METSO MINERALS

621 So. Sierra Madre - P.O. Box 340

Colorado Springs, Colorado 80901
(719) 471-3443 FAX (719) 471-4469

Pumps & Process

TO: FIMA S.A.
CA SILLA, 3837 DATE: 14 December 2006
LIMA 1, PERU
PAGE: 1 OF 1
ATTN: JOSE RIOS

METSO REF: 195300001

YOUR REF: 12695-31
FINAL CUST:

IDENT. NUMBER DESCRIPTION CODE TYPE QTY

METSO DENVER ORION HARD METAL PUMP 3 X 2 X 10

INSTALLATION, OPERATION & MAINTENANCE MANUAL F I 1
CONSISTING OF:
30-400 MACHINE INSTRUCTIONS
SEC 3.5 LUBRICATION INSTRUCTIONS
D37640 (general) GENERAL ARRANGEMENT (03X195300001 not available for
this order)
D92400 ASSEMBLY
D92094 BEARING SHAFT ASSEMBLY
--- PARTS LIST
--- PUMP PERFORMANCE CURVE

CODE:
I - Information Only. RA - Returned Approval.
C - Certified Prints. RC - Returned Certified.
F - Final Prints. P - Preliminary Prints. Not for construction.
A - Approval Prints. Your approval is required. Please return approvals within 2 weeks - Delays in return will extend equipment delivery.
TYPE:
D - Full Size Print X - Reduced Print R - Reproducible M - Mylar E - Electronic Copy
I - Instruction B - Bulletin C - Copy A - Aperture Card

REMARKS: SENT VIA E-MAIL & DHL

DISTRIBUTION:
Repair Order File
Eng. Order File
Purchasing REP: K ADAMS / HT
Other:

Form No. 4.947 Rev. 5/97

 METSO MINERALS 3 X 2 X 10 ORION PUMP
INSTALLATION, OPERATION & MAINTENANCE
INSTRUCTION MANUAL

METSO REF: 195300001

YOUR REF: 12695-31
 30-400
Revised FEB. 2002

Pumps & Process

METSO MINERALS ORION ™

NON-MODULAR PUMP
FRAME C • D • E

Installation, Operation
&
Maintenance Instructions

METSO MINERALS Industries, Inc.

Pumps & Process Division
621 S. Sierra Madre (80903) • P.O. Box 340
Colorado Springs, CO 80901
Tel: (719) 471-3443 • Fax: (719) 471-4469
 TABLE OF CONTENTS
I. INTRODUCTION....................................................................................i

II. WARRANTIES .......................................................................................ii

III. SAFETY...................................................................................................iii

IV. SECTION 1--INSTALLATION............................................................... 1

1.1 MOUNTING..................................................................................... 1
1.1.1 CONCRETE MOUNTING ................................................... 1
1.1.2 STEEL FRAME MOUNTING.............................................. 1
1.2 PIPING ............................................................................................. 1
1.2.1 SUCTION & DISCHARGE.................................................. 1
1.2.2 GLAND FLUSH PIPING & FLOWS................................... 2

V. SECTION 2--OPERATION.................................................................... 4

VI. SECTION 3--MAINTENANCE.............................................................. 7

3.1 INSPECTION AND ADJUSTMENT FOR WEAR....................... 7
3.1.1 CHECKING THE EFFICIENCY OF PUMP ...................... 7
3.1.2 WETTED PARTS LIST ....................................................... 8
3.2 ADJUSTING PUMP FOR WEAR ................................................. 8
3.3 VISUAL INSPECTION ...................................................................10
3.4 INSPECTING WETTED PARTS ..................................................12
3.5 LUBRICATION................................................................................13
3.6 TROUBLE-SHOOTING..................................................................14
3.7 ASSEMBLY-DISASSEMBLY........................................................15
3.7.1 LABYRINTH BEARING SEAL ASSEMBLY.....................15
3.7.2 PISTON RING BEARING SEAL ASSEMBLY..................19
3.8 GLAND SEAL ASSEMBLY...........................................................24
3.8.1 CENTRIFUGAL SEAL ........................................................24
3.8.2 FULL FLOW SEAL..............................................................24
3.8.3 LOW FLOW SEAL...............................................................24
3.8.4 MECHANICAL SEAL ..........................................................26
3.8.5 VACUUM SEAL...................................................................26
3.9 FRAME ASSEMBLY......................................................................27
3.10 PUMP ASSEMBLY.......................................................................29

VII. SECTION 4--ILLUSTRATION AND PARTS.......................................32

VIII. SECTION 5--STORAGE .......................................................................40

IX. APPENDIX A ..........................................................................................42

PARTS DESCRIPTION
BOLT TORQUE CHART
 INTRODUCTION
Your new METSO MINERALS ORION TM pump has been designed and
manufactured to perform for many years with a minimum of maintenance. However,
as with any machine, parts will wear and need replacing. The time between
maintenance periods will greatly depend on you, the end user.

This manual has been written to help you minimize your maintenance and
speed repairs when required. Read and understand this manual.

In the back of the manual you will find a TECHNICAL DATA SHEET. Most of
this sheet will be filled in at METSO MINERALS Pumps & Process before the pump is
shipped. However, there may be sections that are left blank. It is advisable to fill in
these sections for future reference.

ALL PUMPS ARE NOT CREATED EQUAL

WHEN ORDERING PARTS ALWAYS REFER TO THE PUMP SERIAL NUMBER.
THIS NUMBER IS FOUND ON THE NAME PLATE ON THE PUMP AND ON THE
TECHNICAL DATA SHEET OF THIS MANUAL.

ALL BOLT AND THREADS ON THIS PUMP ARE METRIC

i
 WARRANTIES
1) WARRANTIES--Seller warrants that the products covered by this contract
conform to applicable drawings and specifications accepted in writing by Seller,
will be free from defects in material and workmanship, will be merchantable and
will perform in accordance with the detailed specifications accepted in writing by
Seller. These warranties extend for a period of twelve (12) months from the
date of installation or eighteen (18) months from the date of shipment,
whichever occurs first. Buyer's exclusive remedy and Seller's sole duty under
these warranties is to repair or replace the product. Normal wear and tear on
Seller's product shall not constitute a warranty defect. THERE ARE NO
OTHER WARRANTIES, EXPRESS OR IMPLIED, WHICH EXTEND BEYOND
THOSE SET FORTH ABOVE. THE WARRANTY OF MERCHANTABILITY IS
LIMITED TO THE TIME PERIOD SPECIFIED ABOVE. These warranties are
contingent upon the product being stored, installed, maintained, and operated in
accordance with good engineering practices and the instructions contained in
the Operating and Maintenance Manual.

2) LIMITATION ON LIABILITY--Seller's total responsibility for damages whether

arising in contract or tort arising out of or relating to its performance of this
contract or the products covered hereunder shall be limited to the contract price
for the product. In no event shall Seller be liable for any incidental or
consequential damages such as lost profits, loss of use of productive facilities or
equipment, expenses or damages incurred in reliance on Seller's performance
hereunder or lost production whether suffered by Buyer or any third party.
Nothing in this paragraph shall in any way be construed to affect the liability
Seller may have for personal injury or death of any third party.

3) MISCELLANEOUS--Seller will be responsible for compliance with federal, state

and municipal laws, codes and regulations relating to the manufacture of the
products. Seller warrants that the products comply with OSHA standards on
drive guard design and construction in effect at the time of manufacture and
makes no other warranty with respect to any other OSHA standards. Seller
shall not be responsible for failure of parts to fit properly due to deterioration of
or modification to Buyer's existing equipment for which such parts are furnished.
Seller makes no warranty or guarantee that the equipment or parts supplied
hereunder will comply with any existing performance of Buyer's equipment.
Seller reserves the right to furnish substitutes for material not available or whose
use is restricted, provided such substitute material is of equal quality and
performance.

ii
 SAFETY
Safety is the ultimate responsibility of the individual. No amount of written
warning will protect a careless person or make an unsafe condition acceptable. Adapt
and maintain safe work habits.

NOTES, CAUTIONS and WARNINGS are used in this manual in the following
manner:

NOTE: Notes are used to present an operational procedure, condition,

etc., which is essential to highlight.

CAUTION: Cautions are used to alert operations and maintenance

personnel to operating procedures, practices, etc., which, if
not strictly observed, will result in damage or destruction of
equipment.

WARNING
Warnings are used to alert operations and maintenance
personnel to operating procedures, practices, etc., which, if
not strictly observed, will result in personal injury.

STANDARD SAFETY PRECAUTION

1. Only qualified personnel should wire this equipment. The wiring
should be performed according to all Local, State and Federal Codes
which are applicable to the service and environment in which the unit
will operate, as well as all applicable NEMA standards. All electrical
safeties and interlocks should be periodically tested to ensure they are
working properly.

2. Use proper "TAG OUT - LOCK OUT" procedures when working on

this equipment.

3. All guards and any other safety devices should be in place during
normal operation of this equipment.

4. All personnel who will operate, work on, or come in contact with this
equipment should be required to read and understand this manual.

5. Never work on this or any equipment while under the influence of

drugs, including alcohol.

iii
6. Keep the area around this and all equipment clean and free of debris
that could create a tripping hazard.

7. Use the proper lifting equipment to install, maintain or service this

equipment.

8. Use the proper personal protective equipment when installing ,

maintaining or servicing this equipment, i.e., safety glasses, hard hat,
steel toed boots, ear plugs and any other safety equipment required in
the work area.

9. Use the proper tool for the job. Do not take unnecessary short-cuts.

10. Never be too proud to ask for help or admit you don't know enough
about what you've been told to do to do it safely. Ask questions!

11. Never trust the other guy for your safety. Always look out for the safety
of the other guy.

These are general safety precautions. They are intended to define a

minimum of standard safety precautions and procedures. They are not all inclusive.
Each location, machine, particular area, time of day, etc., may require a special set
of safety rules. Know the area you are working in and determine if there are any
unique safety precautions or equipment that are necessary in that area.

Remember

SAFETY IS NO ACCIDENT
THE LIFE (or body parts) YOU SAVE

MAY BE YOUR OWN !

iv
 SECTION 1
PUMP INSTALLATION
1.1 MOUNTING THE PUMP
1.1.1 CONCRETE MOUNTING

If the pump is to be mounted on concrete, the slab must be of sufficient

strength and thickness to support the weight of the pump (SEE TECHNICAL DATA
SHEET FOR PUMP WEIGHT), as well as the starting torque and vibrating
(Dynamic) loads. The slab should be level to within 1/2" in 10'-0".

The anchor bolts should be sized to approximately 1/8" smaller than the
mounting holes provided in the pump base. These anchor bolts will not be subject to
shear and therefore should be the type that will resist pull out. Ideally the bolts
should be cast in the concrete.

1.1.2 STEEL STRUCTURE

If the pump is to be mounted on a steel frame, the frame must be of sufficient

member depth and strength to support the pump weight and dynamic load, between
a given span. The mounting bolts should be sized 1/8" smaller than the mounting
holes in the pump base. All bolts should be grade 5 or better.

1.2 PIPING
1.2.1 SUCTION AND DISCHARGE PIPING

The Suction and Discharge Piping should be of the proper wall thickness
and diameter to handle the flow and pressures required for the pump application
(SEE THE TECHNICAL DATA SHEET FOR DESIGN PRESSURE).The pump
flanges will be drilled per the proper A.N.S.I. bolt pattern, for the designed size and
pressure of your pump application.

All the piping should be independently supported! The pump Casing should
never bear the weight of the piping. The Casing could break and would be very
hard to remove at a later date. Flexible pipe is recommended for both the Suction
and Discharge side of the pump. It must be of a type that will not collapse.

1
 1.2.2 GLAND FLUSH PIPING

The Gland Flush Water must be supplied to all pumps that are equipped with
a Full or Low Flow Seal. The Gland Flush Water must be of sufficient pressure
and volume to flush the Gland Area. The following chart gives the flow rates for the
Full and Low Flow Seal Assemblies.

FULL FLOW

FRAME C D E
LITER/MIN. 30 50 70
G.P.M. 8 13 18

LOW FLOW

FRAME C D E

LITER/MIN .56 .75 1.13

G.P.M. .15 .2 .3

The Gland Flush Water should be 5 to 10 PSI above the discharge pressure
of pump. (.5 bar G). If water is being pumped, the Gland Flush Water may come
from the discharge side of the pump. However, this water must be clean so that no
sand, etc., is pumped into Gland Area. A globe valve should be installed in the line
to adjust the flow. Provide a drain for the discharge water.

CONFIGURING THE PUMP DISCHARGE

All pumps will be shipped as Top Vertical Discharge units unless the
customer orders the pump to be delivered configured differently. If the installation
required a different configuration than was shipped, the subsequent procedure
should be followed.

2
 Remove all the Casing Bolts. Turn the pump discharge opening to the
desired position and reinstall the Casing Bolts. See Section 3 of this manual for a
more detailed procedure.

NOTE: Each pump application is designed to operate as close as

possible to the Best Efficiency Point (BEP) of the pump. The static head,
dynamic head, GPM, HP, and many other factors all play a part in which
pump, speed of the pump, etc., will best service your individual needs. If
for any reason a part of the total pump system is changed, ie., pipe size,
net positive suction head available, discharge pipe length, etc., the pump
will move away from its BEP. The further this move away from the BEP,
the less efficient the performance of the pump. Always contact METSO
MINERALS before changing your pump system!

3
 SECTION 2
OPERATION
After the pump has been properly installed and piped, you must check the
rotation.

CAUTION: Disconnect the drive belts or coupling to check the rotation.

If the pump is started with the rotation backward, the Impeller will instantly
unscrew, causing serious damage to the pump. The pump rotation is shown on
Figure No. 1. When viewed from the driven end, the rotation is clockwise.

Before checking the rotation, the Shaft should be turned by hand to ensure
that the Impeller does not rub the Casing or Backliner. (See Sec. 3.2.1 & 3.2.2)
Check the motor rotation. After you are sure of the proper rotation and the proper
Impeller clearance, you are ready to start the pump. Install and tighten all the drive
belts (per accepted standards for belt tension and alignment) or connect and align
the coupling, if the pump has an in-line drive. Install all the guards.

Before starting the pump, check all the bolts, etc., to be sure they are properly
torqued (See Torque Chart.)

If the pump is equipped with a Centrifugal Seal (See Figure 3), grease the
seal with 3 or 4 shots of grease before starting. The Gland Follower may be loose
and should be snugged finger tight ONLY before starting the pump. Do not over
tighten the Gland Follower as you will burn the Packing and cause damage to the
Shaft Sleeve, which will result in possible bearing failure.

NOTE: A Centrifugal Seal may leak in the Gland Seal Area when the
pump is not running. Do not tighten the Gland Follower to stop this
leaking if the pump is not running. If the Gland Follower is tightened
enough to stop the leaking that may occur when the pump is not running,
the Shaft Sleeve will be damaged when the pump is started. Due to the
Expeller pumping action around the Gland Seal Area, the pump should
not leak when it is running. If the Gland Seal leaks when the pump is
running, the total pump system is not in balance. Contact METSO
MINERALS to determine the exact problem area.

If the pump is equipped with a Full or Low Flow Seal, turn the Gland Flush
Water on before the pump is started. Tighten the Gland Follower Bolts finger tight
ONLY before starting the pump. Never start the pump before the Gland Flush
Water has been turned on. The Gland Seal is cooled and lubricated by the flush
water.

4
 If the pump is equipped with a Mechanical Seal, the Casing must be flooded
at all times or this seal will burn up very quickly after start-up.

Open all the suction side valves and flood the Casing with slurry, etc. Start
the pump and let it come up to speed and pressure.

SPECIAL NOTE: Throttling the flow by closing valves in the Suction

or Discharge Piping to change the pressure or volume of the pump will
cause the pump to become hydrodynamically out of balance. This will
cause the pump to operate at a lower efficiency point and could cause
Bearing failure, etc.

WARNING
Stay clear of rotating parts while making this adjustment
to the Gland Follower.

Do not over tighten. Let the pump run for 10 to 15 minutes to be sure the
gland does not overheat. Grease the Centrifugal Seal again after pump has run 10
to 15 minutes (See Figure No. 3). A Centrifugal Seal should not leak while pump
is running, but may leak when pump is stopped if the suction side head produces a
higher pressure than the Gland Seal can withstand.

If a Full or Low Flow Seal is being used, tighten the Gland Follower Bolts
until a small trickle of water is flowing from the Gland Follower Area. Let the pump
run for 10 to 15 minutes, to be sure the Packing does not overheat. (See Figure No.
4 or 5) These seals will leak clear water while the pump is running and may leak
slurry when the pump is stopped, if the head above the pump produces a higher
pressure than the seal can withstand. The Gland Flush Water may be left on when
the pump is not running, if it will not dilute the slurry to much.

NOTE: There is very little room for the Gland Flush Water to flow
around the Lantern Ring and Packing inside the Gland Area. The
volume and pressure of the Gland Flush Water is very critical. If the
pressure or volume are to high, the gland will leak large amounts of
water, causing the operator to think the Gland Follower should be
tightened. This would put too much force on the Shaft Sleeve and will
damage the Shaft Sleeve and Packing. The ideal ratio would be low
flow through the Gland Area at a higher pressure. The Gland Flush
Water must be on at all times while the pump is running.

5
 After your pump has run awhile, it will wear and need adjustment. Intervals
between adjustments will depend on the material being pumped. When the pump is
new, it is advisable to note and record the negative suction pressure, the positive
discharge pressure, the flow rate and the amp draw on motor. Record this
information in the Notes area of your Technical Data Sheet. By knowing this
information, it will be easier to determine when your pump has become worn and
needs adjustment or new wet end parts (See Figure.7).

6
 SECTION 3
MAINTENANCE

3.1 INSPECTION & ADJUSTMENT FOR WEAR

NOTE: A genuine effort has been made to maintain the same Item
Number for the same part on all Orion Pumps. However, this may not
always be possible. The Item Numbers called out in this manual are
based on the standard Item Number List. Always refer to the computer
generated parts list provided with this manual. This list reflects the exact
parts and part number provided on your pump.

3.1.1 CHECKING THE EFFICIENCY OF THE PUMP (See Figure 7).

After your pump has been on line for awhile, some parts will become worn
causing the pump to loose efficiency. The speed with which these parts wear will
depend on the material being pumped and how often the pump is adjusted. A poorly
adjusted pump will wear much faster than a pump that is kept in proper adjustment.

As noted earlier in this manual, the suction and discharge pressure, as well
as the G.P.M. and AMP draw should have been recorded in the notes section of the
Technical Data Sheet located in the back of this manual.

By comparing the original data with your current readings, the wear and
efficiency of your pump can easily be determined. When the suction or discharge
pressure change or the G.P.M. drop, it is a good sign that the pump is becoming
worn. The pump needs adjustment or wetted parts replaced.

After all the Casing Shims (item 25) have been removed during adjustment
or when the pump fails to pump properly after adjustment, the wetted parts should
be inspected.

7
 3.1.2 WETTED PARTS LIST

Below is a list of all wet end parts that will require replacement at one time or
another. (See the computer generated Bill of Material provided in the back of this
manual for your part numbers). The Shaft Seal Assembly you have will determine
which parts are used on your pump.

ITEM DESCRIPTION QTY

17 .............................CASING...............................................1
24 .............................O-RING ...............................................1
32 .............................EXPELLER.........................................1
41 .............................IMPELLER..........................................1
42 .............................O-RING ...............................................1
46 .............................LANTERN BUSHING........................1
47 .............................LANTERN RING ................................1
49 .............................NECK RING........................................1
50 .............................PACKING............................................5
56 .............................SHAFT SLEEVE................................1
57 .............................O-RING ...............................................2
59 .............................SHAFT SPACER...............................1
70 .............................BACKLINER.......................................1
160...........................O-RING ...............................................1

3.2 ADJUSTING THE PUMP FOR WEAR

CAUTION: Before any adjustment for wear is made, be sure to tag

and lock out all electrical power. Remove the drive belts
or disconnect the coupling.

3.2.1

To adjust the clearance between the Backliner (item 70) and the Impeller
(item 41), loosen the Clamps (item 15)...

NOTE: Item 15 is the Frame of the pump. The Clamp is part of the
Frame and machined as a set. The other Clamp (called the Tension
Block (item 63)) is located inside the Adjusting Screw Cover (item 72).

8
 When the Clamps are loose the Bearing Housing (item 14) is free to move
in the Frame (item 15). While rotating the Drive Shaft (item 13) by hand , tighten the
Adjusting Screws (item 16) to move the entire Bearing Housing away from the
pump Casing (item 17). To do this, you must first loosen the Jam Nuts (item 51) on
Item 16. As you move the Bearing Housing Assembly away from the Casing, the
Impeller will eventually rub the Backliner (item 70).

WHEN THE IMPELLER RUBS THE BACKLINER...STOP.

Place a magnetic base dial indicator on the Drive Shaft and indicate on the
Frame. You may wish to place the indicator on the Frame and indicate on the drive
sheave. Zero the indicator and loosen the Adjusting Screw. Push the Drive Shaft
toward the Casing approximately 1/8". Begin tightening the adjusting screw until the
indicator is .030" from the zero. This will give you .030" clearance between the
Impeller and Backliner.

Tighten the Clamps and Jam Nuts. Check the indicator to be sure Bearing
Housing did not move. Rotate the Drive Shaft to be sure the Impeller does not rub
the Backliner (See Figure 3, 4 or 5).

NOTE: If the pump is equipped with a Centrifugal Seal, the clearance

for the Expeller will be adjusted as you adjust the Impeller.

3.2.2

To adjust the clearance between the Impeller (item 41) and the Casing (item
17), you must loosen the Frame Bolts (item 54) and all the Casing Bolts (item 18).
Do not loosen the top and bottom Casing Bolts (item 21). Tighten the
Withdrawal Screws (item 65) to push the Frame and Bearing Housing Assembly
(item 14) slightly away from the Casing. If required, a pry bar may be used to help
move this assembly.

CAUTION: Be careful not to damage the seal area.

3.2.3

Unscrew the Withdrawal Screws until flush with the Frame. The Casing
Shims (item 25) should now be loose and can be removed. Remove two Shim
Sets from each side of the Casing. Tighten two or more Casing Bolts (item 18), on
opposite sides of the Casing, to evenly draw the Frame toward the Casing. (Shims
should always be of equal number and thickness on both sides of the pump.)

9
 3.2.4

As you tighten the Casing Bolts, rotate the Drive Shaft by hand. If you feel
the Impeller rubbing the Casing before these bolts are tight, stop and loosen them
again. Replace one Shim on each side and re-tighten the Casing Bolts. They
should tighten completely. Tighten all the Casing Bolts and rotate Shaft to be sure
all the parts are clear and do not rub.

3.2.5

If the Casing Bolts can be tightened completely without the Impeller rubbing
the Casing, loosen them again and remove one more Shim Set per side. Re-
tighten the Casing Bolts.

If the Impeller rubs before these bolts are tight, loosen them again and
replace the Shims. Then tighten all the Casing Bolts evenly and check to be sure
the Impeller rotates freely without rubbing the Casing or Backliner.

If the Casing Bolts can be tightened completely without the Impeller rubbing,
continue to remove Shims until it rubs. Then replace one Shim Set and tighten all
the Casing Bolts. Rotate by hand to check the Impeller clearance.

The maximum clearance between the Impeller and the Casing should never
be more then one Shim (item 25) thickness.

NOTE: After this adjustment is made, it may be necessary to realign the drive
sheaves. If the motor is direct coupled, the motor will have to be realigned.

3.3 VISUAL INSPECTION

Inspection is basically achieved by feel during adjustment. However, when all
the Casing Shims (item 25) have been removed during adjustment, a visual
inspection is required if only to prove that the parts need to be replaced. This
inspection is achieved by disassembling the wet end of the pump.

CAUTION: Before any Inspection is made, be sure to tag and lock

out all electrical power. Remove the drive belts or
disconnect the coupling.

10
 Inspection of wet end parts may be done in one of two ways. Either method
may be used , depending on which is best in your application.

Method 1: Remove the Impeller Casing (Must disassemble piping)

Method 2: Remove the Frame assembly (Piping not disassembled)

NOTE: Be sure that the pump Base is securely anchored or the Base /
Casing will pivot and fall.

3.3.1

METHOD 1

Remove the Suction and Discharge Piping. Support the Casing and
remove all the Nuts and Washers (item 19 & 20) from Casing Bolts (item 18), and
then remove the Casing Bolts. Loosen and remove the Casing Clamp Bolts (item
21). Use a pry bar to move the Casing enough to remove the Shims (item 25).

CAUTION: Be careful not to damage the O-Ring Seal Area.

With the Casing well supported (the Casing is very heavy) carefully slide it
away from the Frame, lift and remove the Casing. Set it aside.

3.3.2

METHOD 2

Remove the drive guard and disconnect the belts or coupling. If the unit is a
direct coupled drive, the motor will have to be removed to allow the Frame assembly
to be removed. Loosen and remove the Frame Bolts (item 54). Loosen and
remove the Casing Bolts (item 18, 19 & 20). Using a pry bar, carefully work the
Frame Assembly away from Casing far enough to remove the Casing Shims (item
25).

CAUTION: The Pump Base (item 45) should be securely anchored to

prevent the Pump Base and Casing from trying to pivot up
when Frame is removed.

3.3.3

Using the eye bolt provided, carefully lift and slide Frame away from the
Casing. Use a pry bar to aid in this move. The Impeller and Casing are now open for
inspection.

11
3.4 INSPECTING THE REMAINING WET END PARTS
Lock the Drive Shaft in some manner (that will not damage the Shaft) to stop it
from rotating. Insert a large steel bar in the Impeller Vanes and unscrew in the
direction of normal rotation (clockwise). The center of the Impeller may be heated to
aid in the removal.

CAUTION: Do not overheat the center hub of the Impeller. Water

may have leaked behind the hub and if the hub is heated
to hot, the water will become steam, which could cause the
hub to explode. Never heat to a temperature over 250°F.
Always stand to one side of the Impeller while the heating
is being performed, so that if the hub does crack, etc., no
one will be in front of the hub.

3.4.1

Once Impeller is broken loose, hang the Impeller with a nylon strap or place
a chain through the vanes. Unscrew the Impeller by turning the Drive Shaft. After
the Impeller has been removed, place a nylon strap around the Backliner (make
the strap into a choker). Support the Backliner (item 70) and loosen the Backliner
Bolts (item 29).

CAUTION: The Backliner is very heavy and hard to handle.

3.4.2

Carefully remove the Backliner by tapping on the back side with a soft
hammer, etc. The Gland Area, Shaft Sleeve, etc., may now be inspected.

NOTE: It is recommended that all the O-Rings and Packing Seals exposed
during this operation be replaced.

Replace all worn wet end parts. Reassemble the pump in the reverse order.
Be sure all the O-Ring sealing surfaces are clean so they will fit metal to metal when
the unit is reassembled.

12
3.5 LUBRICATION
3.5.1

All the pumps are fully greased and lubricated prior to shipment.

SUGGESTED GREASES FOR BEARINGS AND LABYRINTH SEALS:

MANUFACTURER LOW TEMP. HIGH TEMP.

Mobil Mobilith AW2 Mobilith AW2

Pennzoil Pennlith EP 712 Maxlife EP2
Exxon Lidok #2 Unirex N2
Shell Alxinia #2 Darina

SEE METSO MINERALS LUBE SPEC. M-100 FOR ALL LUBE

SPECIFICATIONS.

3.5.2

The Centrifugal Seal should be greased with BP Energrease GPZG or as

noted above.

If the pump is running 500 RPM or faster, the Bearings should be greased
more often than slower speeds. This will depend on the type of service.

3.5.3

If the Bearing temperature is continuously 300° to 350°F., a high temperature

grease should be used.

3.5.4

The Bearing should not require greasing for approximately 750 hours after
start up (monthly based on a 24 hr. per day run time). However, it is advisable to
grease them every 170 hrs. (weekly based on a 24 hr. per day run time) with one or
two shots from a standard grease gun. This is not necessarily to lubricate the
Bearing but instead is intended to make the grease in the Bearing move around
and expose new grease to Bearing areas. Lubricate approximately every 750 hours
(monthly based on a 24 hr. per day run time) thereafter with two to four ounces of
grease. The pump should be running when it is lubricated. Disassemble, clean and
repack the Bearings after every 18,000 hours (every two years max.) of operation.

13
 3.5.5

The Labyrinth Seal should be greased every 170 hours (weekly) minimum.
Grease should be added until new grease is coming out around edge of Labyrinth
(item 10). Some pumps will have a Piston Ring Seal instead of a Labyrinth;
grease this seal in the same manner as the Labyrinth. The pump should be
rotating while the new grease is added.

3.5.6

The Centrifugal Seals should be greased every 12 hours with 2 to 4 shots of

grease.

NOTE: This lubrication schedule is for reference only. Application and

environment may require more frequent lubrication. No lubrication schedule
can replace alert maintenance personnel.

3.6 TROUBLE SHOOTING

PUMP WILL NOT BUILD PRESSURE...

Wet end is worn and needs adjustment; leak in suction side piping.

PUMP WILL NOT HOLD PRIME....

Seals in piping or pump are leaking. This leak is probably in the suction side
of the piping, as a leak in the pressure side would be easily seen.

PUMP WILL NOT PUMP NORMAL VOLUME...

Wet end is worn and needs adjustment. Leak in the suction side piping.
Total pump system is out of balance.

LEAKING AROUND PACKING SEAL AREA...

CENTRIFUGAL SEAL: Tighten Gland Follower and grease; replace Packing and
check alignment. Be sure the pump system is per design specifications.

FULL AND LOW FLOW SEAL: Tighten the Gland Follower until a small trickle of
water comes out around Gland Follower; replace Packing.

14
 NOTE: The Gland Follower should never be tightened with a wrench! If the
Gland Follower is tightened to tight, it will cause the Shaft Sleeve to become
over heated and melt the O-Ring on the Impeller end of the Shaft Sleeve. If
this O-Ring is damaged, slurry will leak under the Shaft Sleeve and into the
Bearing Housing. There will be no signs of this leakage until the Bearings
begin to fail.

If the Bearings should fail in a time period that would be considered

premature and the Bearing Housing Assembly is full of slurry (mud),
check and replace the front O-Ring to correct the cause of failure.

MECHANICAL SEAL: Replace the seal assembly. See vendor literature.

VACUUM SEAL: Replace packing.

3.7 PUMP ASSEMBLY AND DISASSEMBLY

3.7.1 BEARING ASSEMBLY WITH DOUBLE SEAL ARRANGEMENT
(FIGURE 2)

Inspect and inventory all parts before you begin assembly. Clean and de-burr
all parts as required. The Bearing assembly procedure should be performed in a
clean, dust free area. Read and understand these instructions before you begin the
assembly.

3.7.1.1

Stand the Drive Shaft (item 13) on end, threaded end up. Install a Grease
Retainer (item 8) over the threaded end of the Drive Shaft. Slide the Grease
Retainer down until it bottoms out on the shoulder on the Shaft.

3.7.1.2

Install a Bearing Cone (item 3) on the Drive Shaft with tapered end up, as
shown. The Bearing may be heated or pressed on. Do not use a torch to heat the
Bearing; use only hot oil or an induction heater (250° F. max.). It would be wise to
use an anti-seize compound under the Bearing Race, so they may be easily
pressed off, if required.

3.7.1.2.1

After the Bearing is in place and cooling, it should be seated against the
Grease Retainer, so that the Grease Retainer can not rotate. This may be done
with a round, blunt nosed punch and a hammer.

15
 3.7.1.3

Turn the Drive Shaft over and install the other Bearing in the manner
previously described. Be sure that neither Grease Retainer can rotate around the
shaft.

3.7.1.4

Next install a Bearing Cup (item 3) into the Bearing Housing (item 1).

NOTE: There are two tapped holes in the side of the Bearing
Housing. Stand the Bearing Housing on end with these two tapped
holes closest to the top. Slide the Bearing Cup into the bore of the
Bearing Housing with the largest end of the tapper down. The Bearing
Cup should be approximately 1/16" below the end of the Bearing
Housing.

3.7.1.5

Next place a .020" thick shim (yellow) on the end of the Bearing Housing
and align the holes to match those in the Bearing Housing. This shim serves as a
grease seal.

3.7.1.6

Install all the Grease Fittings (item 4) into each End Cover (item 5). This
must be done before the End Covers are installed on the Bearing Housing. Install
secondary seal into end covers.

3.7.1.7

Place the End Cover (item 5) on top of the shim and align the holes to match.
The two Grease Fittings in the End Cover should be installed at right angles (90 °)
to the two tapped holes in the Bearing Housing. They may either be at the 9
o'clock or the 3 o'clock position to the holes in the Bearing Housing, depending on
which side of the pump you wish to grease from when the pump is installed. Install
and tighten all the End Cover Screws (items 7 & 12). These screws should be
torqued per the torque chart in this manual.

16
 3.7.1.8

Turn the Bearing Housing over with the assembled end down. This
assembly should be standing on a table with a hole in it, so that when the Drive
Shaft is installed, the threaded end of the Shaft will be able to pass completely
through the Bearing Housing, allowing the Bearing Cone on the Shaft to seat in
the Bearing Cup already installed in the Bearing Housing. Use a fixture similar to
a wire spool to stand the Bearing Housing on, if no table is available. (See Figure
no. 6).

NOTE: This assembly is very heavy. The spool must be able to support the
Bearing Housing Assembly.

3.7.1.9

Pack each Bearing on the Drive Shaft with the proper grease for your
application. Also, cover the Shaft between the two Grease Retainers (item 8) with
grease so it will not rust. Pick the Drive Shaft straight up with the threaded end
hanging down (use the lifting hole provided; remember, it's a metric thread). Lower
the Drive Shaft straight down into the Bearing Housing until the Bearing Cone
seats against the Bearing Cup.

3.7.1.10

Install the remaining Bearing Cup (item 3) over the Shaft and into the bore of
the Bearing Housing, large end of taper down. Push the Bearing Cup as far down
into the Bearing Housing as possible. Ideally it should be 1/16" below the end of
the Bearing Housing.

3.7.1.11

Install the remaining End Cover and seat it against the Bearing Cup just
installed. Install 3 or 4 of the End Cover Screws (item 7 & 12), with equal angles
between each and snug by hand. This will ensure there is no end play in the
Bearings at this time. The Drive Shaft should be hard to turn by hand but should
still be able to be turned by hand. Using a set of feeler gauge, measure gap
between End Cover (item 5) and the end of the Bearing Housing (item 1). Refer to
the chart below for your pump Frame size (SEE TECHNICAL DATA SHEET). Add
the value in the chart for your Frame size to the value you just measured with the
feeler gauges. This is the total thickness of the Shims that must be added between
the End Cover and the Bearing Housing to give the proper Bearing Clearance.

If the pump will be running at less than 500 r.p.m., set the Bearing Clearance
on the low side of the chart value. If the pump will be running faster than 500 r.p.m.,
set the Bearing Clearance on the high side of the chart value.

17
 EXAMPLE: If you measured .045" between the End Cover and Bearing
Housing and you have a Frame C pump, you would add from .003" to .005" of
Shim, depending on how fast the pump will run. Make up a Shim Pack of the
proper thickness and install it between the End Cover and Bearing Housing.
In this case the Shim Pack should be between .048" and .050" thick.

CHART FOR BEARING CLEARANCE

Frame C & D .003" to .005"

Frame E .004" to .006"

3.7.1.12 CHECKING THE BEARING END CLEARANCE:

(SEE FIGURE NO. 7)

The Grease Fittings in the End Covers should be on the same side of
Bearing Housing and be at 90° to the tapped holes in the Bearing Housing. Install
and tighten all the End Cover Screws. Hit the end of the Drive Shaft with a soft
hammer to seat the Drive Shaft and Bearings in the bottom of Bearing Housing.

Place a magnetic based dial indicator on keyed end of Shaft and indicate on
the End Cover. Zero the indicator. Lift the complete Bearing Housing assembly
with the lifting eye in end of the Shaft. Carefully tap the Bearing Housing (so that
you do not disturb the indicator) with a soft hammer to seat the Bearing Housing
against the top Bearing.

The indicator should read the value shown in the chart for the pump Frame
you are assembling.

If it shows less tha n the value shown, remove the End Cover and add the
proper amount of shim. If it shows more than the chart value, remove the proper
amount of shim. Repeat the Bearing clearance check until the readings are in the
proper range.

Be sure each time you move the Shaft up or down in the Bearing Housing,
that the Bearings are well seated in the Bearing Cup. If not, you will get a false
reading and the Bearing clearance will be set improperly. This will greatly reduce
the Bearing life.

18
 3.7.1.13

Lay the Bearing Housing flat on the work surface and install the Labyrinth
Seals (item 10) on each end of Bearing Housing Assembly . Install and tighten the
Lock Nut (item 9) on keyed end of Bearing Housing Assembly , as shown. If the
Shaft is not keyed for a Lock Washer with the Lock Nut, you should "lock tight" the
nut in place. Use a "lock tight" that will allow you to remove the nut at a later date.

3.7.1.14

Grease the two inside Grease Fittings on Bearing Housing assembly (10
shots each). Grease the two outside Grease Fittings to the Labyrinth Seal.
Slowly rotate the Shaft as you grease, until grease is coming out around perimeter
(360°) of Labyrinth Seal. Remove the excess grease and set assembly aside until
needed.

NOTE: If the Bearing Housing assembly is to be stored, plug the

tapped holes in the Bearing Housing to keep dirt, etc., out.

3.7.2 BEARING ASSEMBLY WITH PISTON RING SEALS (FIGURE 2A)

Inspect and inventory all the parts before you begin this assembly. Clean and
de-burr all the parts as required. The Bearing assembly procedure should be
performed in a clean, dust free area. Read and understand these instructions before
you begin the assembly.

3.7.2.1

Stand the Drive Shaft (item 13 ) on end, threaded end up. Install one
Grease Retainer (item 8) over the threaded end of the Drive Shaft.

NOTE: The Piston Ring Bearing Seal Assembly uses a cast Grease
Retainer instead of the stamped plate used on the Labyrinth Seal
Assembly. If your original pump had the Cast Grease Retainers, you
must stay with these castings when ordering parts. The Drive Shaft is
machined differently and will not interchange with the other style.

SPECIAL NOTE: These two Bearing Assemblies will interchange

with each other as a complete assembly. Most of the parts for these two
assemblies will not interchange from one assembly to the other.

ALWAYS REFER TO THE SERIAL NO. ON YOUR PUMP WHEN ORDERING

SPARE OR NEW PARTS!

19
 Slide the Grease Retainer down until it bottoms out on the shoulder of the
Shaft, as shown.

3.7.2.2

Install a Bearing Cone (item 3) on the Drive Shaft with the tapered side up.
(see figure no. 2-A) The Bearing may be heated or pressed on. Do not use a torch
to heat the Bearing; use only hot oil or an induction heater (250°F Max.).

It would be wise to use an anti-seize compound under the Bearing, so they

may be easily pressed off, if required.

3.7.2.2.1

After the Bearing is in place and cooling, it should be seated against the
Grease Retainer, so the Grease Retainer can not rotate. This may be done with a
round, blunt nosed punch and hammer.

3.7.2.3

Turn the Drive Shaft over and install the other Bearing in the same manner
as the previous Bearing. Be sure neither Grease Retainer can be rotated.

3.7.2.4

Next install a Bearing Cup (item 3) into the Bearing Housing (item 1).

NOTE: There are two tapped holes in the side of the Bearing
Housing. Stand the Bearing Housing on end with these two tapped
holes closest to the top.

Slide the Bearing Cup into the bore of the Bearing Housing with the largest
end of the taper down. The Bearing Cup should be approximately 1/16" below the
end of the Bearing Housing.

3.7.2.5

Next place a .020" thick Shim (yellow) on the end of the Bearing Housing
and align the holes to match those in the Bearing Housing.

3.7.2.6

Install all the Grease Fittings (item 4) into each End Cover (item 5). This
must be done before the End Covers are installed on Bearing Housing.

20
 3.7.2.7

Now place the End Cover (item 5) on top of the Shim and align the holes to
match. The two tapped holes in the End Covers should be installed at right angles
(90°) to the two tapped holes in the Bearing Housing. They may either be at the 9
o'clock or the 3 o'clock position to the holes in the Bearing Housing, depending on
which side of the pump you wish to grease from, when the pump is installed. Install
and tighten all the End Cover Screws (items 7 & 12). These screws should be
torqued per the torque chart in this manual.

3.7.2.8

Turn the Bearing Housing over with the assembled end down. This
assembly should be standing on a table with a hole in it, so when the Drive Shaft is
installed, the threaded end of the Shaft will be able to pass completely through the
Bearing Housing, allowing the Bearing Cone on the Shaft to seat in the Bearing
Cup already installed in the Bearing Housing. Use a fixture similar to a wire spool
to stand the Bearing Housing on, if no table is available. (SEE FIGURE NO. 6).

NOTE: This assembly is very heavy. The spool must be able to

support the Bearing Assembly.

3.7.2.9

Pack each Bearing on the Drive Shaft with the proper grease for your
application. Also, cover the Shaft between the two Grease Retainers with grease,
to keep it from rusting. Pick the Drive Shaft straight up with the threaded end
hanging down (use the lifting hole provided; remember, it's a metric thread). Lower
the Drive Shaft straight down into the Bearing Housing until the Bearing Cone
seats against the Bearing Cup.

3.7.2.10

Install the remaining Bearing Cup (item 3) over the Shaft and into the bore of
the Bearing Housing, large end of taper down. Push the Bearing Cup as far down
into the Bearing Housing as possible. Ideally it should be 1/16" below the end of
the Bearing Housing.

21
 3.7.2.11

Install the remaining End Cover and seat it against the Bearing Cup just
installed. Install 3 or 4 of the End Cover Screws (item 7 & 12) with equal angles
between each and snug by hand. Be sure there is no end play in the Bearings at
this time. The Drive Shaft should be hard to turn by hand but should still be able to
be turned by hand. Using a set of feeler gauges, measure gap between End Cover
(item 5) and the end of the Bearing Housing (item 1). Now look at the chart below
for your pump frame size (SEE TECHNICAL DATA SHEET). Add the value in the
chart for your frame size to the value you just measured with the feeler gauges. This
is the total thickness of the Shims that must be added between the End Cover and
the Bearing Housing to give the proper Bearing Clearance.

If the pump will be running at less than 500 r.p.m., set the Bearing Clearance
on the low side of the chart value. If the pump will be running faster than 500 r.p.m.,
set the Bearing clearance on the high side of the chart value.

EXAMPLE: You measured .045" between the End Cover and

Bearing Housing and have a Frame C pump. You would add from
.003" to .005", depending on the speed the pump will run. Make up a
Shim Pack of the proper thickness and install it between the End Cover
and Bearing Housing, ie., in this the Shim Pack would be .048" to .050"
thick.

CHART FOR BEARING CLEARANCE

Frame C & D .003" to .005"

Frame E .004" to .006"

3.7.2.12

NOTE: The Grease Fittings in the End Covers should be on same

side of Bearing Housing and be at 90° to the tapped holes in the
Bearing Housing.

Install and tighten all the End Cover Screws. Hit the end of the Drive Shaft
with a soft hammer to seat the Drive Shaft and Bearing into the bottom of the
Bearing Housing. Place a magnetic based dial indicator on the keyed end of the
Shaft and indicate on the End Cover. Zero the indicator. Lift the complete Bearing
Housing assembly with lifting eye in the end of the Shaft. Carefully tap the Bearing
Housing, so you do not disturb the indicator, with a soft hammer to seat the
Bearing Housing against the top Bearing. The indicator should read the value
shown in the chart for the pump frame you are assembling.

22
 If it shows less than the value shown, remove the End Cover and add the
proper amount of Shim. If it shows more than the chart value, remove the proper
amount of Shim. Repeat the indicator check until the readings are in the proper
range. Be sure each time you move the Shaft up or down in the Bearing Housing,
the Bearings are well seated in the Bearing Cup. If not, you will get a false reading
and the Bearing Clearance will be set improperly. This will greatly reduce the
Bearing life.

3.7.2.13

Grease and install two Piston Rings (item 2) in the grooves on each
Labyrinth Seal Ring (item 10). Turn the splits in the Piston Rings 180° apart.
Slide the Labyrinth Seal Ring Assembly onto the Drive Shaft, flat side out.
Compress the Piston Rings and snap them into the bore of the End Cover.

3.7.2.14

Install a Flinger (item 12) on each end of the Bearing Housing Assembly .
Install and tighten the Lock Nut on the keyed end of the Drive Shaft. If the Shaft is
not keyed for the Lock Washer provided with the Lock Nut, you should "lock tight"
the nut in place. Use a "lock tight" that will allow you to remove the nut at a later
date.

3.7.2.15

Grease the two inside Grease Fittings on the Bearing Housing Assembly
(10 shots each). Grease the two outside Grease Fittings to the Labyrinth Seal.
Slowly rotate the Shaft as you grease. Continue to inject grease until grease is
coming out around perimeter (360°) of Labyrinth Seal Ring. Remove the excess
grease and set assembly aside until needed.

NOTE: If Bearing Housing Assembly is to be stored, plug the tapped

holes in the Bearing Housing to keep dirt, etc., out.

23
3.8 GLAND SEAL ASSEMBLY
There are five primary types of Shaft Gland Seals. See the TECHNICAL
DATA SHEET in the rear of this manual for the type used on your pump.

3.8.1 CENTRIFUGAL SEAL (FIGURE 3)

3.8.2 FULL FLOW SEAL (FIGURE 4)

3.8.3 LOW FLOW SEAL (FIGURE 5)

3.8.4 MECHANICAL SEAL (IF SUPPLIED WITH PUMP)

3.8.5 VACUUM GLAND

CAUTION: Some of the component parts that make up the Seal

Assembly are very heavy and hard to handle. Care
should be taken to avoid personal injury or damage to
parts.

3.8.1 CENTRIFUGAL SEAL (SEE FIGURE 3)

Lay the Expeller Ring (item 33) flat on work surface with the large bore up.
Pack the Lantern Ring (item 47) with grease and lightly grease the I.D. of the Shaft
Sleeve (item 56) and five rings of Packing (item 50). Set these parts aside until
needed. Insert the Neck Ring (item 49) into the Expeller Ring until it rests against
the shoulder in the bottom of the Expeller Ring Bore. Insert the Shaft Sleeve into
bore of the Expeller Ring and through the Neck Ring, until it is standing on the
work surface. Next install two rings of Packing (item 50), the Lantern Ring (item
47) and three more rings of Packing, as shown in Figure 3. The split lines on these
Packings should be 180° apart. Install the Gland Follower (item 36) using the
Gland Follower Screws (item 37), as shown. This unit is now ready for assembly
on the pump.

NOTE: The Packing will hold this assembly together while it is being
positioned on the frame in a later assembly step. Set the Gland Seal
Assembly aside until needed.

3.8.2 FULL FLOW SEAL (SEE FIGURE 4)

3.8.3 LOW FLOW SEAL (SEE FIGURE 5)

NOTE: These two seal assemblies are very much alike and will be
discussed jointly in this section, making note of differences.

24
 3.8.2.1 & 3.8.3.1

Lay the Stuffing Box (item 61) flat on the work surface with the large bore
up.

3.8.2.2 FULL FLOW ONLY (SEE FIGURE NO. 4)

Install the Lantern Ring (item 47) in bore of the Stuffing Box (item 61), it
should rest on the shoulder in the bottom of the bore. Lightly grease the I.D. and
O.D. of the Shaft Sleeve (item 56) and install through the bore of the Lantern Ring
until the Shaft Sleeve is standing on work surface. Lightly grease and install five
rings of Packing (item 50), with the split lines 180° apart.

3.8.3.2 LOW FLOW ONLY (SEE FIGURE NO. 5)

Install the Neck Ring (item 49) into bore of Stuffing Box (item 61), until it
rests on the shoulder in the bottom of the bore. Lightly grease the I.D. and O.D. of
the Shaft Sleeve (item 56) and insert through I.D. of Neck Ring until the Shaft
Sleeve is standing on work surface. Grease and install one ring of Packing (item
50), then insert the Lantern Ring (item 47) and four more rings of Packing (item
50). Be sure the split lines are 180° apart.

3.8.2.3 & 3.8.3.3

Next install the Gland Follower (item 36) using Gland Follower Screws
(item 37). Tighten finger tight.

3.8.2.4 & 3.8.3.4

PUMPS PRODUCED BEFORE FEB. 1990

Clean the counter bore where the Seal (item 62) will fit on Stuffing Box (Full
or Low Flow) or Expeller Ring (Centrifugal Seal), to remove oil, dirt etc. (See the
proper figure.) Glue the seal (item 62) to the Stuffing Box (or Expeller Ring) in the
position shown. Use a fast drying super glue or equivalent. Set this assembly aside
to dry.

NOTE: This seal must be glued in place or it will be squeezed out of

position during assembly. Do not use grease to hold the seal in this
position.

If you wish to convert your pre-1990 style pump to a post-1990 style, yo u

must change both the Backliner and the Expeller Ring or Stuffing Box.

25
PUMPS PRODUCED AFTER FEB. 1990

On the newer pumps an O-Ring may be used instead of the washer type
seal.

ALWAYS REFER TO THE SERIAL NO. ON YOUR PUMP WHEN ORDERING

PARTS.

CAUTION: This assembly may be very heavy and hard to handle!

3.8.4 MECHANICAL SEAL

The Mechanical Seals are not manufactured by METSO MINERALS and all
literature will be provided by manufacturer of the Mechanical Seal.

3.8.5 VACUUM SEAL

Install the O-Ring in the groove provided on the Gland Follower. Install the
Gland Follower and one ring of Packing on the back of the Shaft Sleeve. Install
the next O-Ring in the groove provided on the special Packing Follower.

Install the Special Packing Follower and last ring of Packing on the front
half of the Shaft Sleeve. Loosely install the Gland Follower bolts.

Slide one of the O-Rings onto the Shaft, followed by the Shaft Sleeve
(Gland Follower first) and the last O-Ring. Install the special Packing follower
studs in the Stuffing Box.

Slide the Stuffing Box in place so the studs align with the holes in the special
Gland Follower. Complete the seal and pump assembly using the same procedure
used for the other Shaft Seal configuration.

3.8.5.1

To replace the Packing, simply remove the Gland Follower bolts and slide
the Special Packing Follower forward toward the Impeller. This will expose the
old Packing for easy removal and replacement.

26
3.9 FRAME ASSEMBLY

NOTE: Remove all paint, burrs, etc., from the mating surfaces and
lightly grease all the mating surfaces on this assembly.

3.9.1

Lay the Horizontal Pump Base (item 45) flat on floor, as shown. Set the
Frame (item 15) on the Horizontal Base and loosely install the Mounting Bolts
(items 35 & 54).

3.9.2

Lift Bearing Housing Assembly (item 14) and slide it into Frame, as shown.
Grease the bore of Frame and O.D. of the Bearing Housing so that Bearing
Housing will slip freely in the Frame. Turn the Grease Fittings to right or left side
(3:00 or 9:00 o'clock position) depending on which side you wish to grease from.
The two tapped holes in the Bearing Housing should be straight up (12 o'clock
position). Once you have positioned the Bearing Housing Assembly properly,
install the Clamp (item 15 also) using hardware (items 64 & 91). Snug but do not
tighten.

3.9.3

Insert the Tension Block (item 63) into the space between the Bearing
Housing and the Frame, as shown. Next insert the Adjusting Screw (item 16)
through the hole in the Frame, as shown. As you insert the Adjusting Screw
through the hole in the Frame, place the Tension Block Retaining Washer (item
55) in the position shown, so that the Adjusting Screw will hold this washer in
place. Next, start 2 Jam Nuts (item 51) onto the Adjusting Screw. The first one
should be tightened completely and the second one should be run up approximately
1 inch. Slide the Stationary Saddle (item 52) over the Adjusting Screw, as shown,
and position over the holes in the Bearing Housing. Install the two Socket Head
Cap Screws (item 53), as shown, and firmly tighten the Stationary Saddle in place.
Next, install the last Jam Nut (item 51). The Jam Nuts should be loose, so that the
Bearing Housing will move freely in the Frame. Now install the two Tension Block
Socket Head Cap Screws to hold the Tension Block in place. Tighten the two
Clamp Screws and the two Tension Block Screws. This is to pull the Bearing
Housing assembly down into the Frame, so that the Drive Shaft is centered in the
Frame Bore.

NOTE: Once these parts are assembled, these four screws must be
loosened to adjust the Impeller clearance.

27
 3.9.4

Now you are ready to install the Gland Seal Assembly, previously assembled.
First install the four Backliner Bolts (item 29) into the ears on the Backliner (item 70).
Use the O-Ring (item 38) to retain these bolts in place during assembly .

(SEE THE PROPER FIGURE FOR YOUR SEAL ASSEMBLY).

NOTE: This assembly can be very heavy on the larger pumps. A

nylon strap should be used as a sling to lift and position this assembly.

3.9.4.1

Clean the Drive Shaft and install one gasket (item 57) over threaded end of
the Shaft, as shown. Slide the gasket up against flinger on the Bearing Housing.

3.9.4.2

Pick up the previously assembled Gland Seal Assembly, so that Gland

Follower (item 36) is away from you (Use nylon strap). Insert the Gland Seal
Assembly, Gland Follower first, over the Drive Shaft and slide it up the Shaft until
the Shaft Sleeve is touching the Labyrinth on the Bearing Housing. Take care not
to pinch the O-Ring (item 57), previously installed. There is a counter bore in the
Frame that the Gland Seal Assembly will fit in, to align this assembly with the
Frame. Be sure to turn the Grease Fitting or Flush Water Port in the proper
direction for your installation.

NOTE: The Shaft Seal Assembly does not bolt into place. It is held in
place by the Backliner (item 70).

3.9.4.3

Install the second O-Ring (item 57) over the Drive Shaft and slide it into the
groove in the Shaft Sleeve, as shown.

3.9.4.4

If you are using a Centrifugal Seal, install the Expeller (item 32) onto the
Drive Shaft, as shown (SEE FIGURE 3). If not, install the Shaft Spacer (item 59)
with the O-Ring groove out, as shown. (SEE FIGURE 4 OR 5)

NOTE: It would be wise to coat these parts with grease before

assembly.

28
 3.9.4.5

With the Gland Seal Assembly in place, pick the Backliner up and insert the
Backliner Bolts (item 29) into holes in the Frame, as shown. Install the hardware
(item 30 & 31) and tighten. The Gland Seal Assembly will be sandwiched between
the Frame and the Backliner and will be held in place by the Backliner.

CAUTION: Do not over tighten the Backliner bolts or you will break
the ears off the Backliner. Tighten only enough to get
good metal to metal contact between the Backliner Frame
and the Expeller Ring/Stuffing Box. When the Backliner
Bolts (item 29) are being tightened, they must be tightened
evenly. Torque the bolts only enough to hold the
Backliner securely in place.

NOTE: The Bearing Housing Assembly must be clamped securely in

place to ensure the proper alignment of the Gland Seal Assembly. If
Bearing Housing is not secure, the Drive Shaft may droop down. If
Gland Seal Assembly and Backliner are installed and tightened with
the Drive Shaft drooping, when the Bearing Housing is clamped
securely, the Drive Shaft will rise causing the seal to leak or wear
unevenly.

3.9.4.6

Install the O-Ring (item 42) into the groove in the Expeller or Shaft Spacer,
whichever you are using. Install the O-Ring (item 24) into groove in the Backliner,
as shown.

3.9.4.7

Now that the major Frame parts are assembled and aligned, tightened all the
bolts securely (except items 54).

3.10 PUMP ASSEMBLY

3.10.1

Clean the threads on the Drive Shaft and the threaded hole in Impeller (item
41). Be sure that all the grease and dirt, etc., has been removed. If it is not, the
disassembly of the pump at a later date will be very difficult.

29
 3.10.2

Coat both the threaded end of the Drive Shaft and the threaded hole in the
Impeller with a "Never Seize" compound. Hang the Impeller with a chain or nylon
strap and turn the Shaft until they are threaded together hand tight. (When the pump
is running, the Impeller will tighten further).

3.10.3 (SEE SECTION 3.2.1 AND 3.2.2 FOR PROCEDURE)

Adjust the Bearing Housing Assembly with the Adjusting Screw until you
have .020" to .040" clearance between Backliner and Impeller. Rotate the
Impeller by hand to ensure that there is clearance all the way around. When you
are sure that the Impeller is set with the proper clearance, tighten the Bearing
Housing Clamp Bolts and the Tension Block Screws (items 64 & 91). Rotate the
Impeller again to ensure clearance.

3.10.4

Install the O-Ring (item 24) into the groove in the Backliner, as shown.
Liberally grease the O.D. of Backliner (item 70) and the I.D. of Casing (item 17);
machined surfaces only. Turn the Casing Discharge Outlet in the general
direction required. Slide the Casing over the Backliner and push on as far as
possible. Turn the Casing as required to align the discharge and the Casing Bolt
Holes. Install the Casing Clamp Bolts (item 21), Washers (item 22) and Nuts
(item 23), as shown (top and bottom holes in the pump Frame). Tighten the Clamp
Bolts completely. (These two bolts hold the Casing to the Frame).

3.10.5

Install two Casing Bolts (item 18) using Nuts and Washers (items 19 & 20)
at two points, 180° apart on the Casing. (Left and right side of pump). Evenly
tighten these two bolts until the Casing hits the Impeller. Measure the gap between
the Base (item 45) and the Frame (item 15) in area where the Shims (item 25) will
be installed, as shown. Loosen the two Casing Bolts. Install the Withdrawal
Screws (item 65), one in each tapped hole in the Frame. Tighten these screws to
push the Casing away from Frame enough to install the shim. Back the
Withdrawal Screws out until they are flush with the face of the Frame.

NOTE: A pry bar may be used to help move the Casing away from the
Frame.

30
 3.10.6

Make up two sets of Shims (item 25) equal to the gap measured, plus one (1)
shim. Loosely install the remainder of the Casing Bolts, Washers and Nuts (items
18,19,20). Insert the Shims, as shown, and tighten the Casing Bolts. Rotate the
Impeller to be sure the Impeller clears the Casing. If the Impeller rubs the
Casing, adjust the Shim thickness by adding one Shim in each side.

3.10.7

The total clearance around Impeller should be no more than .140". To check
this clearance loosen the Bearing Housing Clamp Screws and the Tension
Screws (items 91 & 64). Using the Adjusting Screw (item 16), adjust the Bearing
Housing away from Casing until Impeller hits the Backliner. Place a dial indicator
on the base and indicate on back of Bearing Housing. Zero the indicator. Adjust
the Bearing Housing toward the Casing until the Impeller hits the Casing. The
indicator reading should not be more than .140". At this point, move the Bearing
Housing away form the Casing .030". This will locate the Impeller in the Casing.
The closer the Impeller is to the Casing the better the pump will operate. Tighten
the Clamp Screws and Tension Block Screws. Rotate the Impeller to be sure it
does not hit the Casing or Backliner.

3.10.8

Tighten the Base Screws (item 54). Tighten Gland Follower Screws until
the Shaft is difficult to turn by hand (Do not use a wrench...finger tight only). Do not
over tighten these screws or the Shaft Seal and Sleeve will be damaged when the
pump is started. Further adjustment may be required when the unit is put on line.

31
 SECTION 4
ILLUSTRATIONS & PARTS

PARTS DESCRIPTION FIGURE NO.

BEARING HOUSING ASSEMBLY

W/LABYRINTH SEAL NO. 2
W/PISTON RING SEAL NO. 2A

CENTRIFUGAL SEAL ASSEMBLY NO. 3

FULL FLOW SEAL ASSEMBLY NO. 4

LOW FLOW SEAL ASSEMBLY NO. 5

BEARING CLEARANCE & FIXTURE NO. 6

PUMP EFFICIENCY NO. 7

32
33
34
40
41
42
43
44
SECTION 5
PUMP EFFICIENCY & LONG TERM STORAGE
PUMP STORAGE...

If your new pump is to be stored for a long period of time before use, the
following procedure must be followed in order for METSO MINERALS to extend and
honor warranties.

First, notify METSO MINERALS Equipment that the pump is to be stored and
that the storage procedure will be followed. (For some equipment a visual
inspection of this procedure will be required). Notify METSO MINERALS Equipment
when the pump is removed from storage and put into service. Failure to notify
METSO MINERALS will result in your warranty being void.

Your new pump will come pre-lubricated. A small amount of grease should
be applied to all exposed, unpainted metal surfaces, Shaft Sleeve, etc. Plug the
Gland Flush Water port if a Full or Low Flow Seal is used. Make a plywood cover
for the Suction and Discharge openings in the Casing. Use the flanges provided
to hold these covers. These covers should not be air tight, but provide protection
against dust, dirt and nesting animals. If stored out doors, the pump should be
covered.

During storage, the Drive Shaft should be rotated by hand (monthly) to move
the grease around in the Bearing. If pump is stored in an area where it may be
effected by vibration from other equipment, etc., the Shaft should be rotated by hand
more often than if not effected by vibration.

ROTATE EVERY 30 DAYS.

Grease the Bearings (1 to 2 shots from standard grease gun) as you rotate
the Shaft. Also flush the Shaft Seals with new grease. Follow standard start up
procedure outlined in the "Operation" section of this manual.

When the pump is started, watch for excess heat or vibration.

USED PUMP STORAGE...

A used pump should be completely disassembled and cleaned. All unpainted

metal parts should be coated with grease. All painted metal parts should be touched
up or repainted.

Reassemble the pump as outlined in the "Maintenance" section of this

manual or as you would a new pump.

45
STORAGE OF SPARE PARTS

Spare parts may or may not come to you with adequate protective coating
and wrapping for long term storage. It is the customer's responsibility to ensure that
spare parts are prepared properly for storage.

All the Bearings should be stored in their original boxes and put into service
in accordance with the "Lubrication" section of this manual.

46
 APPENDIX A
PARTS DESCRIPTION

BOLT TORQUE CHART

47
 PARTS DESCRIPTION
(Non-Modular)

NOTE: A genuine effort has been made to maintain the same Item
Number for the same part on all Orion Pumps. However, this may not
always be possible. The Item Numbers called out in this manual are
based on the standard Item Number List. Always refer to the computer
generated parts list provided with this manual. This list is the exact parts
and part number provided on your pump.

ITEM DESCRIPTION FUNCTION QTY. FIGURE

1 Bearing Housing Cast tube used to support & 1 2
enclose bearings, etc.
2 Piston Ring Used to seal bearing tube from 4 2A
external contaminants.
3 Bearing Tapered roller bearing used to 2 2
support turning members.
4 Grease Fitting Used to grease bearing & labyrinth 4 2
seals.
5 End Covers Used to enclose end of bearing 2 2
housing.
6 Shims Used to adjust end cover for as 2
proper bearing clearance req'd
7 End Cover Bolts Used to fasten end cover to 16 2
bearing housing.
8 Grease Retainer Used to keep grease in brg. area. 2 2
MUST NOT ROTATE ON SHAFT.
9 Lock Nut Used to retain labyrinth seal plate 1 2
on driven end of Shaft.
10 Labyrinth Used to seal bearing from outside 2 2
dirt, etc.
10 Labyrinth Used to seat piston rings in place. 2 2A
11 Drive Shaft Used to turn Impeller. 1 2
12 Lock Washer Used with Item 7. 16 2
12 Flinger Used to keep contaminants from 4 2A
entering the bearing cylinder.
13 Key Used on driven end of the Shaft to 1 2
keep sheave from turning on Shaft
14 Bearing Housing Assembly of all the above parts. 1 2, 2A
16 Adjustment Screw Used to adjust the bearing housing 1 **
to get the proper Impeller
clearance to Backliner

48
ITEM DESCRIPTION QTY. FIGURE
17* Casing Used to enclose Impeller and 1 **
provide directional output of pump.
18 Casing Bolts Used to hold the casing to the note 1 **
base
19 Casing Nut Used with Item 18. note 1 **
20 Flat Washer Used with Item 18 & 21. note 1 *
21 Casing Clamp Bolt Used to hold casing to base while 2 **
Casing Bolts are loosened to
remove shims.
22 Casing Clamp Nut Used with Item 21. 2 **
24 O-Ring Used to seal Casing and Backliner 1 **
25 Shim Pack Used to adjust Impeller clearance as **
to casing. req'd
26 Disch. Flange Used to connect Disch. Pipe to 1 **
Casing. This unit consists of the
Flange & hardware to mount it.
28 Disch. Joint Used to seal Disch. pipe. 1 **
29 Backliner Bolt Used to bolt the Backliner to the 4 **
adaptor.
30 Backliner Washer Used with Item 29. 4 **
31 Backliner Nut Used with Item 29. 4 **
32 Expeller Used to force mat'l away from the 1 3
seal area on a Centrifugal Seal.
33 Expeller Ring Used to seal back of Impeller area 1 3
& hold Packing.
34 Flat Washer Used with Item 95. 5 **
35 Base Washer Used with Item 98. 2 **
36 Gland Follower Used to tighten Packing. 1 3-4-5
37 Gland Follower Bolt Used to tighten the Gland Follower 3 3-4-5
38 O-Ring Retainer Used to hold the Backliner bolts in 1 **
place durring assembly.
NOT A SEAL
41* Impeller Used to pump Mat'l. 1 **
42* O-Ring Seal Used to seal Impeller to the 1 3-4-5
Expeller or Impeller to spacer.
43 Intake Flange Used to connect suction pipe to 1 **
casing. Unit consists of Flange &
hardware to mount.
44 Intake Joint Used to seal suction pipe. 1 **
45 Horiz. Pump Base Used to anchor pump & mount all 1 **
other pump conponents.

49
ITEM DESCRIPTION QTY. FIGURE
46 Lantern bushing Used to Distribute gland coolant to 14
the Packing area.
47 Lantern Ring Used to distribute grease on a 1 3-5
Centrifugal Seal and coolant flush
on a low flow seal.
49 Neck Ring Used to hold Packing in place on a 1 3-5
Centrifugal & low flow seal.
50* Packing Used to seal where drive shaft 4 3-4-5
enters pump area.
51 Flat Washer Used with Item 53. 2 **
52 Saddle Used to adjust bearing housing to 1 **
get Impeller clearance to Backliner
53 Saddle Bolt Used to hold saddle to bearing 2 **
housing.
54 Bolt Used to attach vertical base to the 4 **
horizontal base.
55 Flat Washer Used with Item 54 4 **
56* Shaft Sleeve Used as a replaceable wear sleeve 1 3-4-5
over drive Shaft.
57* O-Ring Used to seal each end of Shaft 2 3-4-5
Sleeve.
59 Shaft Spacer Used to space between the 1 4-5
Impeller & Shaft Sleeve on full &
low flow seals. The Expeller takes
up this space on Centrifugal Seal.
61 Stuffing Box Used to seal back pump area & 1 4-5
house Packing on full, low &
Mechanical Seals.
62 Seal Used to seal between stuffing box 1 4-5
& the Backliner on full & low flow
seal assemblies.
63 Flat Washer Used with Item 98. 2 **
64 Flat Washer Used with Item 91. 4 **
65 Withdrawal Screw Used to move Frame away from 2 **
casing during adjustments – not
shown in detail.
70* Backliner Replaceable wear back in pump 1 **
area.
71 Grease Fitting Used to grease centrifugal seal. 1 **

90 Frame Used to mount bearing housing 1 **

adapter.
91 Bolt Used to attach clamp to Frame. 4 **

50
ITEM DESCRIPTION QTY. FIGURE
92 Clamp Used to clamp bearing housing 2 **
into Frame.
94 Adapter Used to adapt Frame to fit many 1 **
different casings.
95 Bolt Used to join adapter to Frame. 5 **
96 Vert. Base Used to support casing. 1 **
97 Spacer Used to space Frame for different 1 **
pump sizes. Used only on 30”
Impeller or larger.
98 Bolt Used to attach spacer to horizontal 2 **
base.
99 Nut Used with Item 95. 5 **
160* O-Ring Used to seal between stuffing box 1 3
& Backliner.

* Stock as spare part

**See Assembly Drawing

51
METRIC BOLT TORQUE VALUES
All bolts provided on METSO MINERALS ORION PUMPS will be a metric
thread form with a Strength Grade Designation of 8.8. Strength Grade for metric
hardware is the same as designating a Grade 2 or 5 or 8 in the English System. The
first digit (8) is one tenth (1/10) the minimum tensile strength in kilograms of force
per square millimeter (same as pounds per square inch in English System). The
second digit (8) is one tenth (1/10) the ratio between the minimum yield stress and
the minimum tensile strength, expressed as percentage.

Refer to the computer generated Bill of Material in this manual for the exact
hardware provide on your pump. Many times the hardware will not be referred to in
the proper metric format. For example, instead of calling Item No. 18 on a Frame C
Pump an M-16 X 2-6g-8.8 X ? Length, it is simply called a Casing Bolt. Therefore,
measure the diameter to determine the size of the hardware used. This is a
complete torque listing for a large percentage of metric fasteners available. All bolts
in the listing are not used on all pumps.

Metric Bolt Designation

M = Metric
16 = Approximate diameter in Millimeters
x 2 = Pitch in Millimeters
-6 = Class of Fit
g = External Threads - H = Internal Threads
8.8 = Strength Grade

Conversion Factor:

------- 25.4 millimeters is equal to 1"

2.54 centimeters is equal to 1"
.254 decameters is equal to 1"
.0254 meters is equal to 1"

------- 1.3558 Newton Meter (Nm) is equal to 1 ft/lb of torque

1 Newton Meter (Nm) is equal to .7375 ft/lb of torque
1 Newton Meter (Nm) is equal to 8.851 in/lb of torque
1 Newton Centimeter (Ncm) is equal to .08851 in/lb of torque

52
METRIC DESIGNATION Torque (t) Zinc Plated Oiled or Dry

M 1.6 x .35-6g 17.0 Ncm

1.5 in/lb

M 1.8 x .35-6g 21.0 Ncm

1.85 in/lb

M 2 x .4-6g 35.0 Ncm

3.1 in/lb

M 2.5 x .45-6g 73.0 Ncm

6.5 in/lb

M 3 x .5-6g 128.0 Ncm

11.5 in/lb

M 4 x .7-6g 290.0 Ncm

25.6 in/lb

M 5 x .8-6g 575.0 Ncm

50.9 in/lb

M 6 x 1-6g 10.0 Nm
7.4 ft/lb

M 8 x 1.25-6g 24.0 Nm
17.7 ft/lb

M 10 x 1.5-6g 48.0 Nm
35.4 ft/lb

M 12 x 1.75-6g 83.0 Nm
61.2 ft/lb

M 14 x 2-6g 132.0 Nm
97.4 ft/lb

M 16 x 2-6g 200.0 Nm
147.5 ft/lb

M 18 x 2.5-6g 275.0 Nm
202.8 ft/lb

53
METRIC DESIGNATION Torque (t) Zinc Plated Oiled or Dry

M 20 x 2.5-6g 390.0 Nm
287.6 ft/lb

M 22 x 2.5-6g 530.0 Nm
390.9 ft/lb

M 24 x 3-6g 675.0 Nm
497.8 ft/lb

M 27 x 3-6g 995.0 Nm
733.8 ft/lb

M 30 x 3.5-6g 1350.0 Nm
995.6 ft/lb

M 33 x 3.5-6g 1830.0 Nm
1349.6 ft/lb

M 36 x 4-6g 2360.0 Nm
1740.5 ft/lb

M 39 x 4-6g 3050.0 Nm
2249.4 ft/lb

54