Warman Supplement MDS12 250 - 650 MCR on AH Mechanical End

Centrifugal Slurry Pumps 2701 S Stoughton Rd PO Box 7610 Madison WI 53716 USA

Tel: +1 608 221 2261 Fax: +1 608 221 5810 www.weirminerals.com

WARMAN ASSEMBLY INSTRUCTIONS MODEL MCR MILL CIRCUIT PUMPS (SIZES 250 - 650) WITH WARMAN BEARING ASSEMBLIES

Ron Bourgeois / Mike Viken Product Development Manager / Senior Designer © Weir Minerals North America 2009. Weir Minerals North America is the owner of the Copyright in this document. The document and its text, images, diagrams, data and information it contains must not be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals North America.

Office of origin :

Weir Minerals North America

Reference :

Manual Supplement - MDS12

Date :

First Issue : 04/25/2007

Last Issued:

12/20/2012 (Dwg No. A392059_07)

Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

CONTENTS 1. Introduction and Safety 2. Assembly Instructions / Required Documents Bearing Assembly – Maintenance & Assembly Instructions Parts Identification Frame Assembly Page

 Fitting Bearing Assembly to Base (sizes 250 - 450) ----------------------------------- 10  Fitting Bearing Assembly to Base (sizes 550 - 650) ----------------------------------- 11

Gland Assembly  Fitting Impeller Release Collar, Shaft Sleeve, Lantern Restrictor

and Stuffing Box to Shaft (sizes 250 - 650) --------------------------------------------- 12

Pump Assembly  Installing Frame Plate Liner Insert and Frame Plate Liner (sizes 250 - 350) ----13  Installing Frame Plate Liner Insert and Frame Plate Liner (sizes 400 - 650) ----14  Fitting Frame Plate to Base (sizes 250 - 650) ------------------------------------------ 15  Installing Impeller and setting Back Gap (sizes 250 - 650) ------------------------- 16  Installing Throatbush and Cover Plate Liner (sizes 250 - 350) -------------------- 17  Fitting Cover Plate to Frame Plate (sizes 250 – 350) -------------------------------- 18  Installing Throatbush and Cover Plate Liner (sizes 400 - 650) --------------------- 19  Fitting Suction Cover to Cover Plate (sizes 400 – 650) ------------------------------ 20  Fitting Cover Plate to Frame Plate (sizes 400 – 650) --------------------------------- 21  Setting Impeller to Throatbush clearance (sizes 250 - 650) ------------------------- 22  Centering Stuffing Box (sizes 250 - 650) ------------------------------------------------- 23  Stuffing Box Assembly (sizes 250 - 650) ------------------------------------------------- 24  Warman Basic Part Number & Part List------------------------------------------------ 25

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1. Introduction and Safety Warman® centrifugal slurry pumps, when properly installed and operated, and when given reasonable care and maintenance, will operate satisfactorily for a long period of time. The following paragraphs outline the general principles that should be considered to ensure troublefree pump operation. Warman® slurry pumps are built in a variety of designs and materials and for many different slurry services. The manufacturer’s instruction book should be studied carefully and followed, as there may be specific requirements for a particular machine or application that cannot be covered in a general discussion. The installation and service manual and/or special instructions included in the shipment should be read thoroughly before installing or operating the pump. All instructions regarding maintenance should be retained for reference. Marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform to the applicable CE (European conformity) marking directives covering machinery and, where applicable, low-voltage equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED), and equipment for potentially explosive atmospheres (ATEX). Where applicable, the directives and any additional approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable, this document incorporates information relevant to these directives and approvals. To confirm the approvals applying and if the product is CE marked, check the serial number plate markings and the certification. Safety Legal requirements and local regulations may differ substantially with regard to particular safety requirements and may be regularly modified by relevant authorities without notice. As a consequence, applicable laws and regulations should be consulted to ensure compliance. The following cannot be guaranteed as to its completeness or continuing accuracy. Explanation of safety terminology and symbols These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are: This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life. This symbol indicates safety instructions where non-compliance will involve a high risk to personal safety or the loss of life. This symbol indicates safety instructions where non-compliance would affect personal safety and could result in the loss of life. This symbol indicates safety instructions where non-compliance may result in minor or moderate personal injury and/or damage to the equipment or property.

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This is a general safety alert symbol to indicate the potential risk of personal injury and/or damage to the equipment or property.

This symbol indicates “hazardous and toxic fluid” safety instructions where noncompliance would affect personal safety and could result in loss of life. This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion. This sign is not a safety symbol but indicates an important instruction in the assembly and/or operation process. General guidelines These Instructions must always be kept close to the pump’s operating location or directly with the pump. Warman® slurry pumps are designed, developed and manufactured with state of the art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements. Weir Minerals is committed to continuous quality improvements and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements, applicable safety and health laws/regulations. These Instructions should be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety noted in the instructions have been met. Information in these User Instructions is believed to be reliable. In spite of all the efforts to provide sound and all necessary information, the content of this manual may appear insufficient and is not guaranteed as to its completeness or accuracy. For the safety of operating personnel, please note that the information supplied in this manual only applies to the fitting of genuine Warman parts and Warman recommended bearings to Warman® slurry pumps. Weir Minerals manufactures products to exacting International Quality Management system Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Weir Minerals cannot test parts and

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accessories sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized parts and accessories is considered misuse. Damage or failure caused by misuse is not covered by our warranty. In addition, and modification of Weir Minerals products or removal of original components may impair the safety of these products in their use. The pumps must not be operated beyond the allowable limits of pressure, temperature and speed specified for the application. These limits are dependent on the pump type, configuration and materials used. If there is any doubt as to the suitability of the product for the application intended, contact Weir Minerals for advice, quoting the serial number. If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty), it is requested that the user seek the manufacturer’s written agreement before start up. Personnel qualification and training All personnel involved in the operation, installation, inspection, and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer/supplier to provide applicable training. Always coordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws and regulations. Safety action This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and to equipment.

WEIR MINERALS WOULD LIKE TO BRING TO YOUR ATTENTION THE POTENTIAL HAZARD CAUSED BY THE CONTINUED OPERATION OF CENTRIFUGAL PUMPS WHEN THE INTAKE AND DISCHARGE ARE BLOCKED. EXTREME HEAT IS GENERATED AND RESULTS IN VAPORIZATION OF THE ENTRAPPED LIQUID. THIS CAN RESULT IN A LIFE THREATENING EXPLOSION. The operation of centrifugal pumps on slurry applications can increase this potential hazard due to the nature of the material being pumped. The additional hazard believed to be presented by slurry applications stem from the possibility of solids blocking the pump discharge and remaining undetected. This situation has been known in some instances to lead to the intake side of the pump also becoming blocked with solids. The continued operation of the pump under these circumstances can be extremely dangerous. If you have an installation that may be prone to this occurrence, we suggest you adopt measures to prevent this blockage situation.

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The WARMAN® CENTRIFUGAL SLURRY PUMP is a piece of ROTATING EQUIPMENT which CONTAINS PRESSURE under service conditions. All standard safety precautions for such equipment should be followed before and during installation, operation, and maintenance. For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable speed drives, etc.), standard safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment and maintenance.

For pumps fitted with MECHANICAL SEALS always follow the appropriate instruction manuals and ALWAYS REMOVE THE MECHANICAL SEAL SETTING TABS PRIOR TO STARTING THE PUMP. Failure to remove the setting tabs will result in damage to both the pump and the seal. DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS for prolonged periods (three minutes is considered maximum), OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORIZE. Personal injury and equipment damage could result from the high temperature and pressure created.

DO NOT APPLY HEAT TO THE IMPELLER BOSS OR NOSE IN AN EFFORT TO LOOSEN THE IMPELLER THREAD PRIOR TO IMPELLER REMOVAL. Personal injury and damage to equipment could occur as a result of an explosion. A shaft wrench has been provided to assist impeller removal. In some cases, a release collar has also been provided to assist impeller removal. DO NOT OPERATE THE PUMP without properly installed stuffing box, v-belt and coupling guards in place. All guards for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards must not be removed or opened while the pump is running.

DO NOT OPERATE THE PUMP if solids have settled and the rotating element can not be turned by hand. THERMAL SHOCK Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal shock may cause damage to the internal components and rupture the pump casing. DRIVER ROTATION MUST BE CHECKED to match correct pump rotation direction as marked on the pump casing before belts or couplings are connected. Do not touch rotating members with your hand to establish the direction of rotation. Always check the direction of the pump shaft and not the gearbox input shaft which is in the opposite direction and will be in the wrong direction for the pump. DO NOT START A PUMP that is rotating in reverse, such as the backward rotation caused by slurry runback. Personal injury and damage to equipment could result.

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ENSURE THAT THE IMPELLER IS TIGHT ON THE SHAFT before any start-up, i.e. all components on the shaft between the impeller and the pump end bearing butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking, etc. ENSURE CORRECT LUBRICATION Some equipment such as gear reducers, motors, and oil lubricated pump bearing assemblies are shipped without lubricating oil. Be certain that oil of the proper grade is filled to the proper level in each piece of equipment before start-up.

NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER. Power to the electric motor must be isolated and tagged out. THE PUMP MUST BE FULLY ISOLATED before any maintenance work, inspection or troubleshooting involving work on sections which are potentially pressurized (e.g. casing, gland, connected pipe work) or involving work on the mechanical drive system (e.g. shaft, bearing assembly, coupling). It must be proven that the intake and discharge openings are totally isolated from all potentially pressurized connections and that they are, and can only be exposed to atmospheric pressure. DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous.

    

HANDLING COMPONENTS Tapped holes (for eye bolts) and lugs (for lifting shackles) on pumps are for lifting INDIVIDUAL PARTS ONLY. Exception is the lifting lug on the cover plate which can be used to lift the cover plate with the throatbush, volute and / or the elastomer liner fitted. Worn pump components can have sharp or jagged edges. Caution must be taken in handling worn parts to prevent damage to slings or personal injury. Lifting devices of adequate capacity must be used whenever they are required. Safe workshop practices must be applied during all assembly and maintenance work. Personnel must never work under suspended loads.

DO NOT APPLY HEAT OR HARD-FACE HIGH CHROME COMPONENTS. This can cause cracks, residual stresses, and changes the fracture toughness of the parent material. This may lead to catastrophic failure and could result in personal injury and equipment damage even when operating within recommended speed and pressure limits. CASTINGS made from materials listed are brittle and have low thermal shock resistance. Attempts to repair or rebuild by welding may cause catastrophic failure. Repairs of such castings using these methods must not be attempted. Examples include, but are not limited to the following - A03, A04, A05, A06, A07, A701, A08, A09, A12, A14, A49, A51, A52, A53, A61, A124, A210, A211, A217, A218, A238 and A509.



AVOID CONTAMINATION BURNING of elastomeric pump components will cause emission of toxic fumes and result in air pollution which could lead to personal injury.

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 

LEAKAGE exceeding the specified packing lubrication requirements from the pump shaft seals and/or leakage from worn pump components or seals may cause water and/or soil contamination. LIQUID WASTE DISPOSAL from servicing of pumps or stagnant water from pumps stored for long periods, may cause water and/or soil contamination.

Mixing of NEW AND WORN PUMP PARTS may increase the incidence of premature pump wear and leakage. All METAL MATING FACES MUST BE CLEANED of dirt, rust, paint and other adhering substances prior to pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to catastrophic failure of parts. Large FOREIGN OBJECTS OR TRAMP entering a pump will increase the incidence of higher wear and / or damage to the pump. Routine inspection and maintenance of mill trommel screens will assist to reduce the danger of grinding balls entering a mill discharge pump. Large VARIATIONS IN SLURRY PROPERTIES may lead to accelerated rates of wear and corrosion of pump components, e.g.  Wear increases exponentially with velocity and slurry particle size.  Corrosion rate doubles for every 10 degrees Celsius (18 degrees Fahrenheit) increase in slurry temperature.  Corrosion rate increases exponentially as slurry pH decreases.

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2. Assembly Instructions / Required Documents Supplement 'MDS12' should be read in conjunction with the following Warman Assembly and Maintenance Instruction Supplements: M1 - General Instructions applicable to ALL TYPES of Warman Pumps M2 - Impeller Release Collar Plus one of the following depending on TYPE of Bearing Assembly used; BA1 - Heavy Duty (Frames N - U) BA3 – Modified Basic (Frames CC – GG) BA6 - Oil Filled Bearing Assemblies (Suffix ‘Y’). NOTE: The recommended grease for grease lubricated assemblies is Mobil SHC 220 or equivalent. For oil lubricated assemblies the recommended oil is Mobil gear SHC 220 or equivalent. These lubricant requirements supersede those called out in Supplement BA1, BA3 and BA6 and allow for higher temperature operation with reduced chance of viscosity breakdown. This supplement contains step by step illustrated instructions for complete and correct assembly of Warman Rubber Lined Mill Circuit pumps 250 – 650 MCR.

Bearing Assembly - Maintenance & Assembly Instructions The Bearing Assembly is assembled and maintained according to the instructions contained in the respective Warman Supplement BA1, BA3 and BA6 according to the TYPE of Bearing Assembly utilized.

Parts Identification The comment in Warman Bearing Assembly Supplements regarding Warman Basic Numbers incorporated in Warman Part Numbers applies in the same manner to Warman Pump component parts. For full description and part number identification, refer to the appropriate Warman Components Diagram. Names and Basic Numbers are used in assembly instructions in this manual. All relevant Warman Basic Numbers are listed at the end of this supplement. In all correspondence with Weir Minerals, or their representatives, and especially when ordering spare parts, it is advisable to use correct names as well as full part numbers to prevent misunderstandings or wrong deliveries. When in doubt, the pump serial number should be quoted as well.

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FITTING BEARING ASSEMBLY TO BASE (SIZES 250 THRU 450) (REFER TO FIGURE 1) IMPORTANT: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1. Insert Adjusting Screw (001) in Base (003) from outside the back of Base. Screw on one (1) hex nut and fully tighten. Fit two (2) additional nuts and two (2) flat washers, in between nuts, to Adjusting Screw. These nuts are to be left loose and maximum distance apart to allow bearing housing lug to fit over the Adjusting Screw. 2. Clean machined cradle supports on Base and apply anti-seize. NOTE: Remove any paint that may be present on these machined surfaces. Lower the Bearing Assembly (005) (205) onto the Base. Carefully line up machined surfaces of Bearing Housing with machined surfaces in Base. Check that the bearing housing lug fits over the Adjusting Screw and is positioned between the washers. 3. Fit Clamp Bolts (012) through Base from underneath. Position Clamp Washers (011) over the bolts and thread on clamp nuts. NOTE: Tighten (2) “A” side clamp nuts. “A” side nuts are on the left when looking from impeller end. Leave (2)”B” side nuts snug to maintain alignment but allow for axial movement. Apply anti-seize lubricant to portion of Shaft extending from Labyrinth at impeller end and the shaft thread to prevent moisture damage to the Shaft.

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FITTING BEARING ASSEMBLY TO BASE (SIZES 550 & 650) (REFER TO FIGURE 2) 1. Insert Adjusting Screw (001) in Base (003) from outside the back of Base. Screw on one (1) hex nut and fully tighten. Fit two (2) additional nuts and two (2) flat washers, in between nuts, to Adjusting Screw. These nuts are to be left loose and maximum distance apart to allow bearing housing lug to fit over the Adjusting Screw. 2. Clean machined cradle supports on Base and apply anti-seize. NOTE: Remove any paint that may be present on these machined surfaces. Lower the Bearing Assembly (005) (205) onto the Base. Carefully line up machined surfaces of Bearing Housing with machined surfaces in Base. Check that the bearing housing lug fits over the Adjusting Screw and is positioned between the washers. 3. Fit Clamp Bolts (012) through Base from underneath. Position Clamp Pads (011) over the bolts and thread on clamp nuts. NOTE: Tighten (2) “A” side clamp nuts. “A” side nuts are on the left when looking from impeller end. Leave (2)”B” side nuts snug to maintain alignment but allow for axial movement. Apply anti-seize lubricant to portion of Shaft extending from Labyrinth at impeller end and the shaft thread to prevent moisture damage to the Shaft.

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INSTALLING IMPELLER RELEASE COLLAR, SHAFT SLEEVE, LANTERN RESTRICTOR AND STUFFING BOX TO SHAFT (SIZES 250 THRU 650) (REFER TO FIGURE 3) 1. Fit the Impeller Release Collar O-Ring (109) over the Shaft (073) and slide it back until it seats in the groove in Labyrinth (062). Install Impeller Release Collar over the shaft and slide it back to the Labyrinth capturing the O-ring. Make sure the mating tapers on both parts match. Position the metal ring over the outer diameter of the Impeller Release Collar and tighten the setscrews. NOTE: Fill the recesses of the set screws and pusher holes with silicone or other suitable sealant to prevent moisture from contacting these fasteners and damaging the threads (Instructions for fitting the Impeller Release Collars are also contained in Warman supplement ‘M2’). 2. Fit (1) Shaft Sleeve O-Ring (109) over Shaft and slide it up to the Impeller Release Collar. NOTE: For pump models 550 and 650 thread the Shaft Sleeve Assembly Guide (330) into the end of the shaft. Position the Shaft Sleeve (076) over the Shaft and slide it back until contacting the Impeller Release Collar capturing the O-ring. Remove the guide tool, if necessary, and fit second Shaft Sleeve O-ring into groove in Shaft Sleeve. 3. Install Lantern Restrictor (118) over Shaft Sleeve in orientation shown in Figure 3 Detail A. (i.e. radial flush holes facing Release Collar) and slide it as far back on the Shaft as possible. NOTE: Pump models 550 & 650 have centering o-rings on the Lantern Restrictor. Make sure the two shoulder bolts are tight. 4. Slide Stuffing Box (078) onto Shaft Sleeve and slide it back until the Lantern Restrictor is inside the stuffing box bore.

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INSTALLING FRAME PLATE LINER INSERT AND FRAME PLATE LINER (SIZES 250 THRU 350) (REFER TO FIGURE 4) 1. Strap the Frame Plate Liner Insert (041) (FPLI) as shown in Figure 4 Detail A and lower it onto FPLI tool (318). Lift the FPLI and install FPLI Puller Studs into tapped holes in the reinforcement and fully tighten. NOTE: FPLI tools with square tops are designed for FPLI only. 2. Place the Frame Plate (032) (395) bowl up on the ground and lower the FPLI onto the Frame Plate as shown in Figure 4 Detail B. Install a washer and nut to the FPLI Puller Studs from underneath the Frame Plate and tighten to the torque specified in Table 1 on Page 14. 3. Install Frame Plate Liner Studs into tapped holes in liner reinforcement. Strap the Frame Plate Liner (043) as shown in Figure 4 Detail C and lower it into the Frame Plate. Install a washer and nut to the liner studs from underneath the frame plate and tighten to the torque specified in Table 1 on Page 14.

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INSTALLING FRAME PLATE LINER INSERT AND FRAME PLATE LINER (SIZES 400 & 650) (REFER TO FIGURE 5) 1. Place the Impeller hub side up on the floor. Set the Frame Plate Liner Insert (041) (FPLI) reinforcement side up centered on top of the Impeller as shown in Figure 5 Detail A. TIP: Use eye bolts in the tapped hole of the reinforcement for lifting. Install (4) FPLI Puller Studs into the tapped holes in the reinforcement and fully tighten. 2. Using a three point pick lift Frame Plate (032) as shown in Figure 5 Detail A and lower it onto the FPLI being careful to line up the studs with the untapped holes in the Frame Plate. Install a washer and nut to the FPLI Puller Studs and tighten to the torque specified in Table 1. 3. Place Frame Plate Liner (043) bowl down on the floor as shown in Figure 5 Detail B. TIP: Use blocks of wood inside the liner positioned under the reinforcement for support. Install Frame Plate Liner Studs into tapped holes in reinforcement and fully tighten. Using a three point pick lift Frame Plate as shown in Figure 5 Detail B and lower it onto the Frame Plate Liner. Install a washer and nut to the Frame Plate Liner Studs and tighten to the torque specified in Table 1.

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FITTING FRAME PLATE TO BASE (SIZES 250 THRU 650) (REFER TO FIGURE 6) Apply anti-seize lubricant to the raised diameter portion of the Frame Plate studs and the pilot diameter of the frame plate. Remove any paint on these machined surfaces. 1. Using a two point pick lift the Frame Plate sub-assembly to the vertical position as shown. Thread the Frame Plate Studs (039) into the Frame Plate and fully tighten. NOTE: Pump models 400 thru 650 are equipped with hex on the end of the stud to assist with threading as shown in Figure 6 Detail A. 2. Slowly move the sub-assembly towards the base being careful to line up the studs with the holes in the base. Make certain that the pilot in the frame plate has engaged the recess in the base. Install a hex nut to the studs and tighten to the torque specified in Table 2.

3. Install the Pusher Bolts into the tapped holes in the frame plate and tighten to 35 N-m (25 ftlbs).

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INSTALLING IMPELLER AND SETTING BACK GAP (SIZES 250 THRU 650) (REFER TO FIGURE 7) 1. Fit Shaft Key (070) in keyway and bolt Shaft Wrench (306) onto shaft as shown in Figure 6. NOTE: Check that clamp bolts on “B” side (i.e. on the right when looking from impeller end) are just tight enough to hold the bearing assembly horizontal but not lock it down. 2. Loosen the FPLI puller stud nuts about 10 mm. Using the Pusher Bolts adjust the FPLI so it is flush with the Frame Plate Liner (043) as shown in Figure 7 Detail A. Now tighten the FPLI stud nuts and torque to the values specified in Table 1 on page 14. 3. Place Impeller on a solid flat surface hub side down. Clamp Impeller Lifting Beam (313) to Impeller using the Adjusting Screw *1. NOTE: Max. Torque on adjusting nut is 70 N-m (50 ft-lbs.) Lift the impeller to vertical position and apply anti-seize lubricant to the threads. Align impeller hub with shaft thread and slowly turn shaft while moving the impeller towards the Shaft to engage the threads. NOTE: Shaft wrench rotation shown is for a standard right hand impeller. With the Impeller Lifting Beam still in place, firmly strike the Shaft Wrench several times to seat the Impeller against the Shaft Sleeve. Remove lifting beam from Impeller by adjusting the lower wedge upward and lowering beam out of impeller eye. 4. Using the Axial Adjusting Nuts move the bearing assembly back until the Impeller is contacting the FPLI. Set the “BACK GAP” according to the pump size and number of impeller vanes in Table 3 by offsetting the front axial adjusting nut and washer as shown in Detail B. Move the bearing assembly forward until the lug hits the offset washer and nut. Torque the clamp bolts to the torque specified in Table 4.

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INSTALLING THROATBUSH AND COVER PLATE LINER (SIZES 250 THRU 350) (REFER TO FIGURE 8) 1. Strap the Throatbush (083) as shown in Figure 8 Detail A and lower it onto the lifting tool. Lift the Throatbush and install Throatbush Puller Studs and fully tighten.

2. Place the Cover Plate (013) bowl up on a flat solid surface and lower the Throatbush into the Cover Plate as shown in Figure 8 Detail B. Install a washer and nut to the puller studs from underneath the Cover Plate and fully tighten.

3. Install Cover Plate Liner Studs and tighten. Strap the Cover Plate Liner (018) as shown in Figure 8 Detail C and lower it into the Cover Plate and around the Throatbush. Install a washer and nut to the liner studs from underneath the cover plate and torque to the values specified on Table 1 on page 14.

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FITTING COVER PLATE TO FRAME PLATE (SIZES 250 THRU 350) (REFER TO FIGURE 9) 1. Install Alignment Pins (489) in the Frame Plate based on your discharge position. NOTE: See component diagram drawing for the location designation of the Alignment Pins.

2. Using a one point pick lift the Cover Plate sub-assembly to the vertical position as shown and install the Throatbush Pusher Bolts until hand tight.

3. Slowly move the Cover Plate toward the Frame Plate carefully lining up the Casing Alignment Pins with the mating holes in the Cover Plate. Insert the Cover Plate Bolts from the front of the Cover Plate as shown. Install a hex nut to each Cover Plate Bolt. NOTE: On some models the Cut-Water Bolt may be larger than the Cover Plate Bolts. Tighten to the torque specified in Table 5.

4. Apply a coating of liquid soap (or equivalent) to the Intake Joint Ring (060) (372) diameter with the seal beads. Push the Intake Joint Ring into the throatbush until it is seated against the Cover Plate counter bore. NOTE: Use a block of wood and rubber hammer to help install the Intake Joint Ring. Do not hammer directly on the Intake Joint Ring as it may distort the reinforcing plate of the seal. Apply a thin coat of silicone to the Discharge Joint Ring (132) and press into place on top of the discharge flange.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

INSTALLING THROATBUSH AND COVER PLATE LINER (SIZES 400 THRU 650) (REFER TO FIGURE 10) 1. Begin with the Throatbush (083) lying reinforcement side up as shown in Figure 10 Detail A. Install Throatbush Puller Studs into tapped holes in the reinforcement and fully tighten. 2. Install (3) clevises onto the lifting lugs of the Suction Cover (190). NOTE: For model size 400MCR pick 4 equally spaced tapped holes and install eye bolts for lifting. Lift and lower the Suction Cover onto the Throatbush being careful to line up the studs with untapped holes in the Suction Cover. Install a washer and nut to the Throatbush puller studs and tighten to the torque specified in Table 6. Leave clevises attached to Suction Cover at this time. 3. Place Cover Plate Liner (018) bowl down on the floor. TIP: Use blocks of wood inside the liner positioned under the reinforcement for support on larger sizes. Install (8) Cover Plate Liner Studs into tapped holes in reinforcement and fully tighten. Using a three point pick lift Cover Plate as shown in Figure 10 Detail B and lower it onto the Cover Plate Liner. Install a washer and nut to the Cover Plate Liner Studs and tighten to the torque specified in Table 6.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

FITTING SUCTION COVER TO COVER PLATE (SIZES 400 THRU 650) (REFER TO FIGURE 11) 1. Install (16) Suction Cover Studs into the tapped holes in the Cover Plate (013) and fully tighten. Install (4) Throatbush Pusher Bolts into the tapped holes in the Suction Cover (190) and tighten to 35 N-m (25 ft-lbs). 2. Lift and lower the Suction Cover onto the Cover Plate. IMPORTANT: Make certain the Liner Stud Nuts are inside the (8) clearance holes in the Suction Cover. Install a washer and nut to the Suction Cover Studs and tighten using a crossing pattern to the torque specified in Table 7. The clevises can now be removed from the Suction Cover. 3. Apply a coating of liquid soap (or equivalent) to the Intake Joint Ring (060) (372) diameter with the seal beads. Push the Intake Joint Ring into the throatbush until it is seated against the Cover Plate counter bore. NOTE: Use a block of wood and rubber hammer to help install the Intake Joint Ring. Do not hammer directly on the Intake Joint Ring as it may distort the reinforcing plate of the seal.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

FITTING COVER PLATE TO FRAME PLATE (SIZES 400 THRU 650) (REFER TO FIGURE 12) 1. Turn the Cover Plate (013) over using a two (2) point pick. Install two (2) Alignment Pins (489) in the Frame Plate based on your discharge position. NOTE: See component diagram drawing for the location of the Alignment Pins depending on discharge position.

2. Assemble Anti-Rotation Nuts (284) by hand fully onto Cover Plate Studs (015).

3. Using a two point pick lift the Cover Plate sub-assembly to the vertical position as shown. Slowly move the Cover Plate toward the Frame Plate carefully lining up the Casing Alignment Pins with the mating holes in the Cover Plate.

4. NOTE: Assemble the Anti Rotation Nuts onto the Cover Plate Studs by hand prior to installing in the Frame Plate. Insert the Cover Plate Stud with the Anti-Rotation nut assembled from the back of the Frame Plate as shown. Install a washer and nut to each Cover Plate Studs. Thread nuts on fully by hand before using impact wrench. NOTE: The Cut-Water Stud is larger than the Cover Plate Studs) Tighten the nuts using a crossing pattern to the torque specified in Table 8. Apply a thin coat of silicone to the Discharge Joint Ring (132) and press into place on top of the discharge flange.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

SETTING IMPELLER TO THROATBUSH CLEARANCE (SIZES 250 THRU 650) (REFER TO FIGURE 13) 1. Back the throatbush puller stud nuts off about 10 mm to allow the Throatbush to move towards the Impeller. Slowly rotate the Impeller clockwise with the Shaft Wrench. Pick two Throatbush Pusher Bolts 180 degrees apart and alternate tightening one bolt at a time so the Throatbush does not tilt and become locked in Suction Cover pilot. IMPORTANT: Tighten each bolt no more than 1-1/2 turns at a time. TIP: Mark a reference line on the O.D. of the socket to assist with the number of turns. Continue tightening the Pusher Bolts until the Impeller just starts to rub the Throatbush. NOTE: It should still be possible to turn the Impeller completely by hand when it starts to rub on the Throatbush. Do not adjust the Throatbush any further against the Impeller. Check the clearance with feeler gauges to verify it is uniform. 2. Back each of the Throatbush Pusher Bolts off by one fourth of a turn (one and a half flats of nut). NOTE: It is recommended to put a mark on one flat of each bolt to keep track of its original position. 3. Lock the Throatbush in place by tightening the Throatbush Puller Stud nuts to the torque specified in Table 1 on Page 14. NOTE: Check the clearance with feeler gauges to verify it is uniform. Check to make sure the Pusher Bolts are tight to 35 N-m (25 ft-lbs). NOTE: Before removing the Shaft Wrench make certain the Impeller turns freely. The Impeller to Throatbush clearance should now be set to 1 mm at front seal face.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

***IMPORTANT*** CENTERING STUFFING BOX (SIZES 250 THRU 650) (REFER TO FIGURE 14) ***Centering of the Stuffing Box is an essential step in the assembly of the pump; it assures that the Stuffing Box and the Shaft Sleeve are concentric to each other, thus extending the life of all components contained within the Stuffing box. 1. Slide the Stuffing Box (078) forward lining up the tapped holes in FPLI with holes in Stuffing Box. Place a washer and a bolt in stuffing box holes and hand tighten. NOTE: It may be necessary to lift the stuffing box up slightly to align holes. Slide the Lantern Restrictor (118) into the bottom of the stuffing box bore. 2. Position the Stuffing Box Centering Tool (331) over the Shaft Sleeve (076) and slide the tool in the stuffing box bore as shown in Figure 14. NOTE: The three alignment pins should be able to rotate and rattle. Fully tighten each of the stuffing box bolts to the torque specified in Table 9. IMPORTANT: Tighten the bolts at the bottom of the Stuffing Box first. 3. The Stuffing Box is now concentrically located about the Shaft Sleeve. Remove the Stuffing Box Centering Tool and store for a future re-build event. Jackscrew holes on centering tool may need to be used to help with removal.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

STUFFING BOX ASSEMBLY (SIZES 250 THRU 650) (REFER TO FIGURE 15)

1. Fit (1) Packing Ring (111) around Shaft Sleeve (076) and push into the bottom of the Stuffing Box (078). NOTE: Install packing rings with the red dots either against the shaft or on the outside as shown in Detail A.

2. Repeat step 1 with (3) additional Packing Rings. NOTE: Stagger packing joints 180 degrees.

3. Assemble the two piece Gland (044) around the Shaft Sleeve. Install the Gland Bolts and tighten only enough to assure Packing Rings are seated in the Stuffing Box bore. NOTE: The Gland Bolts should be backed off and hand tight for start-up.

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Weir Minerals North America | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (SIZES 250 THRU 650)

WARMAN BASIC PART NUMBER AND PARTS LIST PUMP ASSEMBY TOOLS 302 FPLI Lifting Beam 306 Shaft Wrench 309 Suction Cover Lifting Beam 313 Impeller Lifting Beam 318 Frame Plate Liner Insert/Throatbush Lifting Tool 330 Shaft Sleeve Assembly Guide 331 Stuffing Box Centering Tool BASIC PART NUMBER 001 Adjusting Screw 003 Base 005 Bearing Assembly 011 Clamp Washers / Clamp Pad 012 Clamp Bolts 013 Cover Plate 018 Cover Plate Liner 032 Frame Plate 039 Frame Plate Studs 041 Frame Plate Liner Insert 043 Frame Plate Liner 044 Gland 045 Gland Bolt 060 Intake Joint Ring 062 Labyrinth 070 Shaft Key 073 Shaft 076 Shaft Sleeve 078 Stuffing Box 083 Throatbush 109 O-Ring 111 Packing 118 Lantern Restrictor 132 Discharge Joint Ring 145 Impeller – 4 Vane Closed 147 Impeller – 5 Vane Closed 190 Suction Cover 205 Bearing Assembly (Reverse Rotation) 221 Discharge Flange 239 Impeller Release Collar 257 Discharge Seat Ring 394 Cover Plate Reverse Rotation 395 Frame Plate Reverse Rotation 489 Alignment Pin

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