Starting the motor with incorrect rotation can cause the impeller to come loose from the pump shaft and crack the housing, which can cause personal injury. With the pump disconnected from the motor, check that the motor rotates correctly according to section 5.2. Never heat the runner when removing it from the pump shaft, as there is a risk of the runner exploding due to trapped fluid, which can cause serious injury.
The mass of the foundation is at least 3 times greater than the mass of the pump/drive assembly. The motor and pump spindle must be properly aligned and the belt properly tensioned. It is also recommended that a removable section of pipe of sufficient length be installed on the suction side of the pump.
It is important to verify that the motor rotation is correct and this verification is performed with the motor disconnected from the pump. Starting the motor with the wrong torque can cause the impeller to come off the pump shaft, which could cause personal injury. Gland water should be available at a pressure of 10 psi. maximum) above the pump discharge pressure.
The gland follower should be set to allow a small flow of gland water along the shaft while the pump is running.
C MECHANICAL SEAL
Before the pump is shut down, it must be allowed to run for a short period on clean water to remove the solids from the pump and clear the system. If a drain valve is fitted in the suction line, this must be left open while the pump is not in use. If the pump is to be taken out of service for some time, check Section 8 for proper storage procedure.
HANDLING OF RUBBER COMPONENTS
HANDLING OF MECHANICAL COMPONENTS
A BEARING ASSEMBLY
Place two lifting eyes on one end of the cap (in opposite end cap bolt holes) and lower on the axle until all weight is on the bearing cone. Heat the other bearing cone to 104°C (220°F) using an induction heater and drop it on the small diameter shaft against the bearing cup, then tap it down into position against the cup. Mount a dial indicator on the bottom of the housing with the actuation pin on the bottom of the shaft.
NOTE: Before adjusting the indicator, make sure that the end of the shaft is free of dirt and burrs). To reduce the distance, hold the weight with the shaft on the floor and hit the bearing with the shaft. For more clearance, transfer the weight to the housing and punch the shaft through the bearing.
After that, pump grease through both grease nipples into the bearing until the grease that was packed between the rollers starts to push out. Place the unit on its side, (preferably on a pedestal) and remove the retaining nut from the spindle thread, followed by the spacer. Apply a layer of silicone to the edges of the housing, followed by the end cap.
Fit a dowel pin in the hole on the face of the second flake and slide it into place, small O.D. Insert the rocker pin into one of the slots of the lock nut and tighten against the bearing. Install the bearing lock washer flat end first onto the drive end of the shaft, aligning the inner tab with the keyway and against the installed lock nut.
Locate the second lock nut on the lock nut threads with the flat face out and tighten securely in place. Bend one of the lock washer's angled tabs into a slot on the other lock nut.
B BEARING ASSEMBLY TO PEDESTAL
GLAND SIDE CASING AND SHAFT PREP
Install the shaft seal O-ring, bushing spacer O-ring, or gasket (23) (whichever is appropriate for the pump you are assembling) on the shaft against the mudguard. If a sleeve spacer (22) is required, install it on the shaft, followed by the shaft seal O-ring or other sleeve spacer seal (23).
GLAND ARRANGEMENT
A CENTRIFUGAL SEAL
Place the first ring of gasket (26) around the axle bushing and into the bore of the drive ring. Fully fill the lantern ring (34) with grease to reduce grease gun application required at start-up, then insert the lantern ring over the shaft bushing and slide it down against the gasket. Insert the remaining packing rings with the end gaps offset on opposite sides of the bore and press down evenly.
Tighten the 3 stuffing box bolts evenly until they press the washers against the gland. Present the stuffing box in such a way that the shaft sleeve (27) slides over the impeller shaft. Place the shaft seal O-ring or gasket on the end of the shaft, against the shaft sleeve.
Install the actuator (32) onto the shaft with the actuator vanes positioned against the actuator ring (33).
B WATER FLUSH SEAL
Insert the stuffing box screws (18) with washers (17) into the stuffing box (24) and tighten evenly until the stuffing box screws contact the gland, but only hand-tight. Some pumps use studs instead of screws and the stuffing box follower is installed in the same manner as the centrifugal seal in 10.2.A.
C MECHANICAL SEAL
GLAND SIDE CASING LINER
IMPELLER
SUCTION SIDE CASING ASSEMBLY
Install washers (3) and nuts (9) on the studs and tighten evenly to fully seat the suction side housing liner into the suction side housing. Install wear ring screws (31) into the tapped holes of the suction liner until they are flush with the bottom of the metal insert in the suction liner. Install the wear ring (25) into the formed ribbed groove of the suction liner, with the studs and screws in the suction liner facing down.
Push the wear ring into the suction tube until it is fully seated and the flat surface of the wear ring is flush with the raised ring of the suction tube. Lubricate the taper OD suction lining and the taper ID lining of the suction side housing (4) with glycerine, soap or an approved rubber lubricant. Install the intake liner with wear ring into the intake side casing liner by fitting the tapered OD of the intake pipe with the tapered ID of the intake side casing liner.
Rotate the intake liner until the studs line up with the smaller drilled holes in the intake side housing (6) and the wear ring bolts (31) line up with the larger drilled holes in the intake side housing. Install washers (3) with nuts (9) on intake manifold studs through intake side housing and tighten evenly to fully seat intake liner into intake side housing liner. After tightening the nuts, the intake pipe should be flush or slightly offset with the casing lining on the intake side at their mating surfaces.
ASSEMBLY OF SUCTION SIDE CASING TO GLAND SIDE CASING
IMPELLER ADJUSTMENT
Adjust until the impeller is in contact with the wear ring and the reverse adjusting screw to move the impeller 1.5 mm (0.06”) from the wear ring. Tighten the clamp bolts and rotate the impeller by hand to ensure that it turns easily.
ROUTINE MAINTENANCE
WEAR RING ADJUSTMENT
SHAFT SEAL ADJUSTMENT .A CENTRIFUGAL SEAL
B WATER FLUSH SEAL
BEARING LUBRICATION
Consult FLSmidth Krebs for speeds greater than those listed in the chart above for synthetic grease lubricants. There is no substitute for establishing baseline readings after startup such as vibration and temperature and then regularly monitoring them for changes in these readings to indicate a need for attention to the bearings. The grease nipples fitted to the bearing housing end caps are for lubrication of the lip seal and crank area and provide a grease barrier to prevent slurry and/or gland water from entering the bearings.
It must be lubricated daily so that clean grease ejects from the edge of the flinger. For dirty environments common in coal applications, or in the case of an excessively leaking gland seal, the frequency of lubrication should be halved regardless of the bearing's operating temperature. New bearing assemblies are pre-greased at the factory, but additional grease must be added when starting.
In general, most slurryMAX XD part replacement procedures are straightforward and reverse installation.
IMPELLER
To allow the fan to be easily unscrewed, the release collar must be removed before unscrewing the fan. Using a metal rod, strike the flat edges on the release collar segments to drive them out between the sleeve spacer (22) and crank. Tapped holes the same size as the socket head cap screws are provided to help push out the segments if necessary.
There are punch marks on the flat surface of two of the three segments of the release collar. It is important to assemble the release collar segments with the hole marks together as shown below. It may be necessary to install the release collar on the shaft with screws loose before final torque is applied.
Fill the slot head cap screw cutout with silicone sealant to prevent moisture from contacting these connectors and contaminating the threads. Shim OD on gland side bushing if necessary to provide air gap between axle sleeve OD and exhaust ring ID or headlight bushing.
ON INITIAL START-UP
DURING OPERATION
