Warman Supplement MDS28 400-760 MCR-M

WARMAN® ASSEMBLY INSTRUCTIONS Model MCR-M Mill Circuit Pumps (Sizes 400 thru 760) With M-Style Bearing Assemblies

Copyright © 2014, 2014 Weir Slurry Group, Inc. All rights reserved. WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; CAVEX, HAZLETON, AH, WRT, WBH, WGR and MULTIFLO are registered trademarks of Weir Minerals Australia Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda.; LINATEX is a registered trademark of Linatex Ltd; SENTINEL is a registered trademark of Weir Slurry Group, Inc.; MC, MCR and MCU are trademarks of Weir Slurry Group, Inc.; WEIR is a registered trademark of Weir Engineering Services Ltd. Certain features of some of the products featured in this publication are protected worldwide by patents pending and registered.

Office Of Origin: Date:

Madison, Wisconsin 01.14.2014

References: Document Number:

MDS28 A702088_00

Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Table of Contents PREFACE

1

INTRODUCTION AND SAFETY

2

Marking and Approvals......................................................................................................... 2 Safety ................................................................................................................................... 2 Explanation of safety terminology and symbols .................................................................... 2 GENERAL GUIDELINES

3

Personnel qualification and training ...................................................................................... 4 Safety actions....................................................................................................................... 5 ASSEMBLY INSTRUCTIONS / REQUIRED DOCUMENTS

8

Bearing Assembly - Maintenance & Assembly Instructions .................................................. 8 Parts Identification ................................................................................................................ 8 FRAME ASSEMBLY

9

Fitting Shaft Sleeve and Frame Plate Adaptor to Bearing Assembly .................................... 9 GLAND ASSEMBLY

11

Installing Impeller O-ring, Lantern Restrictor and Stuffing Box to Shaft ...............................11 Installing 2 Piece Stuffing Box to Shaft ................................................................................12 PUMP ASSEMBLY

13

Installing Frame Plate Liner Insert to Frame Plate (Sizes 400 thru 650) ..............................13 Installing Frame Plate to Frame Plate Adaptor (Sizes 400 thru 650) ...................................14 Installing FPLI to Frame Plate Adaptor & assembling to Frame Plate..................................15 Installing Frame Plate to Frame Plate Adaptor (Sizes 750 & 760) .......................................16 Installing Volute Liner to Frame Plate ..................................................................................17 Installing Clamp Ring segments to Volute Liner (Size 760) .................................................18 Installing Impeller to Shaft and Setting Back Gap ................................................................21 Installing Throatbush to Suction Cover ................................................................................21 Installing Suction Cover Sub-Assembly to Cover Plate........................................................23 Installing Volute Liner Spacer Ring to Cover Plate (Size 760) .............................................23 Installing Cover Plate to Frame Plate ..................................................................................25 Setting Impeller to Throatbush Clearance ...........................................................................26 Centering Stuffing Box ........................................................................................................27 Stuffing Box Assembly ........................................................................................................28 WARMAN BASIC PART NUMBER AND PARTS LIST Pump Assembly Tools.........................................................................................................29 Basic Part Number ..............................................................................................................29

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PREFACE To insure long, trouble-free service from your Warman® Product, the instructions contained in this manual must be carefully followed. When ordering spare parts, it is advisable to provide the product model, serial number, part description, and complete part number. We reserve the right to make changes or improvements in design or constructions. For information not covered in this manual, contact: Customer Service Department Weir Slurry Group Inc. 2701 South Stoughton Road P.O. Box 7610 Madison, Wisconsin 53707-7610 Telephone: (608) 221-2261 Fax: (608) 221-5809

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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.

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This symbol indicates safety instructions where non-compliance may result in minor or moderate personal injury and/or damage to the equipment or property. 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 must be read and clearly understood 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. 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 accessories sourced from other vendors, the incorrect incorporation of such parts and

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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 in which the pump has been selected. 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.

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Safety actions 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. 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 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 ANY SURFACE OF THE IMPELLER 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 ATTEMPT TO START 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.

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DO NOT OPERATE THE PUMP if solids have settled and the rotating element cannot 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 rotation by viewing the direction of the motor or gearbox output shaft only. DO NOT START A PUMP in reverse rotation or when pump is rotating in reverse, such as the backward rotation caused by slurry runback. Personal injury and damage to equipment could result. 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 before removing any protective guarding. 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 eyebolts) 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.

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DO NOT APPLY HEAT TO 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 will lead to catastrophic component 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. 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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Assembly Instructions / Required Documents Supplement 'MDS28' should be read in conjunction with the following Warman Assembly and Maintenance Instruction Supplements: M1 - General Instructions applicable to ALL TYPES of Warman Pumps NOTE: The recommended grease for grease-lubricated assemblies is Mobil SHC 220 or equivalent. They also 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 Metal Lined Mill Circuit pumps 400 thru 760 MCR-M on “M” style bearing frames.

Bearing Assembly - Maintenance & Assembly Instructions The Bearing Assembly is assembled and maintained according to the instructions contained in Warman Supplement MDS14.

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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FRAME ASSEMBLY Fitting Shaft Sleeve and Frame Plate Adaptor to Bearing Assembly (FIGURE 1 & 2) IMPORTANT: Apply an anti-seize lubricant to threads of any bolts, studs, or nuts. NOTE: For detailed instruction on installing the Release Collar for all sizes refer to Warman Supplement MDS14. 1. Make certain the Release Collar Cover O-ring is in place as shown in Figure 1. Apply anti-seize to the Shaft surface extending from the Release Collar Cover and slide the pump Shaft Sleeve (076) on the Shaft, tapered edge first, until it slides past the Release Collar Cover O-Ring and seats against the Release Collar Wedges. IMPORTANT: Make certain that the Shaft Sleeve is installed on the shaft with the tapered end facing towards the Release Collar or the wedges will not reset properly. TIP: If Shaft Sleeve will not slide easily under Release Collar Cover O-Ring, apply a small amount of vacuum grease to Shaft Sleeve O.D. and gently tap into place with a rubber mallet.

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2. Clean the machined surfaces on the Frame Plate Adaptor (380) and Bearing Housing (004) and apply light coat of anti-seize lubricant to these surfaces. IMPORTANT Remove any paint that may be present on these machined surfaces. Liberally apply anti-seize lubricant to shaft threads to prevent moisture damage to shaft. 3. While lining up the mounting holes in the Frame Plate Adaptor with the tapped holes in the Bearing Housing, insert eight (8) Bearing Housing Adaptor Bolts as shown in Figure and hand tighten. IMPORTANT: Fully tighten Bearing Housing Adaptor Bolts using a crossing pattern to the torque specified in Table 1.

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GLAND ASSEMBLY Installing Impeller O-ring, Lantern Restrictor and Stuffing Box to Shaft (FIGURE 3 & 4) 1.

Stretch Impeller O-Ring over shaft and slide it into the groove on the end of Shaft Sleeve (076).

2.

Install Lantern Restrictor (118) over Shaft Sleeve as shown in Figure 3 Detail A. IMPORTANT: Install Lantern Restrictor with radial flush holes facing bearing assembly and slide it as far back on the shaft as possible. NOTE: Larger size models will have two (2) O-Rings on the O.D. of the Lantern Restrictor to assist with centering it inside the Stuffing Box as shown in Figure 3 Detail B.

NOTE: For installation of 2-piece Stuffing Box refer to Figure 4 on page 12. 3.

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 2 Piece Stuffing ✓ Box to Shaft (FIGURE 4) 1. Assemble eye bolts into the lifting lugs on both halves of the Stuffing Box. Lift both halves with separate cranes until they hang vertical as shown in Figure 4 Detail A. Liberally apply a bead of silicon calking into the machined grooves on each half. Insert four (4) shoulder bolts into one half. Continue to move the two halves toward each other carefully lining up the shoulder bolts with the mating holes on the other half. Install a washer and nut to the bolts and tighten to 120 N-m (90 Ft-Lbs). Lower the assembled Stuffing Box to the floor. 2. Using a single crane and a two point pick slide Stuffing Box (078) onto Shaft Sleeve and slide it back until the Lantern Restrictor is inside the Stuffing Box bore. Remove the eye bolts from the Stuffing Box. IMPORTANT: Rotate the Stuffing Box until the tapped gland water connection is at the 12 O’clock position. 3. Note: As an option the Stuffing Box halves can be installed and removed through the openings in the side of the Frame Plate Adaptor (380).

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PUMP ASSEMBLY Installing Frame Plate Liner Insert to Frame Plate (Sizes 400 thru 650) (FIGURE 5) 1. Place the Impeller hub side up on the floor. Place the Frame Plate Liner Insert (041) (FPLI) tapped holes side up centered on top of the Impeller as shown in Figure 5. 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)(395) 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 Frame Plate Liner Studs and tighten to the torque specified in Table 2.

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Installing Frame Plate to Frame Plate Adaptor (Sizes 400 thru 650) (FIGURE 6) 1. Using a two (2) point pick lift the Frame Plate (032)(395) to the vertical position as shown in Figure 6. Install the FPLI Pusher Bolts into the tapped holes in the Frame Plate and tighten to 35 N-m (25 Ft-Lbs). 2. Thread the Frame Plate Adaptor Studs into the Frame Plate and fully tighten. Note: Model 650 thru 760 have a hex on the end of the stud to assist with assembly as shown in Detail A. Slowly move the Frame Plate towards the base being careful to line up the studs with the holes in the Frame Plate Adaptor. Make certain that the pilot in the Frame Plate has engaged the pilot in the adaptor. Install a hex nut and washer to the studs. IMPORTANT: Fully tighten Frame Plate Adaptor Stud nuts using a crossing pattern to the specified torque in Table 3. 3. Insert Shaft key (070) and attach the Shaft Wrench (306) as shown in Figure 6.

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Installing FPLI to Frame Plate Adaptor & assembling to Frame Plate (Sizes 750 & 760) (FIGURE 7) 1. Begin with the Frame Plate Liner Insert (041) (FPLI) lying reinforcement side up as shown in Figure 7 Detail A. Install FPLI Puller Studs into tapped holes in the reinforcement and fully tighten. Install the Stuffing Box Seal (121) into the I.D. of the Frame Plate Liner Insert. NOTE: If you are installing a rubber FPLI (R55) you will not need to install the Stuffing Box Seal. 2. Position the Adaptor Plate flat side down on the floor. Pick 4 equally spaced tapped holes and install eye bolts as shown in Detail A. Lift and lower the Adaptor Plate onto the FPLI being careful to line up the studs with untapped holes in the Adaptor Plate. Install a washer and nut to the FPLI puller studs and tighten to 1000 N-m (750 Ft-Lbs) Leave the eye bolts in the Adaptor Plate for now. 3. Install (16) Casing Studs into the tapped holes in the Frame Plate (032)(395) and fully tighten. Install (4) FPLI Pusher Bolts into the tapped holes in the Adaptor Plate and tighten to 35 N-m (25 Ft-Lbs). 4. Note: The (2) cast lifting lugs must be at the 12 O’clock position depending on your required discharge orientation. This is required for the quick change out procedure detailed in MDS25. Top vertical discharge orientation is shown in Figure 8. Lift and lower the Adaptor Plate onto the Frame Plate. Install a washer and nut to the Casing Studs and tighten using a crossing pattern to the torque specified in Table 4. Remove the eye bolts from the Adaptor Plate.

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Installing Frame Plate to Frame Plate Adaptor (Sizes 750 & 760) (FIGURE 8) 1. Using the hex on the end of the Frame Plate Studs (039) thread the studs into the tapped holes in the Adaptor Plate and fully tighten. 2. Slowly move the Frame Plate sub-assembly towards the Frame Plate Adaptor (380) being careful to line up the studs with the holes in the adaptor. Make certain that the pilot in the Adaptor Plate has engaged the pilot in the Frame Plate Adaptor. Install a hex nut and washer to the studs. IMPORTANT: Fully tighten Frame Plate Stud nuts using a crossing pattern to 2400 N-m (1700 Ft-Lbs). 3. Insert Shaft key (070) and attach the Shaft Wrench (306) as shown in Figure 8.

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Installing Volute Liner to Frame Plate (FIGURE 9, 10 & 11) NOTE: Apply anti-seize lubricant to all fasteners and machined surfaces of item *4 and *5 before fitting. NOTE: For size 760 the Volute Liner must be equipped with a Clamp Ring on the frame plate side, if not already installed see Page 18 Figure 9 for installing the Clamp Ring segments (376FP) to Volute Liner before proceeding with this section. 1. Place the Volute Liner (110) cover plate side up on a flat solid surface. Align Volute Liner Lifting Beam (304) between the cast alignment bars in accordance with your selected discharge position. The upper hook *1 (see Figure 10) should be positioned between the alignment bars. 2. Install upper hook *1 under the Volute Liner edge. Do not tighten upper hook jacking bolt *2. NOTE: Be certain both the upper and lower bumper blocks *3 are in contact with the machined face of the volute liner. 3. Position lower hook *4 at the maximum distance through the center of the machined bore on the volute liner. Check beam position by measuring perpendicular from beam edges across the diameter of the machined bore as shown in Figure 10. Install the jacking wedge *5 and tighten lower hook jacking bolt *6. Then tighten the lower hook jacking bolt *7. Finally tighten upper hook jacking bolt *2. NOTE: When properly installed items 1 & 4 should contact the machined bore of the volute. There should not be visible gaps between the contacting surfaces. Maximum torque on all lifting beam nuts and bolts is 70 N-m (50 Ft-Lbs.) 4. Tighten the lifting beam locking bolts *8 until snug against the Volute Liner, they will straddle the cast alignment bars. 5. Lift Volute Liner to vertical position as shown in Figure 11 and insert (8) Volute Liner Studs into tapped holes and fully tighten. NOTE: Install 8 studs on frame plate side only. The cover plate side is drilled and tapped for reverse rotation. 6. Align Volute Liner Studs with Frame Plate holes and move the Volute Liner into the Frame Plate so that the O.D. of the Frame Plate Liner Insert engages with the I.D. of the Volute Liner. 7. Fit (1) washer and (1) nut onto Volute Liner Studs and tighten to 200 N-m (150 Ft-Lbs.) 8. Remove lifting beam by loosening the lifting beam locking bolts *8 and upper hook jacking bolt *2. Loosen lower hook jacking bolts *6 & *7 and remove jacking wedge *5. Remove the lower hook *4 and remove lifting beam. (See Figure 10) NOTE: For sizes 750 and 760 install the Volute Liner Seat Ring (257) with tape around the volute liner discharge flange as shown in Figure 10 Detail A.

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Installing Clamp Ring segments to Volute Liner (Size 760) (FIGURE 9) 1. Place the Volute Liner (110) frame plate side up on a flat solid surface. 2. Thread the timing set screw into one of the tapped thru holes in the Clamp Ring segments (376FP) until it protrudes 6mm (1/4”) out the bottom of the segment as shown in Figure 9 Detail A. 3. Align the set screw with the timing slot in the Volute Liner and slide the segment into the slot as shown in Figure 9 Detail B. NOTE: There should be an air gap between the end of the set screw and the volute liner timing slot as show in Figure 9 Detail B. 4. Assemble the remaining (3) segments around the Volute Liner. Insert the Clamp ring Bolts into the segments and hand tighten. 5. Make a final check to ensure the timing set screw is still in the timing slot and torque the Clamp Ring Bolts to 200N-m/150Ft-Lbs. 6. Turn the Volute Liner over and proceed to the previous section on Installing Volute Liner to Frame Plate.

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PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Installing Impeller to Shaft and Setting Back Gap (FIGURE 12) 1. Loosen the FPLI Puller Stud nuts about 10 mm. Tighten the Pusher Bolts adjusting the FPLI so it is flush with the Frame Plate Liner (043) as shown in Detail A below. Now tighten the FPLI stud nuts and torque to the values specified in Table 5. 2. Place Impeller on a solid flat surface hub side down. Clamp Impeller Lifting Beam (313) to the impeller using the adjusting nut. NOTE: Max. Torque on adjusting nut is 70 N-m (50 Ft-Lbs.) Using a one (1) point pick, lift the impeller to vertical position and apply antiseize lubricant to the threads. NOTE: Make certain that the Impeller O-ring is installed and still in place as described on Page 11 (Figure 3) before proceeding. 3. Align impeller hub with shaft thread and turn shaft by means of the shaft wrench to screw into 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 turning the adjusting nut and moving the lower wedge upward, lower the beam out of impeller eye. 4. Measure and confirm the “BACK GAP” at impeller O.D. from pump size in Table 6.

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Installing Throatbush to Suction Cover (FIGURE 13) 1. Begin with the Throatbush (083) lying reinforcement side up as shown in Figure 13. 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 7. Leave clevises attached to Suction Cover at this time.

01/14/2014

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Installing Suction Cover Sub-Assembly to Cover Plate (FIGURE 14) 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. Install a washer and nut to the Suction Cover Studs and tighten using a crossing pattern to the torque specified in Table 8. 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.

01/14/2014

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Installing Volute Liner Spacer Ring to Cover Plate (Size 760) (FIGURE 15) NOTE: Size 760 must have a Volute Liner Spacer Ring (376CP) installed into the Cover Plate (013). If not already installed follow the steps below for installation of the spacer segments. 1.

Install (8) M36 Spacer Ring Studs into the tapped holes in Spacer Ring Segments (376CP) and fully tighten, there will be (2) studs per segment.

2.

Install the segments as shown below and torque the hex nuts to 270 N-m/200 Ft.-Lbs.

01/14/2014

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Installing Cover Plate to Frame Plate (FIGURE 16) 1. 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. 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 9. Place the Discharge Joint Ring (132) on top of the Volute Liner.

01/14/2014

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Setting Impeller to Throatbush Clearance (FIGURE 17) 1. Back the Throatbush Puller Stud Nuts off about 15mm to allow the Throatbush to move towards the Impeller. 2. Slowly rotate the Impeller in the direction of rotation during operation 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 Cover Plate 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. 3.

Back each of the 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.

4. Lock the Throatbush in place by tightening the Throatbush Puller Stud Nuts to the torque specified in Table 7 in on Page 22. NOTE: Check the clearance with feeler gauges to verify the gap uniform. Check to make sure the Pusher Bolts are tight to 35 N-m (25 FtLbs). 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

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Centering Stuffing Box (FIGURE 16)

***IMPORTANT*** ***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 pins into the stuffing box bore as shown in Figure 16. NOTE: The three alignment pins should be able to rotate and move freely before inserting into the stuffing box. Fully tighten each of the stuffing box bolts to the torque specified in Table 10. 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. The tapped jackscrew holes on centering tool may need to be used to help with removal.

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

Stuffing Box Assembly (FIGURE 17) 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.

01/14/2014

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Weir Minerals

PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR-M (SIZES 400 THRU 760)

WARMAN BASIC PART NUMBER AND PARTS LIST Pump Assembly Tools 302 304 306 309 313 331

Frame Plate Liner Insert Lifting Beam Volute Liner Lifting Beam Shaft Wrench Suction Cover Lifting Beam Impeller Lifting Beam Stuffing Box Centering Tool

Basic Part Number 004 005 013 032 041 044 045 060 070 073 076 078 083 109 111 118 121 132 145 147 190 205 239 380 394 395 397 451 489 532

Bearing Housing Bearing Assembly Cover Plate Frame Plate Frame Plate Liner Insert Gland Gland Bolt Intake Joint Ring Shaft Key Shaft Shaft Sleeve Stuffing Box Throatbush Shaft Sleeve O-Ring Packing Lantern Restrictor Stuffing Box Seal Discharge Joint Ring Impeller – 4 Vane Closed Impeller – 5 Vane Closed Suction Cover Bearing Assembly (Reverse Rotation) Impeller Release Collar Frame Plate Adaptor Cover Plate (Reverse Rotation) Frame Plate (Reverse Rotation) Impeller 5 Vane Closed (Reverse Rotation) Impeller 5 Vane Closed (Reverse Rotation) Alignment Pin Throatbush (Reverse Rotation)

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