ASSEMBLY

AND

MAINTENANCE

INSTRUCTIONS

KREBS millMAX

22X20-56 UMD WATER SEAL

CONVERSION KIT

TO

WARMAN 20X18 TUAH

SERIAL NUMBER: KM07591

TAG: 410-PP-001

FOR

MINERA CANDELARIA

PO.: ZC000000YN

CONTRACT N° 32451201247-001

FLSmidth S.A.
Aven. Fresia 2132 , Renca, Santiago, Chile.
Teléfono: (2) 4638300, Fax: (2) 463-8383
Nuestros contactos:
Darrell Mckiernan (Darrell.mckiernan@flsmidth.com)
Max Wedeles (Max.Wedeles@flsmidth.com)
Page 2 of 13

Foreword
This manual contains information for assembly and maintenance only of the mill-
MAX™ Conversion Kit.

For information on the following, refer to the original Warman Manual:

x Safety Precautions
x Installation
x Commissioning
x Operating Instructions

This Manual Is Divided Into The Following Sections:

x Servicing and Repair Information
x Preparation of Donor Warman Pump
x Assembly of Conversion Kit
x Routine Maintenance
x Parts Replacement
x Component Parts

The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installa-
tion, operation and maintenance of the equipment. An exhaustive enumeration of
all conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instructions, and which the operator is/or feels unable to handle, it is recom-
mended that FLSmidth is contacted without undue delay for advice on appropriate
action.

All references to relevant safety standards are given at the EC declaration of con-
formity if required.
Reference by seller to any international or national standard does not incur an
obligation on seller; to provide any recipient, reader or user of the documentation
with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own
cost – to obtain necessary knowledge of the contents of any of the standards
referred to.

Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or
parts of the installation.
Attention text is concluded with a filled black square to symbolize end of attention
text. „

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 3 of 13

Table of contents
1.0 PREPARATION OF DONOR WARMAN PUMP................................................... 4
1.1 REMOVAL OF WET END COMPONENTS................................................... 4
1.2 CLEANING OF PEDESTAL MOUNTING POSTS .......................................... 4
1.3 ADJUSTMENT OF BEARING CARTRIDGE ASSEMBLY ................................. 4
2.0 ASSEMBLY OF CONVERSION KIT ................................................................ 4
2.1 MOUNTING SHAFT SLEEVES AND GLAND COMPONENTS.......................... 4
2.2 HUB PLATE ADAPTER (1) TO BACKLINER (2A) ........................................ 4
2.3 STUFFING BOX (24) TO HUB PLATE ADAPTER ........................................ 5
2.4 HUB PLATE ASSEMBLY TO PEDESTAL .................................................... 5
2.5 IMPELLER (19) ................................................................................... 5
2.6 CASING (6) ....................................................................................... 5
2.7 SUCTION LINER (2) AND SUCTION PLATE (37) ...................................... 6
2.8 ADJUSTMENT OF IMPELLER CLEARANCE ................................................ 6
2.9 STUFFING BOX ALIGNMENT AND PACKING ............................................ 6
2.10 FLANGE GASKETS ............................................................................. 7
3.0 Maintenance ............................................................................................ 7
3.1 ROUTINE MAINTENANCE ..................................................................... 7
3.2 SUCTION LINER WEAR RING ADJUSTMENT ............................................ 7
3.3 GLAND WATER REQUIREMENT ............................................................. 7
3.4 GLAND SEAL ADJUSTMENT .................................................................. 7
4.0 PARTS REPLACEMENT ............................................................................... 8
4.1 SUCTION LINER (2) ............................................................................ 8
4.2 SUCTION LINER AND WEAR RING ASSEMBLY......................................... 8
4.3 IMPELLER (19) ..................................................................................12
4.4 CASING (6) ......................................................................................12
4.5 BACKLINER (2A)................................................................................13
4.6 GLAND WATER SEAL ..........................................................................13

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 4 of 13

1.0 PREPARATION OF DONOR WARMAN PUMP

1.1 REMOVAL OF WET END COMPONENTS

x The millMAX ™ conversion kit requires only the existing Warman pump ped-
estal with bearing cartridge assembly.
x Remove all wet end components as normal for a total wet end rebuild includ-
ing all gland parts with shaft sleeve.
x Remove the frame plate from the five mounting posts on the pump pedestal.
x Follow the disassembly procedures outlined in the Warman Manual.

1.2 CLEANING OF PEDESTAL MOUNTING POSTS

x Ensure rabbet location fit on the five mounting posts is clean to accept the
conversion kit adapter (1).

1.3 ADJUSTMENT OF BEARING CARTRIDGE ASSEMBLY

x Loosen clamp bolts holding bearing cartridge to pedestal and check that as-
sembly moves freely in both directions using the adjusting screw.
x If bearing cartridge assembly does not slide freely in both directions it must
be lifted from the pedestal and the mating surfaces cleaned to ensure a neat
fit.
x Tighten clamp bolts to ensure bearing cartridge assembly sits down fully in
normal working position. This allows the gland to be centered in the correct
position during subsequent assembly.

2.0 ASSEMBLY OF CONVERSION KIT

2.1 MOUNTING SHAFT SLEEVES AND GLAND COMPONENTS

x Fit sleeve spacer gasket (23) on shaft, up against the existing release collar.
x Fit sleeve spacer (22) over shaft and against sleeve spacer gasket.
x Fit another sleeve spacer gasket (23) on shaft, up against sleeve spacer.
x Fit shaft sleeve (27) with tapped holes facing the away from the sleeve
spacer and slide down to sleeve spacer (22).
x Fit gland follower (16) with large flange facing bearing assembly over shaft
sleeve and slide down to release collar.

2.2 HUB PLATE ADAPTER (1) TO BACKLINER (2A)

x Locate back liner (2A) and orient with studs facing up.
x Locate hub plate adapter (1) and orient with small flange with two o-ring
grooves facing up.
x Fit o-rings (5) and (10) in grooves of hub plate adapter using gasket adhe-
sive to hold in place.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 5 of 13

x Turn hub plate adapter over and fit over back liner aligning the machined
rabbet near the OD and the studs in the back liner with the machined ID
rabbet and drilled through holes of the hub plate adapter.
x Bolt together using flat washers (3), lock washers (28), and nuts (9).
Tighten ensuring the hub plate and back liner is flush with each other on the
face near the OD of the back liner.

2.3 STUFFING BOX (24) TO HUB PLATE ADAPTER

x Fit lantern bush (21) with small OD end down into bore of stuffing box (24).
x Locate stuffing box gasket 24A against the drive side of the hub plate
adapter (1), aligning the holes with the tapped holes of the hub plate
adapter. Locate stuffing box (24) flange next in the same way. Install stuff-
ing box bolts (33) and flat and lock washers (32 and 34). Ensure sealing
water ports are on horizontal center-line before installing fasteners. Tighten
the stuffing box bolts firmly enough to hold stuffing box against hub plate
adapter, but still allow the stuffing box to be moved later for alignment with
the shaft sleeve.

2.4 HUB PLATE ASSEMBLY TO PEDESTAL

x Fit five base studs (38) in tapped holes of the hub plate adapter bosses (1).
x Locate hub plate adapter (1) in position on the five pedestal mounting posts
and ensure it fits flush to the face of the posts.
x Fit washers (40) and nuts (39) and bolt securely in position on pedestal.

2.5 IMPELLER (19)

x Fit two impeller gaskets (20) over shaft thread and against shaft sleeve.
Liberally coat the threads of the shaft with grease or anti-seize compound.
x Suspend impeller (19) vertically and offer up to shaft thread.
x Rotate drive end of shaft in a clockwise rotation. If resistance is felt, raise or
lower impeller slightly. Rotate until tight. Ensure that all sleeve components
are rotating with impeller when tight.
x It is important that the impeller is located tightly. If it is not, on start-up the
initial torque will further screw on the impeller, and alter the adjustment of
the impeller relative to the suction liner. If the impeller fouls against the
back liner during installation, adjust the bearing assembly forward to free
it.„

2.6 CASING (6)

x Orient casing for proper discharge position and fit to hub plate so that it fits
over the back liner and the internal rabbet of the casing fits in the OD rabbet
of the hub plate just past the o-ring. Also make sure the tapped holes in the
casing align with the through holes in hub plate.
x Bolt casing to hub plate using bolts (35) and washers (3).

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 6 of 13

2.7 SUCTION LINER (2) AND SUCTION PLATE (37)

x Locate the suction plate (37) and orient with the o-ring grooves facing up.
Fit the casing and suction liner o-rings (5 and 10) into grooves on the suc-
tion plate, using gasket adhesive to hold in place.
x Locate the suction liner (2) and orient so the studs are facing up. The suc-
tion liner is supplied with the wear ring (25) already fitted. Remove the two
wear ring stud nuts (31C) and washers (31B).
x Roll suction plate over and fit on suction liner so suction liner studs align with
through holes in the suction plate, and wear ring screws (31) and wear ring
studs (31A) go through holes in suction plate. Ensure that suction liner rab-
bet fit goes in suction plate rabbet.
x Fit suction liner flat washers (3), lock washers (28), and nuts (9) on suction
liner studs and tighten evenly until suction plate and suction liner are metal
to metal at the suction liner OD face area.
x Fit the wear ring stud washers (31B) and nuts (31C) on wear ring studs
(31A) and tighten enough to keep the washers (31B) from being loose on
the studs.
x Offer suction plate/liner assembly to casing, aligning the suction plate holes
with the casing tapped holes. Insert suction liner into casing tapered bore.
x Bolt suction plate to casing with bolts (35) and washers (3) and tighten
evenly until suction plate large flange face is flush with casing machined in-
serts.
x Adjust bearing assembly away from suction liner if necessary to prevent im-
peller from interfering with installation of suction plate. Rotate shaft during
the tightening of the suction plate bolts to ensure suction liner is not fouling
on impeller. Impeller must rotate freely after installation of suction plate to
casing.

2.8 ADJUSTMENT OF IMPELLER CLEARANCE

x Adjust bearing assembly to bring impeller (19) within 1.5mm (1/16”) from
the wear ring (25). This can be verified by looking into the ID of the suction
liner. Do not loosen the rear bearing assembly hold down bolts enough to
make the bearing housing come up out of the pedestal saddle or the impeller
will not be parallel with the suction liner. Rotate the shaft a full turn to en-
sure there is no fouling of the impeller against the suction liner. If the shaft
will not rotate, adjust the bearing assembly further away from the suction
side until the shaft rotates freely. Tighten the bearing assembly hold down
bolts.

2.9 STUFFING BOX ALIGNMENT AND PACKING

x Adjust the stuffing box position on the hub plate adapter until the gap be-
tween the stuffing box bore and the O.D. of the shaft sleeve is consistent
within 0.25mm (.010”). Finish tightening the stuffing box bolts (33) and
torque to 270Nm (200 ft. lbs.).
x Install the four rings of packing (26), staggering the seams of the joints 90
degrees for each ring. Coat the ID of the packing rings with anti-seize com-
pound before fitting into the stuffing box.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 7 of 13

x Fit the four gland studs (18) in the tapped holes of the stuffing box. Fit the
gland follower (16) to the stuffing box, aligning the slots with the studs just
fitted. Fit the washers (17) and nuts (39) and tighten the end of the gland
follower contacting the packing is flush with the top of the stuffing box bore.
DO NOT TIGHTEN FURTHER „

2.10 FLANGE GASKETS

x A flange gasket (11) is provided with thick soft rubber for sealing on the cas-
ing flange. A gasket is not needed for the suction flange.

3.0 Maintenance

3.1 ROUTINE MAINTENANCE

x Routine maintenance is carried out to prolong the life of the pump parts and
to maintain pump performance to sustain the efficiency of the plant opera-
tion. Critical maintenance is adjustment of impeller running clearances.

3.2 SUCTION LINER WEAR RING ADJUSTMENT

x The wear ring (25) must be adjusted on initial start up and adjustment of
this critical clearance should be carried out about six times in the life of the
pump. The adjustment should be carried out when the pump is operating.
Caution: Over adjustment will give increased grinding and wear on mating
faces of impeller and wear ring, with a corresponding reduction in life.„
x Loosen the wear ring stud nuts (31C) so the wear ring can be moved toward
the impeller.
x The Wear ring screws (31) should be adjusted clockwise two flats each until
resistance is felt against the impeller by all screws. Slacken off by three flats
each to reset the optimum clearance.
x Tighten the wear ring stud nuts (31C).

3.3 GLAND WATER REQUIREMENT

x Connect water supply either one or two 1-1/4” NPT tapped holes in the stuff-
ing box.
x Flow required is 3.5 liters/sec (55 gpm) maximum, available at 69 kPa (10
psig) above discharge pressure of pump.

3.4 GLAND SEAL ADJUSTMENT

x Packing has to be run-in and it is good practice to start the pump with the
gland follower (16) quite loose. Packing that is too tight will cause undue
friction, creating heat, which will glaze the packing and score the shaft

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 8 of 13

sleeve. If gland water leakage is excessive, tighten the four gland nuts (39)
until water flow is reduced to prevent spraying on bearing housing.
x After running for 10 minutes, the gland follower (16) should be tightened
evenly by the four gland nuts (39) until a constant trickle is achieved.

4.0 PARTS REPLACEMENT

4.1 SUCTION LINER (2)

x Support weight of suction plate and liner.
x Remove casing to suction plate bolts (35) and washers (3) and suction plate.
x Remove suction liner nuts (9), lock washers (28), and flat washers (3).
Remove the wear ring stud nuts (31C) and washers (31B).
x Remove suction plate from suction liner.
x Replace o-rings (5 and 10).
x Replace suction liner as in 2.7.
x Adjust impeller clearance as in 2.8.

4.2 SUCTION LINER AND WEAR RING ASSEMBLY

x The wear ring can be removed by removing the wear ring stud nuts (31C)
and washers (31B). Then the wear ring screws (31) can be used to push the
wear ring out of the suction liner.
x The instructions to assemble the Suction Liner Assembly with "Rubber Suc-
tion Liner" & Wear Ring are as follows:
x Locate wear ring (25). Orient it so the two tapped holes are facing up. See
illustration below:

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 9 of 13

x Locate two wear ring studs (31A). Thread them into the tapped holes in the
wear ring. See illustration below:

x Locate the rubber suction liner (2). Orient it so the wear side is facing down.
See illustration below:

x Locate four wear ring screws (31). Lubricate the threads with anti-sieze
compound for a length of about 20mm from the threaded end. Screw the
wear ring screws about 20mm into the tapped holes in the suction liner. See
illustration on next page:

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 10 of 13

x Turn suction liner over so the suction face is on the floor. Make a solution of
50% soap and 50% water. Apply this solution to the contact faces where
the suction liner and wear ring fit together. See illustration below:

x Fit the wear ring into the suction liner aligning the two studs with the two
through holes in the suction liner. Push the wear ring in as far as possible by
hand. Two people can also stand (& jump) on it (wear ring) to help push it in
to place. See illustration on next page:

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 11 of 13

x Turn the suction liner assembly over and fit two washers (31B) and two nuts
(31C) on the studs. See illustration below:

x Thread the nuts all the way down to the steel insert of the suction liner.
Tighten the nuts with a wrench to pull the wear ring all the way into the suc-
tion liner. See top illustration on next page. When properly fitted, the wear
ring should be located as shown in the lower illustration on next page:

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 12 of 13

x Remove the two nuts and washers before fitting the suction liner assembly
to the suction plate. See image below:

4.3 IMPELLER (19)

x See Warman manual for "Release Collar Removal" instructions.
x Impeller is removed by reversing procedure 2.5. An "Impeller Lifting Jig"
must be used if the casing has not been removed.
x Replace and adjust impeller as in procedure 2.5 and 2.8.

4.4 CASING (6)

x Support the casing (6) and remove the casing to adapter bolts (35) and
washers (3).
x Remove axially away from hub plate adapter flange.
x To replace, follow sequence 2.4.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Page 13 of 13

4.5 BACKLINER (2A)

x Remove the stuffing box bolts (33), lock washers (34), and flat washers
(32). Separate the stuffing box from the hub plate adapter (1) so it will not
be removed.
x Remove the hub plate adapter/hub liner assembly by removing the base stud
nuts (39) and washers (40). Orient the hub plate adapter on the floor with
the back liner facing down.
x Remove the back liner stud nuts (9), washers (3), and lock washers (28).
Lift the hub plate off the back liner.
x Replace back liner as in sequence 2.2 and hub plate adapter as in 2.4.
x Bolt stuffing box (24) back to hub plate and align as in 2.9.

4.6 GLAND WATER SEAL

x The stuffing box (24) & lantern bush (21) should be checked when the im-
peller is replaced, so removal will be easy. The stuffing box (24) is split for
easy removal.
x To replace, follow sequences 2.3 and 2.9.

The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 CANDELARIA
TEST
KM07591
7-16-12