquid during the draining process.Clean out any remaining solids by flushing with ahose.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambienttemperatures because of heat generated byfriction. Temperatures up to 160 F(71 C) areconsidered normal for bearings, and they canoperate safely to at least 180 F(82 C).


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Checking bearing temperatures by hand isinaccurate. Bearing temperatures can be

measured accurately by placing a contact-typeThermometer against the housing. Record thistemperature for future reference.

A sudden increase in bearing temperature is awarning that the bearings are at the point of failingto operate properly. Make certain that the bearinglubricant is of the proper viscosity and at thecorrect level (see LUBRICATION inMAINTENANCE AND REPAIR).

Bearing overheating can also be caused by shaftmisalignment and/or excessive vibration.

When pumps are first started, the bearings mayseem to run at temperatures above normal.Continued operation should bring the temperaturesdown to normal levels.


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18

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILSTO PRIME

Not enough liquid in casing.

Suction check valve contaminated ordamaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gasket.

Suction lift or discharge head too high.

Strainer clogged.

Add liquid to casing. See PRIMING.

Clean or replace check valve.

Correct leak.

Replace suction Hose.

Check pump vacuum. Replace leakingOr worn seal or gasket.

Check piping installation and install bypass line ifneeded. See INSTALLATION.

Check strainer and clean if necessary.

WARNING!

Before attempting to open or service thepump:

1. Familiarize yourself with this manual.2. Lock out or disconnect the power

source to ensure that the pump willremain inoperative.

3. Allow the pump to cool if overheated.

4. Check the temperature before openingany covers, plates, or plugs.

5. Close the suction and discharge valves.6. Vent the pump slowly and cautiously.7. Drain the pump.


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19


PUMP STOPS ORFAILS TO DELIVERRATED FLOW ORPRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gasket.

Strainer clogged.

Suction intake not submerged atproper level or sump too small.

Impeller or other wearing parts worn ordamaged.

Impeller clogged.

Pump speed too slow.

Discharge head too high.

Suction lift too high.

Correct leak.

Replace suction hose.

Check pump vacuum. Replace leaking or

worn seal or gasket.

Check strainer and clean if necessary.

Check installation and correct submergenceas needed.

Replace worn or damaged parts. Checkthat impeller is properly centered androtates.

Free impeller of debris.

Check driver output; check belts or couplingsfor slippage.

Install bypass line.

Measure lift w/vacuum gauge. Reduce liftand/or friction losses in suction line.

PUMP REQUIRESTOO MUCH POWER

Pump speed too high

Discharge head too low.

Liquid solution too thick.

Bearing(s) frozen.

Check driver output; check that sheaves ormotor rpm are correctly sized.

Adjust discharge valve.

Dilute if possible.

Disassemble pump and check bearing(s).

PUMP CLOGSFREQUENTLY

Liquid solution too thick.

Discharge flow too slow.

Suction check valve or foot valveClogged or binding.

Dilute if possible.

Open discharge valve fully to increase flowrate, and run power source at maximumgoverned speed.

Clean valve.


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20


EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

Reduce suction lift and/or friction losses insuction line. Record vacuum and pressuregauge readings and consult localrepresentative or factory.

Locate and eliminate source of air bubble.

Secure mounting hardware.

Clean out debris; replace damaged parts.

BEARINGS RUNTOO HOT

Bearing temperature is high, but withinlimits.

Low or incorrect lubricant.

Suction and discharge lines not properlySupported.

Drive misaligned.

Check bearing temperature regularly toMonitor any increase.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.


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21

PUMP MAINTENANCE AND REPAIR SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATINGPERFORMANCE.

STANDARD PERFORMANCE FOR PUMP MODEL WP 04

Based on 70 F(21 C) clear water at sea level

with minimum suction lift. Since pumpinstallations are seldom identical, yourperformance may be difference due to suchfactors as viscosity, specific gravity, elevation,temperature, and impeller trim.

CAUTION!

Pump speed and operating condition points mustbe within the continuous performance range shownon the curve.


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SECTION DRAWING

Figure 1. Pump Model WP04


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PARTS LIST

Pump Model WP04

ITEM NO. PART NAME QTY PART NUMBER

01 PUMP CASING 01 960013500002 * REPAIR ROTATING ASSY 01 9600147000

03 SUCTION FLANGE 01 980090200004 PIPE PLUG 01 3310271020

05 HEX HD CAPSCREW 04 210126508006 LOCKWASHER 04 2321080880

07 * DISCH FLANGE GSKT 01 990136700008 DISCHARGE FLANGE 01 3354211180

09 NAME PLATE 01 990132500010 DRIVE SCREW 04 2750201200

11 * VALVE ASSEMBLY 01 970046300012 ROTATION DECAL 01 9901433000


15 ROT ASSY SCREW SET 04 210213387016 * WEAR PLATE ASSY 01 9800904000

17 CASING DRAIN PLUG 01 331027112018 * BACK COVER ORING 01 3606129300

19 HEX NUT 02 221127003020 LOCKWASHER 02 2321080800

21 HAND NUT 02 990134500022 STUD 02 9901347000

23 BACK CVR PLATE ASSY 01 970048200024 WARNING PLATE 01 9901328000

25 DRIVE SCREW 04 275020120026 CAUTION DECAL 01 9901329000

27 PRESS RELIEF VALVE 01 376850030028 BACK COVER PLATE 02 9800887000



33 * SUCT CHK VALVE ASSY 01 990136600034 CHECK VALVE PIN 01 9901365000

35 PIPE PLUG 01 331027102036 CLAMP BAR 01 9800868000

37 MACHINE BOLT 02 210256515038 * FILL COVER GASKET 01 9901330000

39 CLAMP BAR SCREW 01 990131100040 FILL COVER ASSY 01 9901299000

41 WARNING PLATE 01 990133100042 DRIVE SCREW 02 2750201200

43 PIPE PLUG 01 3310271020

* INDICATES PARTS RECOMMENDED FOR STOCK


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24

SECTION DRAWING

Figure 2. Repair Rotating Assembly

DRIVE END VIEW

SEAL AREA DETAIL


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25

PART LIST

Repair Rotating Assembly

ITEM NO. PART NAME QTY PART NUMBER

01 * IMPELLER 01 970048900002 * SEAL ASSEMBLY 01 9800906000

03 SEAL PLATE 01 970049100004 * INBOARD OIL SEAL 01 3680047800

05 * SEAL PLATE GASKET 01 990133300006 BEARING HOUSE 01 9700490000

07 * INBOARD BALL BEARING 01 318001206008 VENTED PLUG 01 9901335000

09 * BEARING CAP OIL SEAL 01 368004780010 SOCKET HD CAPSCREW 01 2102141950

11 AIR VENT 01 331099006012 IMPELLER WASHER 01 9901313000


15 BEARING CAP 01 980087000016 * SHAFT KEY 01 9901351000

17 IMPELLER SHAFT 01 990131200018 BEARING RETAINING RING 01 3921501041

19 SIGHT GAUGE 01 348050020020 PIPE PLUG 01 3310271080

21 * BEARING CAP GASKET 01 990133700022 * OUTBOARD BALL BEARING 01 3180074380

23 BEARING HOUSING DRAIN PLUG 01 331027106024 SEAL CAVITY DRAIN PLUG 01 3310271060


27 * SEAL PLATE O-RING 01 360622273028 * ROTATING ASSY O-RING 01 3606129300

29 * SEAL PLATE O-RING 01 3606220240

* INDICATES PARTS RECOMMENDED FOR STOCK


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26

WARNING!

Use lifting and moving equipment in goodrepair and with adequate capacity to preventinjuries to personnel or damage to equipment.

Back Cover And Wear Plate Removal

(Figure 1)

The wear plate (16) is easily accessible and maybe serviced by removing the back cover assembly(23). Before attempting to service the pump,remove the pump casing drain plug (17) and drainthe pump. Clean and reinstall the drain plug.

Remove the hand nuts (21) and pull the backcover and assembled wear plate from the pumpcasing (1). Inspected the wear plate, and replace itif badly scored or worn. To remove the wear plate,disengage the hardware (19 and 20).Inspect the back cover O-ring (18) and replace it ifdamaged or worn.

Suction Check Valve Removal

(Figure 1 )

If the check valve assembly (11) is to serviced,remove the check valve pin (32), reach through theback cover opening and pull the completeassembly from the suction flange (3).

NOTEFurther disassembly of the check valve is notrequired since it must be replaced as acomplete unit. Individual parts are not soldseparately.

Rotating Assembly Removal

(Figure 2)

The rotating assembly may be serviced withoutdisconnecting the suction or discharge piping;however, the power source must removed toprovide clearance.

PUMP AND SEAL DISASSEMBLY ANDREASSEMBLY

Review all SAFETY Information in Section A.

Follow the instructions on all tags, label and decalsattached to the pump.This pump requires little service due to its rugged,minimum-maintenance design. However, if itbecomes necessary to inspect or replace thewearing parts, follow these instructions which arekeyed to the sectional views (see Figures 1 and 2)and the accompanying parts lists.

Many service functions may be performed bydraining the pump and removing the back coverassembly. If major repair is required, the piping

and/or power source must be disconnected. Thefollowing instructions assume complete disassemblyis required.

Before attempting to service the pump, disconnector lock out the power source and take precautionsto ensure that it will remain inoperative. Close allvalves in the suction and discharge lines.

For power source disassembly and repair, consultthe literature supplied with the power source, orcontact your local power source representative.

WARNING!

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.2. Disconnect or lock out the power source

to ensure that the pump will remaininoperative.

3. Allow the pump to cool if overheated.4. Check the temperature before opening

any covers, plates, or plugs.5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.7. Drain the pump.


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NOTE

An optional disassembly tool is availablefrom the factory. If the tool is used, follow theinstructions packed with it. A similar tool maybe assembled using inch pipe (schedule 80steel or malleable iron ) and a standard tee(see Figure 4).All threads are inch NPT. Donot pre-assemble the tool.

TEE

APPROX. 14 IN.

(356 MM) LONG

APPROX. 6 IN.

(152MM) LONG

Figure 4. Rotating Assembly Tool

To install the tool, remove the air vent (8,Figure 2) from the bearing housing, andscrew the longest length of pipe into the venthole until fully engaged. Install the tee, andscrew the handles into the tee. Use cautionwhen lifting the rotating assembly to avoidinjury to personnel or damage to theassembly.

Remove the bearing housing and seal plate O-rings (27 and 28).

Impeller Removal

(Figure 2)

With the rotating assembly removed from the

pump casing, unscrew the impeller from theshaft. Use caution when unscrewing the impeller;tension on the shaft seal spring will be releasedas the impeller is removed. Inspect the impellerand replace if cracked or badly worn.

Remove the impeller adjusting shims tie and tagthe shims, or measure and record their thicknessfor ease of reassembly.

The impeller (1) should be loosened while the rotatingassembly is still secured to the pump casing. Beforeloosening the impeller, remove the seal cavity drainplug (24) and drain the seal lubricant. This will preventthe oil in the seal cavity from escaping when theimpeller is loosened. Clean and reinstall the sealcavity drain plug.

Immobilize the impeller by weding a block woodbetween the vanes and the pump casing, and removethe impeller capscrew and washer (10 and 12).

Install a lathe dog on the drive end of the shaft (17)with the V notch positioned over the shaft keyway.

With the impeller rotation still blocked, see Figure 3and use a long piece of heavy bar stock to pry againstthe arm of the lathe dog in a counterclockwisedirection (when facing the drive end of the shaft). Usecautionnot to damage the shaft or keyway. When theimpeller breaks loose, remove the lathe dog and woodblock.

NOTEDo not remove the impeller until the rotating assemblyhas been removed from the pump casing.

Turn

Counterclockwise

Lathe Dog Arm

Heavy Bar Stock

Set Screw

Lathe Dog

Impeller Shaft

Shaft Keyway

"V" Notch

Figure 3. Loosening impeller

(Figure 1)

Remove the hardware (13 and 14) securing therotating assembly to the pump casing. Separate theRotating assembly by pulling straight away from thepump casing.


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CAUTION!

To prevent damage during removal from theshaft, it is recommended that bearings becleaned and inspected in place. It is strongly

recommended that the bearings be replaced anytime the shaft and bearings are removed.Clean the bearing housing, shaft and allcomponent parts (except the bearings) with asoft cloth soaked in cleaning solvent. Inspect theparts for wear or damage and replace asnecessary.

WARNING!

Most cleaning solvents are toxic and flammable.Use them only in a well-ventilated area free form

excessive heat, sparks, and flame. Read andfollow all precautions printed on solventcontainers.

Clean the bearings thoroughly in freshcleaning solvent. Dry the bearings withfiltered compressed air and coat with light oil.

CAUTION!

Bearings must be kept free of all dirt and foreign

material. Failure to do so will greatly shortenbearing life. DO NOTspin dry bearings. This mayscratch the balls or races and cause prematurebearing failure.

Rotate the bearings by hand to check forroughness or binding and inspect the bearingsballs. If rotation is rough or the bearing balls arediscolored, replace the bearings.

The bearing tolerances provide a tight press fitonto the shaft and a snug slip fit into the bearinghousing. Replace the bearings, shaft, or bearing

housing if the proper bearing fit is not achieved.

If bearing replacement is required, remove theoutboard bearing retaining ring (18), and use abearing puller to remove the bearings from theshaft.

Press the inboard oil seal (7) from the bearinghousing.

Seal Removal

(Figure 2)

Slide the integral shaft sleeve and rotating portion ofthe seal off the shaft as unit.

Use a pair of stiff wires with hooked ends to removethe stationary element and seat.

An alternate method of removing the stationary sealcomponents is to remove the hardware (25 and 26),and separate the seal plate (3) and gasket (5) fromthe bearing housing (6). Position the seal plate on aflat surface with the impeller side down. Use awooden dowel or other suitable tool to press on theback side of the stationary seat until the seat, O-rings, and stationary element can be removed.

Remove the shaft sleeve O-ring .

If no further disassembly is required, refer to sealinstallation.

Shaft and Bearing Removal and Disassembly

(Figure 2)When the pump is properly operated andmaintenance, the bearing housing should notrequire disassembly. Disassemble the shaft andbearings only when there is evidence of wear ordamage.

CAUTION!

Shaft and bearing disassembly in the field is notrecommended. These operations should beperformed only in a properly equipped shop byqualified personnel.Remove the bearing housing drain plug (23) anddrain the lubricant. Clean and reinstall the drainplug.Disengage the hardware (13 and 14) and slide thebearing cap (15) and oil seal (9) off the shaft.Remove the bearing cap gasket (21), and press theoil seal from the bearing cap.Place a block of wood against the impeller end ofthe shaft and tap the shaft and assembled bearings(7 and 22) from the bearing housing.After removing the shaft and bearings, clean andinspect the bearings in placeas follows.


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SEAL PLATE

O-RINGS

SLEEVE

O-RING

INTEGRAL

SHAFT

SLEEVE

SHEAR

RING

(SHEARED)

STATIONARY

SEAT

STATIONARY

ELEMENT

ROTATING

ELEMENT

DRIVE BAND

SPRING

CENTERING

WASHER

BELLOWS

IMPELLER

SHAFT

IMPELLER

SHIMS

IMPELLER

SPRING

RATAINER

Figure 5. Cartridge Seal Assembly

remove any that exist. The stationary seat boremust be completely clean before installing theseal.

CAUTION!

A new seal assembly should be installed any timethe old seal is removed from the pump. Wearpatters on the finished faces cannot be realignedduring reassembly. Reusing an old seal couldresult in premature failure.

To ease installation of the seal, lubricate the shaftsleeve O-ring and the external stationary seat O-ring with a very small amount of light lubricating oil.See Figure 5 for seal part identification.

Seal Installation

(Figures 2,5,6 and 7)

WARNING!

Most cleaning solvents are toxic and flammable.Use them only in a well-ventilated area free fromexcessive heat, sparks, and flame. Read andfollow all precautions printed on solventcontainers.

Clean the seal cavity and shaft with a cloth soakedin fresh cleaning solvent. Inspect the stationary seatbore in the seal plate for dirt, nicks and burrs, and

CAUTION!

This seal is not designed for operation attemperatures above 160 F (71 C). Do not useat higher operating temperatures.

If the seal plate was removed, install the seal plategasket (5). Position the seal plate over the shaft andsecure it to the bearing housing with the hardware(25 and 26).

To prevent damaging the shaft sleeve O-ring on theshaft threads, stretch the O-ring over a piece oftubing 1-1/4 I.D. x 1-1/2 O.D x 2 inches long (32mmx 38mm x 51mm).


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NOTE

If the suction or discharge flanges wereremoved, replace the respective gaskets, apply Permatex Aviation No 3 Form-A-Gasket orequivalent compound to the mating surfaces,and secure them to the pump casing with theattaching hardware.

Back cover Installation

(Figure 1)If the wear plate (16) was removed forreplacement, carefully center it on the back coverand secure it with the hardware (19 and 20). Thewear plate must be concentric to prevent bindingwhen the back cover is installed.

Replace the back cover O-ring (18), and lubricate itwith a generous amount of No.2 grease. Clean any

scale or debris from the contacting surfaces in thepump casing that might interfere or prevent a goodseal with the back cover. Slide the back coverassembly into the pump casing. Be sure the wearplate does not bind against the impeller.

NOTE

To ease future disassembly, apply a film ofgrease or Never-Seez on the back covershoulder, or any surface which contacts thepump casing. This action will reduce rust andscale build-up.

Secure the back cover assembly by tightening thehand nuts (21) evenly. Do not over-tighten thehand nuts; they should be just tight enough toensure a good seal at the back cover shoulder. Besure the wear plate does not bind against thecasing.

PRESSURE RELIEF VALVE MAINTENANCE

(Figure 1)The back cover is equipped with a pressure relief

valve (27) to provide additional safety for the pumpand operator (refer to Liquid Temperature AndOverheatingin OPERATION).

It is recommended that the pressure relief valveassembly be replaced at each overhaul, or anytime the pump overheats and activates the valve.Never replace this valve with a substitute whichhas not been specified or provided by WhalesPumps Inc..

Install the bearing housing and seal plate O-rings(27 and 28) and lubricate them with light grease.Ease the rotating assembly into the pump casingusing the installation tool. Be carefulno to damagethe O-rings.

Install the four screw sets of rotating assemblyadjusting screw (15) using the same thickness aspreviously removed. Secure the rotating assemblyto the pump casing with the hardware (13 and 14).Do not fully tighten the capscrew until the backcover has been set.

A clearance of .010 to .020 inch (0,25 to 0,51mm)between the impeller and the wear plate is alsorecommended for maximum pump efficiency. Thisclearance can be obtained by adjust an equal ofscrew from each rotating assembly screw set untilthe impeller scrapes against the wear plate whenthe shaft is turned. After the impeller scrapes, adjust

approximately .015 inch (0,4mm) of clearance withthe screw set.

NOTE

An alternate method of adjusting this clearanceis to reach through the suction port with a feelergauge and measure the gap. Adjust rotatingassembly screw accordingly.

Suction Check Valve Installation

(Figure 1)

Inspect the check valve assembly (11), and replaceit if badly worn.

NOTE

The check valve assembly must be replaced asa complete unit. Individual parts are not soldseparately.

Reach through the back cover opening with thecheck valve (11), and position the check valveadaptor in the mounting slot in the suction flange(3). Align the adaptor with the flange hole, andsecure the assembly with the check valve pin (32)


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Bearings

(Figure 2)

The bearing housing was fully lubricated whenshipped from the factory. Check the oil levelregularly through the sight gauge. When lubricationis required, add SAE No. 30 non-detergent-oilthrough the hole for the air vent (11). Do not over-lubricate. Over-lubrication can cause the bearingsto overheat, resulting in premature bearing failure.

NOTE

The white reflector in the sight gauge must bepositioned horizontally to provide proper

drainage.

Under normal conditions, drain the bearing housingonce each year and refill with approximately 28ounces (0,8 liter) clean oil. Change the oil morefrequently if the pump is operated continuously orinstalled in an environment with rapid temperaturechange.

CAUTION!

Monitor the condition of the bearing lubricantregularly for evidence of rust or moisturecondensation. This is especially important in areaswhere variable and cold temperatures arecommon.

For cold weather operation, consult the factory or alubricant supplier for the recommended grade ofoil.

Power Source

Consult the literature supplied with the powersource, or contact your local power sourcerepresentative.

Periodically, the valve should be removed forinspection and cleaning. When reinstalling the reliefvalve, apply Loctite Pipe Sealant With Teflon No.592, or equivalent compound, on the relief valvethreads. Position the valve as shown in Figure 1with the discharge port pointing down.

Final Pump Assembly

(Figure 1)

Install the shaft key (16, Figure 2) and reconnect thepower source. Be sure to install any guards usedover the rotating members.

DANGER!

Do not operate the pump without the guards in

place over the rotating parts. Exposed rotatingparts can catch clothing, fingers, or tools,causing severe injury to personnel.

Install the suction and discharge lines and open allvalves. Make certain that all piping connections aretight, properly supported and secure.

Be sure the pump and power source have beenproperly lubricated, see LUBRICATION.

Remove the fill cover assembly and fill the pumpcasing with clean liquid. Reinstall the fill cover and

tighten it. Refer to OPERATION, Section C, beforeputting the pump back into service.

LUBRICATION

Seal Assembly

(Figure 2)

Before starting the pump, remove the vented plug(8) and fill the seal cavity with approximately 20ounces (0,6 liters) of SAE No. 30 non-detergent oil,or to a level just below the tapped vented plug hole.Clean and reinstall the vented plug. Maintain the oilat this level.


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THE WHALES PUMPS INC.

WARRANTY

Pumping units manufactured by the Whales PumpsCompany, are guaranteed to be free from defects inmaterial and workmanship for one year from date ofshipment from factory. The obligation under this Warranty,

statutory or otherwise, is limited to replacement or repairat factory or at a point designated by Whales of such aspart as shall appear to us upon inspection at such point,to have been defective in material or workmanship.

This Warranty does not obligate the Whales PumpsCompany to bear the cost of labor or transportationcharges in connection with replacement or repair ofdefective parts; nor shall it apply to a pump upon whichrepairs or alterations have been made unless authorizedby Whales Pumps.

No warranty is made in respect to engines, motors or

trade accessories, such being subject to warranties oftheir respective manufactures.

In Submersible Pumps, pump and motor are integral andSubmersibles are warranted as a unit. Since motor issubject to an important degree upon quality andperformance of electrical controls, unit warranty is validonly when controls have been specified and provided byWhales Pumps .

No express implied or statutory warranty, other here setforth is made or authorized to be made by Whales Pumps.

In no event shall the Whales Pumps Company be liablefor consequential damages or contingent liabilities arisingof the failure of Whals Pumps pump or parts there of tooperate properly.

WP04 Manual Braun

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