COVER SHEET

Project Name: Constancia Project

PO Number: 2172-0009 Variation 01
Supplier Name: Weir Minerals Latin America (VULCO PERU
SA)
Transmittal Number: 162
Date issued July 11th, 2013
List of data including number, revision Installation, Operation and Maintenance
and title: Manual in English and Spanish [CERTIFIED]

IOM: 3222-PU-006/3224-PU-008 (English)

VDDR items code: 11.01

Ausenco’s code: V-2172-0009-0072

Reason for issue: For Information

 Excellent
Weir Minerals Latin América Minerals
Vulco Perú S.A. Solutions

Instructions Operation & Maintenance

Content
Drawing List Commissioning
Certified drawing 04
Equipment Identification Pre-commissioning recommendations 39
Pumping assembly 06 Commissioning recommendations 39
Part List / Recommend Spare 08
Operation and Service Problem detection
Pump Data Sheet 11
Bolt List 15 No flow| 40
Performance Curves 17 Trapped material 40
Bearing Assembly Insufficient flow 40
Bearing drawing 19 Not enough discharge pressure 40
Lubrication Data Sheet 21 Shaft breakage or damage 40
Motor The motor works with temperature or stops 40
Motor Data Sheet 23 Problem quick guide 41
Motor Drawing 25 Operational
Instrumentation
Design Characteristics Periodical Service 41
Introduction 30 Pump maintenance instructions
Nomenclature 30
General disassembly 42
Inspection and storage Humid part disassembly 42
Bearing column disassembly 43
Inspection 32
Storage Recommendation and Procedures 32 Pump assembly instructions
Indoor long-period storage with Controlled
environment for: General assembly 46
Temperature, humidity, dust and vibration 32 Bearing column assembly 47
Bearing lubrication 49
Indoor / Outdoor with non-controlled Humid part assembly 49
Environment under all types of conditions 32 Spark test for antacid units 51
Safety and Installation General Annexes
Recommendations Pulley assembly 52
Motor storage 53
Safety Precautions 32 General instructions 54
Inspection when receiving the equipment 33 Delivery 54
Pump location 34 Storage 54
Piping 34 It is recommended to storage bearing 54
Sump design and installation instructions 34 With relation to motor storage 55
Suction extension for inferior screen 34 Motor Manual 57
Belt tension 35 Recommend Spare Parts 92
Level controls 36 Lubrication Schedule for all Motors 95
Stick or bar type level control 37
Flotation type level control 37
Bearing lubrication, grease lubrication 38
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Certified drawing

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Pumping assembly

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Part List / Recommended Spare

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Excellent
Weir Minerals Latin America Minerals
Solutions
Vulco Perú S.A.

Listado de Partes

GALIGHER 100MR4-5100x1800 D100MR4-5100 Rev. C

RUBBER LINED
ITEM DESCRIPCION CANT CODIGO VULCO
1 PEDESTAL 1 V640701029
2 BEARING ASSEMBLY 1 V604702029
3 * IMPELLER 1 V640003029
4 * LOWER SCREEN 1 V640004029
5 * UPPER SCREEN 1 V640005029
6 SHAFT 1 V604702529
7 * COVER PLATE 1 V640007062
9 HEX NUT (UP SCREEN) 4 1130145000
9A FLAT WASHER 4 1070143000
10 * CASING 1 V640010029
11 HEX NUT (DIS. PIPE) 22 1130253000
11A LOCK WASHER 22 1070252000
12 STUD (CASING) 16 V640012000
15 MOTOR BRACKET 1 V604015000
16 COTTER PIN 1 1080802000
17 HEX NUT 2 1130130000
17A FLAT WASHER 2 1070111000
18 ADJUSTING SCREW 1 V603018000
19 CLEVIS PIN 1 V604019000
22 MTR. BRACKET BRACE 1 V604022000
23 HEX NUT 4 1130251000
24 FLAT WASHER 4 1070102000
25 HEX SCREEW (DIS. PIPE) 2 1106110000
25A HEX NUT 2 1130128000
25B LOCK WASHER 2 1070206000
25C FLAT WASHER 4 1070108000
26 DISCHARGE PIPE 1 V640726029
27 HEX SCREEW (BELT GUARD) 3 1105113000
27A LOCK WASHER 3 1070205000
27B FLAT WASHER 3 1070106000
29 HEX NUT (ADJ) 6 1130125000
30 HEX SCREEW (MTR.BRKT.BRACE) 4 1100033000
30A HEX NUT 4 1130127000
30B LOCK WASHER 4 1070207000
37 HEX SCREEW (MTR.BRKT.BRACE) 6 1102168000
37A FLAT WASHER 6 1070109000
37B LOCK WASHER 6 1070207000
41 PUMP SHEAVE 1
41-1 PUMP SHEAVE BUSHING 1
42 MOTOR SHEAVE 1
42-1 MOTOR SHEAVE BUSHING 1
43 V-BELT
44 CAPNUT 4 V640044000
45 MOTOR 1
46 * IMPELLER WASHER 1 V630046000
47 BELT GUARD 1 V604047000
66 CAPNUT 22 V630006829
67 CAPNUT 4 V600006729
90 NAME PLATE 1 5009003000
91 NAME PLATE 1 5009053000
93 LOCK WASHER 3 1070216000
94 CAPNUT 4 1070216000

* RECOMENDED SPARE PARTS

 Excellent
Weir Minerals Latin America Minerals
Solutions
Vulco Perú S.A.

Listado de Partes

GALIGHER 100MR4-5100x1800
BEARING ASSEMBLY D4MRK*5002 GREASE LUBRICATION
ITEM DESCRIPCION CANT CODIGO VULCO
1 BEARING COLUMN 1 V604002100
2 BRG COLUMN BASE 1 V604002200
3 LOWER BEARING CAP 1 V604002300
4 SLINGER 1 V604002400
5 GREASE FITTING 2 1062001000
6 SHAFT 1 V604702529
7 * BEARING CONE 2
8 * BEARING CUP 1 1160066000
9 * CONE SPACER 1
10 * LOCK WASHER 1 1070309000
11 * HEX NUT 1 1130729000
12 * O-RING (LOWER) 1 1031213000
13 * LOWER SEAL 1 1010437000
14 * CHEKSEAL (LOWER) 1 V604002971
15 HEX SCREW 12 1105113000
15A LOCK WASHER 12 1070205000
16 HEX SCREW 6 1105121000
16A * LOCK WASHER 6 1070206000
17 SEAL RING 1 V604002600
18 * UPPER BEARING 1 1160037000
19 UPPER BEARING CAP 1 V604002700
20 * CHEKSEAL (UPPER) 1 V604002972
21 FLINGER 1 V604002829
22 * SEAL RING 1 1010391000
23 * RELIEF FITTING 1 1061905000
24 O-RING 1 1031213000
25 V-RING 1 V604002970
… ….
27 SET SCREW 2 1100637000
28 NIPLE GRASERA 1 1061902000

* RECOMENDED SPARE PARTS

 Weir Minerals │ 5000 Serie Vertical Pump Manual

Pump Data Sheet

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 HUDBAY PERU S.A.C.
CONSTANCIA PROJECT

Rev
DATA SHEET
DOCUMENT NO: 2172-3000-DS-009C
PACKAGE TITLE: SLURRY PUMPS
EQUIPMENT NO(S): 3222-PU-006 & 3224-PU-008 1
EQUIPMENT NAME(S): Grinding Area Sump Pump
EQUIPMENT DESCRIPTION:
VENDOR:
1.00 PROCESS INFORMATION
1.01 Sump pump is used to clean spillage from the grinding area and
PROCESS DESCRIPTION discharge to the Cyclone Feed Hopper. The pump discharge to the
grinding line 1 and line 2 cyclone hoppers.
1.02 DUTY 1 duty, 24 h/day, 7days/wk, 365 days/yr
1.03 DESIGN LIFE 16 years
1.04 LOCATION Outdoors, exposed to elements
1.05 SITE ELEVATION (ABOVE SEA LEVEL) (m) 4 000 – 4 205
1.06 SLURRY DESCRIPTION Coarse Slurry (settling) with traces of debris
1.07 SLURRY TEMPERATURE (°C) 20 - 40
1.08 SLURRY VISCOSITY (cP) 59.5
1.09 SLURRY pH 7 - 12
1.10 PARTICLE SIZE P80 = 2000µm and D50 = 300µm
1.11 SOLIDS SG (t/m3) 3.23
1.12 VAPOR PRESSURE (ABS) (kPa) 2.3
1.13 REAGENTS PRESENT IN SLURRY LIME
1.14 FROTH FACTOR N/A
2.00 DESIGN CRITERIA Minimum Nominal Maximum
2.01 SOLIDS THROUGHPUT (t/h) 124.3 1
2.02 SOLIDS CONCENTRATION (%w/w) 57.6
2.03 SLURRY SG (t/m3) 1.66
2.04 SLURRY FLOWRATE (m3/h) 130.0 1
2.05 SLURRY DISCHARGE PRESSURE (kPa) Atmospheric
2.06 DESIGN DYNAMIC SUCTION HEAD (SLURRY) [NOTE 9.04] (m) 0.3 1
2.07 DYNAMIC DISCHARGE HEAD (SLURRY) [NOTE 9.01] (m) 11.9 1
2.08 TOTAL DYNAMIC (DEVELOPED) HEAD (SLURRY) [NOTE 9.01] (m) 11.6 1
2.09 NPSHA (SLURRY) (m) -
2.10 PERCENTAGE OF TIME USED AT NOMINATED DUTY (%) 100
3.00 PUMP FEATURES
3.01 PUMP CONFIGURATION Vertical Cantilevered Centrifugal, column length 1800mm 1

3.02 DRIVE CONFIGURATION V Belt drive

3.03 DISCHARGE CONFIGURATION Flange on mounting plate
3.04 MEANS FOR MAINTAINING EFFICIENCY / ADJUSTMENT FOR WEAR

3.05 BASE-FRAME MOUNTING ARRANGEMENT Pump, bearing pedestal and drive to be supported by an integral
horizontal mounting plate.
3.06 MOTOR TERMINAL BOX ARRANGEMENT On RHS, facing motor shaft
3.07 SPEED CONTROL Fixed Speed
3.08 SHAFT SEALING SYSTEM -
3.09 PUMP SUCTION / DISCHARGE FLANGES ASMEB16.5 or Manufacturer's standard. Supply with matching flange
for incorporation in Purchaser's piping if not to ASME B16.5.
3.10 POWER SUPPLY (V / Hz / ph) 460/60/3

Data Sheet-009C-Sump pump modified.xls 3222-PU-006&3224-PU-008 Page 1 of 3

 SCHEDULE OF TECHNICAL INFORMATION
4.00 EQUIPMENT DATA Vendor to provide/confirm details
4.01 TENDERER / SUPPLIER Weir Minerals
4.02 MANUFACTURER Weir Minerals
4.03 MODEL NO. / DESIGNATION 100 - MR4 - 5100 x 1800
4.04 DRIVE CONFIGURATION
4.05 CAPACITY AND POWER DATA
4.06 PROPOSAL CURVE NO. C4-5081/C
4.07 PERFORMANCE
4.08 SLURRY FLOW-RATE (m3/h) 130.00
4.09 TOTAL HEAD (WATER) [NOTE 9.01] (m) 11.61
4.10 EFFICIENCY (%) 45.1
4.11 SHAFT POWER (kW) 12.00
4.12 PUMP SPEED (rpm) 985.00
4.13 NPSHR (ABS) (SLURRY) (m) -
4.14 PUMP CHARACTERISTICS
4.15 MAX POWER (kW) 12
4.16 SHUT-OFF HEAD (m) 19
4.17 MIN CONTINUOUS FLOW-RATE (m3/h) 25
4.18 MAX ALLOWABLE SPEED (rpm) 1700
4.19 SPECIFIC SPEED -
4.20 PUMP CONSTRUCTION
4.21 IMPELLER DIAMETER (mm) 342.9
4.22 ROTATION CW / ACW (FACING PUMP COUPLING) CW
4.23 MAX WORKING PRESSURE (kPag) 517
4.24 HYDROTEST PRESSURE (kPag) -
4.25 CONNECTIONS
4.26 SIZE (NS) (mm)
4.27 FLANGE RATING
4.28 FLANGE FACING
4.29 LOCATION (FRONT / TOP / SIDE)
4.30 CASING
4.31 TYPE Double suction
4.32 MOUNTING (FOOT / CENTRELINE) Horizontal
4.33 CASING SPLIT (AXIAL / RADIAL) Axial
4.34 MATERIAL Cast iron
4.35 LINING MATERIAL Rubber Natural
4.36 LINING THICKNESS (mm) To be confirmed
4.37 IMPELLER
4.38 TYPE Semi open
4.39 MATERIAL Cast iron covered
4.40 LINING MATERIAL Rubber Natural
4.41 MAX POSSIBLE DIAMETER (mm) 342.9
4.42 ATTACHMENT (THREADED / KEY) -
4.43 SHAFT
4.44 DIA @ BEARINGS / IMPELLER (mm) To be confirmed
4.45 MATERIAL SAE 1045
4.46 SLEEVE MATERIAL Doesn´t Apply
4.47 SHAFT SEAL Doesn´t Apply
4.48 MAKE/TYPE
4.49 MATERIALS
4.50 SEAL WATER FLOW-RATE (l/m)
4.51 SEAL WATER SUPPLY PRESSURE (kPag)
4.52 BEARINGS
4.53 MANUFACTURER SKF / Timken or similar
4.54 RADIAL BEARING SIZE / DESIGNATION (mm) To be confirmed
4.55 THRUST BEARING SIZE / DESIGNATION (mm) To be confirmed
4.56 LUBRICATION Grease
4.57 SEAL TYPE Labyrinth
4.58 B10 LIFE (h) > 60 000
4.59 DRIVE
4.60 TYPE V-belt
4.61 RATIO 1.78
4.62 NO OF BELTS 4
4.63 BELT SPECIFICATION / MANUFACTURER 5V / TB Woods

Data Sheet-009C-Sump pump modified.xls 3222-PU-006&3224-PU-008 Page 2 of 3

5.00 MOTOR [Note 9.03]
5.01 MOTOR SUPPLIER Teco Westinghouse
5.02 DRIVE TYPE Vertical
5.03 RATED OUTPUT (kW) 30 (40 HP) 1
5.04 NUMBER OF POLES 4
5.05 VOLTAGE (V) 460
5.06 FRAME D200L-55
5.07 STARTER TYPE DOL 1
5.08 WINDING TEMPERATURE SENSORS (NUMBER & TYPE) 3 PTC thermistors (one per phase)
5.09 BEARING TEMPERATURE SENSORS (NUMBER & TYPE) N
5.10 MOTOR HEATER (Y/N) N
5.11 MOTOR HEATER VOLTAGE (V) -
6.00 SURFACE PROTECTION / PAINT SYSTEM
6.01 SURFACE PREPARATION
6.02 PRIME COAT SPECIFICATION / DFT (µm)
6.03 INTERMEDIATE COAT(S) SPECIFICATION / DFT (µm)
6.04 FINISH COAT SPECIFICATION / DFT (µm)
6.05 TOP COAT COLOUR
7.00 MASSES AND SIZES (approx)
7.01 OVERALL DIMENSIONS (L X W X H) (mm)
7.02 HEAVIEST PIECE FOR INSTALLATION (kg)
7.03 HEAVIEST PIECE FOR MAINTENANCE (kg)
7.04 TOTAL SHIPPING MASS (kg)
8.00 ASSEMBLY AND TESTING
8.01 EXTENT OF SHOP ASSEMBLY
8.02 EXTENT OF SHOP TESTING
8.03 EXTENT OF ASSEMBLY FOR DELIVERY
9.00 NOTES
9.01 Head figures do not include (HR and ER) derating factors. Supplier to check and advise Purchaser.
9.02 Three PTC thermistors (one per phase) Motor < 37kW (VSD driven only)
Three PTC thermistors (one per phase) 37kW <= Motors <= 75kW
Six PTC thermistors (two per phase) Motors >= 75kW
Three PT100 RTD's (one per phase) >= 110kW + Bearing Temp for Drive end and Non-drive end
Motor >= 110kW Shall include Heater 220V a.c. 1 phase

9.03 Head figures do not include suction losses of any kind. The suction head quoted is the assumed free liquid surface level above the pump's impeller

Data Sheet-009C-Sump pump modified.xls 3222-PU-006&3224-PU-008 Page 3 of 3

 Weir Minerals │ 5000 Serie Vertical Pump Manual

Bolt List

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Curve

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Vertical Pump
4 5000
CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water,
corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame
suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.
60 Pump
Maximum RPM for Rubber Impeller is 1414 RPM
Discharge 102mm
Impeller
1700 rpm Vane ø 342.9mm
20% Part No Material
30%
40% Frame (Rating - KW)
50
45% Max Pump Speed
1600 rpm
49% Pump Length Drives
(Inches)
No 2 No 3 No 4
51.5%
24 1100

36 1100 1400 1700

40 48 1100 1300 1700

60 1200 1700
1400 rpm
49% 72 1100 1400

NCY
Seal

CIE
EFF I
No Sealing
30 Nominal Correg.
NI 15366 Liner (Norm Max r/min)
Flow = 130.0 m³/hr
TAG: 3222-PU-006 & 3224-PU-008

Head, H (m)
1200 rpm H(W) = 14.7 m Unlined 1700
GRINDING AREA SUMP PUMPS
Speed = 985 rpm Curve
45%
CONSTANCIA PROJECT
Eff = 45.1 % Revision 2
Consideraciones.
NPSHr = - m
Revision Notes B
P = 12 kW
G.e Púlpa = 1.66 Reference
Sm = 1.00
20 1000 rpm G.e Sólidos = 3.3 Madison tests 08-1004, 1210, 1222,
% Sol. Peso = 57.6 1224
D50 =300 um Last Issued Jun 96
Hr = 0.792
Issued Jul 09
Nominal Er = 0.753
800 rpm
Flow = 130.0 m³/hr
H(SL) = 11.6 m Vel. Periférica = 17.7 m/s
10
Speed = 891 rpm
Eff = 42.8 % BHP = 26.86
NPSHr = - m Motor de 40 HP
P = 10 kW Efectivo a 4200 m.s.n.m
Sm = 1.00
© 10/2012 Weir Minerals North America
All Rights Reserved
50 100 150 200 250 300 TYPICAL PUMP PERFORMANCE CURVE

Flow Rate, Q (m³/hr) C4-5041/B

 Weir Minerals │ 5000 Serie Vertical Pump Manual

Bearing drawing

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Lubrication Data Sheet

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Motor Data Sheet

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Motor Drawing

© Copyright Weir Minerals Peru, Inc. 2009

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

II. DESIGN FEATURES

1. Introduction

Galigher Vertical Pumps are rugged, cantilevered,

centrifugal slurry pumps that can handle fluids with
abrasive solids, pulps, acids, chemical slurries, and
froths with ease.
These pumps can be furnished with abrasion resistant
ELASTOGARD covered parts for long life, acid-proof
parts for corrosion protection, or with metal
construction for higher pressure and higher
temperature service. Materials of construction can be
mixed to provide unique arrangements of elastomer
and metal for special application requirements.

The double-suction design and construction provide a

thrust less impeller that will not air lock. A rugged
heavy duty bearing assembly supports the shaft and
bearings and is designed to provide dependable
operation and long life.

A three point mounting and adjustment feature allows

easy setting of impeller clearances while maintaining
pump shaft and case alignment.
The discharge pipe terminates above the heavy-duty
mounting plate to provide easy access for connections
to external piping.

The Galigher Vertical Pumps can be furnished with

special features and arrangements. Suction pipe
extensions are available to allow moderate increase in
sump depth operation. Liquid level sensor and controls
are available which will allow automatic operation.
Weir Minerals stands ready to assist in solving
performance, operational, or maintenance problems
that may be experienced.

2. Nomenclature

The recognition of the nomenclature of Vertical Pumps

Galigher is vital for the correct identification of the parts
that you need in each particular team, then shows all
possible configurations in Figure II.1

© Copyright Weir Minerals Peru, Inc. 2009 30

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Nomenclatura Bombas Verticales Serie 5000 Tamaños Portarodamientos

n° Bomba
Tipo Construcción 0 40
S Pulgadas 1 40, 50
M Milímetros 2 40, 50, 80, 100
3 40, 50, 80, 100
Tamaños Descarga 4 80, 100, 150, 200
mm pulg 5 150, 200
40 1.5 6 300
50 2
80 3
100
150
4
6
50 MR2-5100 x1500A Posee Agitador

200 8 Largos
Modelo tipo mm pulg
Tipo Material 600 24
A Antiabrasiva 900 36
R Antiácida 1200 48
N Alto Cromo 1500 60
H Fundición 1800 72

Figura VII.1.- VII.1 Nomenclature pumps Galigher Vertical

As stated earlier it is important to clarify the type of

pump and material of the equipment being used in
the request for spare parts.

Orders for parts should specify the quantity ordered, the

code Vulcan, the description of the item and/or type
material (type of rubber foundry, etc.).

If you do not have available the overall package supplied

with the pump, use the serial number of the pump and
use the item numbers of the general body of the plane,
shown on the nameplate of the equipment, see figure
VI.2.

Figure II.1 Plate of Identification of the Pumas Galigher Vertical.

© Copyright Weir Minerals Peru, Inc. 2009 31

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

III. GENERAL SAFETY RECOMMENDATIONS AND

INSTALLATION

1. Safety precautions

Centrifugal pumps can be dangerous if used improperly.

Disregarding any of the following precautions may result in
a pump which does not function properly and which could
cause damage or injury. Operation and maintenance
instructions must be read before starting the pump.

The following list is not comprehensive, but is provided as

examples of actions that can damage a pump and cause
injury.

1. Do no connect the pump to the drive system before first

checking to see that the drive motor rotation is correct.
Rotation must be clockwise when viewed from the drive
end of the pump.

2. Do not work on a pump unless the drive system is

locked out and the pump is disconnected from the drive
system.

3. Do not operate a pump when the bearing temperature

measured in the outside of the housing exceeds 220°F.

4. Do not continue to operate a pump when there are

indications of internal rubbing, binding or knocking.

5. Do not operate a pump with the belt or coupling guard

removed.

6. Do not operate a pump with the discharge line

restricted or plugged or the discharge valve closed.

7. Do not start a pump which is “wind-milling” in the

reverse direction because fluid is flowing back down
the discharge pipe and into the pump.

8. Do not stick hands, arms, legs or any other objects into

the rotating components of the pump or motor.

9. Do not use worn of faulty parts.

10. Do not weld attachments to the pump.

11. When the top screen of the vertical pump is exposed

while pumping, it is normal for splashing of the sump
fluid to occur. Proper splash protection should be
provided.

© Copyright Weir Minerals Peru, Inc. 2009 32

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

12. Lubrication water, when required, must be turned on

before starting the pump.

13. Do not operate the pump if solids have settled in the

casing and rotating elements cannot be turned by
hand.

For maximum safety and reliability, use only genuine

Galigher pump replacement parts. Only Galigher pump
parts meet all original manufacturing specifications.
Weir Minerals ELASTOGARD proprietary rubber
compounds insure maximum abrasion and corrosion
resistance.

The use of non-Galigher pump parts in the company’s

products is not authorized, and may result in voiding the
Company’s factory warranty and in providing factory
service support. Further, the Company disclaims products
liability for any product in which non-Galigher pump parts
are used.

IMPORTANT: It is recommended to include all safety

procedures for maintenance, safety measures to
avoid accidents in the maintenance and removal
of equipment

Note: For maximum safety and performance, use only

genuine spare parts Galigher. Only spare parts for
pumps Galigher, comply with all the original
manufacturing specifications. Elastomer rubber
compounds used by VULCAN SA in the
manufacture of spare parts Galigher ensures
maximum resistance to abrasion and corrosion.

The use of parts of pumps, which are not Galigher in

the company's products are not authorized may
result in cancellation of the factory warranty of
Vulcan SA and the provision of support services
from the factory. In addition, Vulcan SA, neglected
the responsibility on the product for any team, in
which parties have used non Galigher.

2. Inspection Upon Arrival

Your pump has been carefully inspected prior shipment

to ensure that it meets your requirement to ensure that
it meets your requirements. Please inspect the pump
upon arrival for any damage which may have occurred
during shipment. Report any damage immediately to

© Copyright Weir Minerals Peru, Inc. 2009 33

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

the carrier. Leave all shipping covers and shaft

blocking attached until ready for installation.

Spare parts should be inspected with equal care for

shipping damage. Storage locations for rubber
components should be made in cool shaded areas
away from electrical equipment to extended shelf life as
long as possible.

3. Pump Location

Select the pump location so that unit is accessible for

inspection during operation and during maintenance
operations involving removal and disassembly.

4. Piping

A check valve and a gate valve are often installed in

the discharge line. The check valve is used to prevent
fluid from flowing back through the pump while it is shut
down .
The gate valve blocks the discharge line during
maintenance.

When rigid discharge piping is used, caution should be

exercised so that external stresses are not applied to
the pumps discharge flange from mis-alignment, lack of
support or vibration.

It is recommended that an expansion joint and

independent pipe support be used so that the pump will
not have to support the weight of the discharge piping.

It is recommended that provisions be made to supply

Base Plata Puma Vertical clear water to allow flushing out the casing and piping
Galigher after pumping settling type solids.

5. Mounting Instructions

Heavy-duty mounting plates are furnished on all Galigher

Vertical Pumps. These pumps may be mounted on tanks,
sumps, barges, or floats (with motor properly electrically
grounded), The pump should be firmly mounted on a
level mounting plate or cross-beams and should not rest
on the pump casing or screen. Minimum recommended
sump dimensions for proper operation are shown below
in Table 1.

© Copyright Weir Minerals Peru, Inc. 2009 34

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

PUMP MINIMUN SUMP MINIMUM SUMP

SIZE DIMENSION DIMENSION WITH
FLOAT CONTROL

1.1/2 24 x 22 27.1/2 x 27

2 25.1/2 x 23.1/2 28.1/4 x 27.1/4

3 29-1/2 x 27.1/2 30 x 28

4 34 x 31.1/4 34 x 31.1/4

Allow 2” for minimum clearance between sump bottom

and bottom of pump.

6. V. Belt Tension

V-belts are not installed at the factory when the pump

is shipped. Motor direction or rotation must be checked
before the V-belts are put on the sheaves. Use a
straight edge to align sheaves horizontally V-belts
should the be adjusted so that the belts have from 1/2“
to ¾” play when depressed midway between sheaves.
Excessive belt tension will cause unnecessary load on
the beating and excessive belt wear.

7. Coupling Alignment

When a direct-connected motor is used, alignment

between the motor and the pump must be maintained
for extended life and reliable service. After checking the
motor direction of rotation, install and align the coupling
using the following procedure.

Check parallel and angular misalignment by measuring

the dimensions shown on the sketch, Figure 1. table 2
shows maximum allowable limits for the Woods type
couplings. For other types couplings, follows the
manufacturers recommendations.

© Copyright Weir Minerals Peru, Inc. 2009 35

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Coupling "A" "B" Minus "C" "G"

Size Máx. Máx. Ref.
6 .015 .070 7/8
7 .020 .081 1
8 .020 .094 1-1/8
9 .025 .109 1-7/16
10 .025 .128 1-5/8
11 .032 .151 1-7/8
12 .032 .175 2-5/16
13 .040 .195 2-11/16

LOWER SCREEN SUCTION EXTENSIONS

When replacing or adding a lower screen suction

extension, the connection between the pump casing and
the flange on the suction extension MUST BE AIR TIGHT.

Always apply a coat of Silastic RTV sealant or neoprene

putty on mating surfaces of acid-proof and abrasion-
resistant models. Use a gasket on hard iron or alloy
pumps. Tighten nuts and bolts evenly. See Figure 2.

8. Controls

All Galigher Vertical Pumps can be controlled by a

manual motor starting switch or by automatic liquid
level controls with either a float, probe, or mercury
switch. Probe type level controls are recommended for
pumps longer than 6 feet.

© Copyright Weir Minerals Peru, Inc. 2009 36

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Minimum submergence required for Galigher Vertical

Pumps to start pumping liquid “3 above the upper screen.
These pumps will continue pumping until liquid is pumped
down to the lower screen, although the capacity will be
slightly reduced when the liquid level is below the upper
screen.

- PROBE TYPE LEVEL CONTROL

A probe type level control shown in Figure 3 consists of

probes, probe housing and control box and is
assembled in the following manner.

1. Screw the probe housing into the threaded opening

provided the mounting plate. After installing the
probe housing, screw the probes in the bottom of the
housing. Two probes are used for hard iron and
abrasion-resistant pumps and three probes for acid-
proof pumps for off/on control only. Additional
probes may be used for other functions.
Instalation of level control probe
2. Cut one probe to desired depth where the pumps is
to start operating and one probe to the depth where
the pump is to shut off (Note: The third probe on
acid-proof pumps is the electrical ground.)

3. Install the necessary wiring from the probe housing

to the motor control box.
The control box is usually mounted remotely from
the pump

NOTE. Installation Sketch shows the setup for single

pump operation only. For control of multiple
pump operation or alarm in incorporation refer to
the wiring schematic provided with the pump.

Figure IX.2. Schema type level control probe.

- FLOAT TYPE LEVEL CONTROL

To assemble the float type level control, follow the

procedure listed below referring to the drawing shipped
with the pump and Figure 4. DO NOT USE A FLOAT
TYPE LEVEL CONTROL ON PUMPS LONGER THAN
84”.

© Copyright Weir Minerals Peru, Inc. 2009 37

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

1. Secure the switch bracket (1) float switch (7) float

rod guide (3), if provided, to the pump mounting
plate.

2. Screw the float rod (6) into the float ball (2).

3. if the ball and rod are rubber covered (acid-proof)

apply neoprene putty or Silastic sealant to the joint
between the ball and rod to insure and acid-proof
seal.

4. Slip the float rod up through the rod hole in the

mounting plate or guide and put the lower set collar
(5) over the top of the rod (6). Push the road
through the clamp on the float switch arm and slip
the upper collar (5) over the rod.

5. Adjust the ball to the position desired for the pump

to shut-off, and set the upper collar securely just
above the float switch arm.

6. Raise the ball to the position desired for the pump

to start-up and set the lower collar securely just
below the float switch arm. Be sure the float switch
arm. Be sure the float switch is tripped “off” by the
upper rod collar before the lower rod collar hits the
mounting plate.

7. Install the necessary wiring from the float switch to

the motor controls in accordance with the Float
Switch Assembly Drawing furnished with the pump.
.

Figura IX.3.Schema type level control float

© Copyright Weir Minerals Peru, Inc. 2009 38

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

NOTA: Installation sketch , Figure 4, shows a setup for

single pump operation only. For controls for multiple
pump operation or alarm incorporation, refer to the wiring
schematic provided with the pump.

IV. OPERTATING AND SERVICING RECOMMENDATIONS

1. Pre-Starting Recommendations

a. Visually check all main and auxiliary piping to insure

that all connections have been properly made.

b. Check voltage, fuse size, starter, heater amperage

ratings and frequency of the electrical supply
against the motor nameplate.

c. Visually inspect all the electrical conections to the

motor and the control circuit.

d. Check to be sure that the wood blocking has been

removed between the pump shaft and the support
tubes and that the upper screen is secured to the
coverplate .

e. With the motor disconnected from the pump

assembly, check the motor direction of rotation by
momentarily starting the motor. Direction of rotation
must be as shown on the name-tag on the pump
(clockwise looking toward the impeller from the
motor end of the shaft)

CAUTION: STARTING AND RUNNING THE PUMP

BACKWARD WILL CAUSE DAMAGE TO INTERNAL
PARTS.

f. All pumps have been properly greased before

shipping. For initial start up and subsequent
servicing, we recommend using a superior general
purpose grease with good high temperature
characteristic such as CHEVRON EP-2 or equal for
the pump bearing, seals and motors.

2. Star Up Recommendations.

a. Visual inspection should be made of the pump and

its installation before starting.

© Copyright Weir Minerals Peru, Inc. 2009 39

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Check that all mounting support, external nuts, bolts

and fitting are secure, and that the discharge piping
is tight and secure.

b. It is normal to have the discharge valve 90% closed

when the pump is started since much less horse
power is required under these conditions.

DO NOT OPERATE THE PUMP IN A RESTRICTED FLOW

CONDITION FOR LONGER THAN NECESSARY.

c. All flow, pressure and temperature gauges should be

monitored to insure that the pump is operating within
specified limits. If the bearing column temperatures
are monitored, they should not exceed 220° F
V. GENERAL OPERATION INSTRUCTIONS

a. The unit should always be started under the lowest

possible load. This is usually accomplished by starting
with the discharge valve 90% closed. This is especially
important when two pumps are operated in parallel or
when switching to a standby unit.

b. Automatic level controls should be set to start the unit

when the liquid is at least 3 inches above the upper
inlet screen.

c. Do not start operating the pump while it is “windmilling”

backwards from fluid running back through the pump
case from the discharge line.

d. Flush out the pump with clear fluid whenever possible

prior to shut down to reduce solids settling problems
that could load up the impeller on startup.

e. Completely drain the pump lines and sump, if the

possibility exist of freezing while not operating.

Puma Galigher Vertical, placed in the f The pump must never be submerged above the
horizontal mounting plate as serious damage to both the motor
and bearing assembly could result. If submerged, the
pump bearing assembly should be disassembled,
cleaned, the bearing repacked with fresh grease, and
the motor checked out before further operation.

g. It is recommended that the motor be well ventilated

when in operation. Please refer to the motor
manufacturer for recommended service instructions.

© Copyright Weir Minerals Peru, Inc. 2009 40

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

VI. SYSTEM AND PUMP TROUBLE SHOOTING

The following table is provided to aid the operator in

finding and correcting pump and system
malfunctions.

Problem c Possible Cause

Failure to Deliver Liquid
o * Insufficient pump speed
r * Discharge head requirement too high
r * Impeller or suction strainer plugged
e * Wrong direction of rotation
c * Discharge valves not opened
t * Air leakage in suction extension
a * Discharge piping plugged
Motor Runs Hot * Low system head causing excessive flow
d * Fluid specific gravity too high
i * Fluid viscosity too high
r * Improper impeller adjustment
e * Speed too high
c * Lack of motor ventilation
c * Low motor voltage
Insufficient Capacity iand Pressure * Speed too low
ó * System head higher than pump rating
n * Impeller or suction strainer partially plugged
* Wrong direction of rotation
d * Discharge pipe partially plugged
e * Froth or air in fluid
* Mechanical defects
r Casing worn
o Impeller worn or damaged
Pump vibrates or is Noisy
t * Misalignment of motor coupling
a * Pump mounting plate not anchored
c * Impeller partially plugged-unbalanced
i * Mechanical defects in pump or motor shaft
ó Bent.
n Rotating elements out of balance
, Worn bearings
* Discharge pipe not anchored
* Loose bolts or belt guard
* Sheaves not aligned or balanced
* Pump operating at no flow

© Copyright Weir Minerals Peru, Inc. 2009 41

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

VII. PUMP OVERHALL INSTRUCTIONS

1. General Disassembly

The component item numbers listed in the disassembly

and assembly instructions refer to item numbers on the
General Assembly.

Impeller, ítem 3

2. Wet-end Disassembly

Note: Disassemble only to the point of repair.

A. Remove the belt guard (47) and the V-belts (43).Match

mark the motor electrical leads so that propor direction
of rotation will be obtained when reconnected.
Disconnect all electrical wiring and remove the motor

© Copyright Weir Minerals Peru, Inc. 2009 42

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

(45) from the pump assembly. Unbolt the pedestal

mounting plate from the supporting beams.

Note: With small motors, it may not be necessary to

disconnect and remove the motor to effect repair of the
pump.

B. Using and overhead crane or hoist, remove the pumps

from the sump or tilt the unit until the wet–end is raised
out of the sump. Swing the pump assembly to one side
of the sump fro support or block with a cross-beam.

C. On rubber-covered or acid-resistant units, remove the

rubber-covered case cap nuts (8) by carefully cutting
the bonded rubber at the parting line with a sharp knife
Puma Casing, ítem 10
and unscrew counterclockwise with channel lock pliers.

D. Loosen and remove the casing nuts (11) attaching the

casing (10) to the pedestal (1). Leave the three nuts
holding the cover plate (7) to the pedestal on 3” and 4”
pumps.
Remove the casing (10) and lower screen (4) together.
A pair of C-clamps may be used to hold the cover
plate against the pedestal on the 1.1/2” and 2” pumps
to aid in impeller removal.

E. The impeller (3) is removed by unscrewing the impeller

from the shaft (6). Block the pump shaft to prevent
rotation. Using two flat-sided bars placed between the
pumping vanes on opposite sides of the impeller, apply
pressure counterclockwise to unscrew the impeller.
The threads are right hand.

F. Inspect the cover plate (7) for wear or damage. If

replacement is necessary, loosen the final three nuts
holding the cover plate to the pedestal and remove the
cover plate.

G. Remove the screens (4) and (5), if necessary, and

follow assembly instructions (page 10) to install new
wet-end components.

3. Bearing Column Disassembly

The following procedure should be followed if major repair

of the bearing column assembly is necessary. Item
numbers used refer to parts shown on the Bearing Column
Assembly (page 4)

© Copyright Weir Minerals Peru, Inc. 2009 43

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

A. Remove impeller (3), casing (19), and cover plate (7)

following instructions for wet-end disassembly (See
page 6). Remove components of the motor bracket
assembly as required to facilitate repair of the bearing
column assembly.

B. On some models the flinger (21) must be removed

before the bearing assembly and shaft can be pulled
from the pedestal mounting plate. Visually check to see
if the flinger will pass through the hole in the pedestal
Column Bearing Assembly mounting plate. Soapy water applied to the shaft will
make it easier to remove the flinger.

C. To insure proper orientation at re-assembly, mark the

pedestal (1) and bearing column (2) to show the
relation between parts.
Remove the upper positioning nuts (29) and lock
washers (93) and separate the bearing column
assembly from the pedestal.

D. Clean the upper end of the shaft of any rust or

corrosion and remove the key from the keyway.
Remove the dust seal (25) and the screws (15) that
attach the upper bearing cap (19) to the bearing
column (1). Mark the cap and column so that they may
be reassembled in the same position.

E. The outer race and rollers of the upper bearing (18) will
now slide out of the bearing column. A hooked wire is
helpful in removing these parts. The seal (20) may also
be removed with the aid of the hooked wire.

F. Remove the screws (15) attaching the lower bearing

cap(3) to the bottom of the bearing column (1).

G. Drive the shaft (6) and lower bearing out of the bearing
column (1) with a soft-faced mallet.

H. The upper bearing inner racer (18) and seal ring (17)
should be removed from the shaft with a puller.

© Copyright Weir Minerals Peru, Inc. 2009 44

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Figura X.2.- Bearing Assembly Puma Vertical Galigher

I. The lower bearings may be removed from the shaft (6)

with a bearing puller or press if suitable equipment is
available. Remove the seal (14), bearing locknut (11)
and lockwasher (10) from the shaft. The bearing (7) (8)
(9) may now be pressed off toward the drive end of the
shaft.

J. If a suitable puller is not available, burn off the outer

race of the bearing (8) with an acetylee torch. Remove
all rolling elements. Heat y inner races with torch and
drive the inner races off the shaft with a hammer and
drift punch.

CAUTION: Do not overhead the shaft while heating the

bearing and do not mar the shaft with the hammer or
punch.

© Copyright Weir Minerals Peru, Inc. 2009 45

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

K. Remove the lower bearing cap (3) and seal (13) from
the shaft.

L. The slinger (4) does not need to be removed from the

shaft. It is made of metal, loosen the two set screws
and pusch the slinger towards the impeller end of the
shaft until it contacts the shoulder. If it is rubber, simply
slide it down to the shoulder.

M. Proceed with repair and reassembly.

VIII.PUMP ASSEMBLY INSTRUCTIONS

1. General Assembly
Lifting of the Pump Vertical
Galiggher with chains The component item numbers listed in the assembly
instructions for this section refer to item numbers on
the Assembly Drawings (pages 2 & 4).

Assembly instructions are divided into two

sections: (1) Bearing column assembly, and (2)
Wet-end assembly. Pump reassembly would start
at the appropriate to effect repair.

INSPECTION

Every part should be carefully inspected before

reinstallation for general wear, corrosive attack or
damage. Normally, where complete disassembly has
been performed, complete replacement of all seals and
gaskets should be made.

SHAFT

The threaded ends of the shaft should not show any

signs of corrosion or chemical attack. The drive-end of
the shaft and the bearing seating should be free of rust
and burrs. The shaft must be straight within 0005 inch
per foot of length.

BEARINGS

There should be no signs of rusting or contamination

by dirt, chips or metal particles. When slowly rotated,
there should be no drag or hangup between the rolling
elements and races.

© Copyright Weir Minerals Peru, Inc. 2009 46

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

2. Bearing Column Assembly

a) All parts should be thoroughly cleaned and inspected

prior to re-assembly.

b) Install lip seal (13) into lower bearing cap (3) with the
seal lip away from the bearing.

c) Be sure the slinger (4) is on the shaft. It should be

against the shoulder on the shaft with the tapered face
pointing toward the drive end.

d) Slide the bearing cap onto the shaft from the drive end.
Make sure the seal lip is not “turned under” when it is
positioned on the proper area of the shaft. Coat the
O’ring (12) with grease and position the O’ring. Against
the bearing cap flange.

e) The lower bearing come as a matched set of parts and

must not be interchanged with any other bearing parts.
The set consists of two cones (7), a spacer ring (9) and
the outer race (8). To install, place the cones on an
electric bearing heater or in an oven and heat to 275°
to 300° F. The first cone is placed on the shaft wi th the
taper pointing toward the drive end of the shaft.
Quickly slide the cone down the shaft until it seats
against the shoulder on the shaft.
Next place the spacer (9) on the shaft and slide it down
until it contacts the bearing cone. It is not necessary to
heat the spacer as it has a slip fit on the shaft. Now
place the outer race (8) on the shaft and slide it down
until it seats on the cone. The second cone is now
placed on the shaft with the taper pointing toward the
impeller end of the shaft. Quickly slide it down the shaft
until it seats with the outer race and spacer. Place the
lockwasher and locknut on the shaftand tighten the
locknut on the shaft and tighten the locknut. Allow the
bearing to cool to the touch and then retighten the
locknut. Tighten until of the tangs of the lockwasher
can be bent into the slot on the locknut. Bend the
lockwasher tang into the slot.

f) Place the seal (14) on the shaft with the lip pointing
away fro the lower bearing.
Position it on the shaft in the recess just above the
locknut. The correct position is with the inner surface of
the seal against the small shoulder nearest the drive
end of the shaft.

© Copyright Weir Minerals Peru, Inc. 2009 47

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

g) Install the seal ring (17) onto the shaft. Heat the seal
ring on the bearing heater or in an oven to 275° to 300°
F and quickly slip it onto the shaft. Slide it down the
shaft until it contacts the shoulder. The inner race of
the upper bearing (18) is installed in the same manner.
Slide the inner race down the shaft until it contacts the
seal ring.

h) A light coating of grease should be applied to the lower

bearing bore and seal surfaces of the bearing column
casting.

i) Suitable support the bearing column casting in a

horizontal position. Suspend the shaft with a fabric
sling on a hoist. Slide the end of the shaft through the
base of the bearing column.

CAUTION: DO NOT DAMAGE THE INNER RACE OF

THE UPPER BEARING DURING SHAFT INSTALLATION.

Push the shaft assembly into the bearing column until the
outer race of the bottom bearing seats against the
shoulder in the housing.

j) Position the lower bearing cap (3) against the bottom of

the bearing column (1). Be sure the O’ring (12) is in the
proper position. Attach the cap to the column with the
bearing cap screws (15).

k) If the surface for the seal (20) was not previously

greased, do so now. Push seal (20) into place with the
seal lip pointing toward the bottom bearing. Push it
down until it lightly contacts the surface in the bearing
column.

l) The outer race and rollers of the upper bearing (18)

may now be installed. Simply push them into the
bearing column.

m) The lip seal (22) should now be installed in the upper

bearing cap (19). Be sure the lip is pointing away from
the upper bearing. Coat the O’ring (24) with grease and
position the O’ring against the upper bearing cap
flange.

n) The upper bearing cap may now be installed over the

shaft and fastened to the bearing column with the
bearing cap screws (15). A piece of tape placed over
the keyway will help prevent cutting of the seal lip when

© Copyright Weir Minerals Peru, Inc. 2009 48

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

installing the bearing cap. Be sure the O-ring (24) is in

its proper position.

ñ) Apply a light coat of grease to the machined area

around the shaft on the upper surface of the bearing
cap. Place the dust seal (25) over the shaft and push it
down until it contacts the upper bearing cap. Replace
the key in the keyway.

o) Replace the grease fittings (5) and pressure relief (23)

if they were removed.

p) Slide the slinger (4) toward the lower bearing cap (3)
until there is a 1/32” clearance between the two parts. If
the slinger is rubber, this is all that needs to be done. If
the slinger is metal, tighten the two set screws and
recheck the clearance. The shaft should be able to be
rotated by hand, although it may feel “stiff”.

q) BEARING LUBRICATION:

Both bearing locations should be lubricated after

assembly by injecting Chevron EP2 grease or equal
into the fittings. The upper bearing should be greased
until the relief fitting (23) opens and allows some
grease to escape.
The lower bearing should be greased until grease
squeezes out between the lower bearing cap (3) and
the slinger (4).

r). Replace the bearing column assembly (2) onto the

pedestal (1) and screw the upper positioning nuts (29)
and lockwashers (93) on the studs so there is about 2-
3/8 inches between the bottom of the column base (2)
and the top of the pedestal (1). Check the marks made
during disassembly to be sure the parts have the
correct orientation.

s) Replace the flinger on the shaft if it was removed

during disassembly. Soapy water applied to the shaft
will ease installation of the flinger. A twisting motion is
most effective in moving the flinger to its proper
position.

3. Wet-end Assembly

a) Position the cover plate (7) over the end of the shaft
(6) and temporarily secure into place against the
pedestal (1) with nuts and bolts or clamps. Be sure the

© Copyright Weir Minerals Peru, Inc. 2009 49

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

upper screen (5) is in place on the cover plate before

attaching the cover plate to the pedestal.
Tighten the bolts or clamps until metal to metal contact
is made between the cover plate and pedestal.

b) Apply a good quality antiseize compound to the threads

on the shaft to prevent the impeller (3) from seizing on
the shaft during installation or operation.

c) Coat the surface of the impeller washer (46) with DOW

CORNING RTV 732 SEAL-ANT. Press the impeller
washer (46) into the recess in the end of the impeller
hub (3).
d) Screw the impeller (3) onto the shaft (6) and tighten
against impeller washer (46) using two padded bars
placed in the impeller vanes. The shaft must be
blocked against turning. The impeller must be as
tight as possible without damaging the impeller.

e) Adjust the tripod positioning nuts (29) attaching the

bearing column (2) to the pedestal mounting plate (1)
so that the clearance “A” and “B” between the impeller
(3) and the cover plate (7) is 1/16 inch for the
1.1/2”,2”,3” and 4” pumps, and equal on all sides of the
impeller as shown in figure 2.

Figura XI.1. Space Assembly or adjustment of the impeller.

f). Bolt the casing (10) into position against the cover plate
(7) and pedestal flange (1). Secure with casing nuts
(11).

© Copyright Weir Minerals Peru, Inc. 2009 50

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

g) Make a final clearance check after casing installation to

insure the impeller is properly positioned. This is done
by rotation the pump shaft and listening or feeling for
any rubbing between the impeller and casing. If rubbing
exists, remove the casing and rubbing exists, remove
the casing and recheck the clearance between the
impeller and casing. If rubbing exists, remove the
casing and recheck the clearance between the
impeller and back plate. See Step 5.

h) Assemble the discharge pipe (26) to the discharge

flange of the cover plate and secure with the necessary
nuts (11), Secure the top of the pipe to the pipe lugs
with fasteners (25).

i) Position and secure the lower screen (4) and upper

screen (5) with screen nuts (9) and item (44).

j) On acidproof pumps, rubber cap nuts are used to

protect the exposed metal studs and nuts. For an
acidproof seal between parts, fill the internal hole of all
cap nuts (8), (9) and (94) with DOW CORNING RTV
732 SEALANT.
Place the cap nuts over the exposed casing nuts,
screen nuts and studs. Screw down tight until the sides
of the cap nuts start to bulge and the sealant squeezes
out of the joint. Allow 1 to hours’s cure at 70° be fore
testing or using the pump. Warm the parts to reduce
cure time but do not exceed 150° F.

k). It may be desirable to test the cap nut joint on acidproof

units to insure that no pin hole leaks to metal exist.

Wet-end Assembly (Cont’d)

SPARK TESTING for acid-proof units: the elastomer

under test is scanned with the electric probe passing
over but not in contact with the material. Use a high
frecuency, low amperage test electrode having an
adjustable voltage from 4,500 to 30,000 volts potential.
The probe should emit a continuous bluish haze except
when near a fault in the elastomer where the color
brightens and tracks directly to the flaw. The electrode
must be carefully controlled and kept in motion to avoid
overheating and burnthrough. Use the lowest voltage
possible but sufficient to jump the air gap and pass
through any pin holes in the elastomer.

© Copyright Weir Minerals Peru, Inc. 2009 51

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Note: Do not spark test parts made from Galigher

compound # L7211 or ELASTOGARD 570 series
compounds.

l) If previously removed, reinstall the motor bracket (15),

and motor (45), the sheaves (41) and (42).

m) If the motor has been electrically disconnected during

removal, re-check the direction of motor rotation before
installing the V-belts (43) or coupling. Refer to belt
adjustment and alignment instructions on page 3 of the
installation & Operating Manual. After correct rotation is
determined, install the V-belts and the belt guard (47).

n) For other information on Pump Operation refer to

series 5000 Vertical Pump Installation and Operation
Instructions.

IX. ANEXOS

1. Pulley Assembly

a. Check the smooth entry of the key in the keyway of

the shaft, checking that it has not been damaged
during the transport of elements.

b. Check the smooth entry of the sleeve on the shaft.

Subsequently enter the correct pin of your location.

c. Mount the pulley on the shaft, followed it, and finally

mount the cuff key. Tighten by hand the three bolts
holding.

d. Riding a comparator with its front end measurement at

the periphery of the outer face of the pulley.

e. With the right tool, in part, and tighten the bolts

alternately clamp. After the final tightening of the bolts,
the outer face of the pulley should not show a
misalignment greater than 0.02 to 0.05 mm.

Mounting-belt systems, should be checked by a reglilla

plate to the outer surface of the pulleys of the pump
and motor are on the same axis.

© Copyright Weir Minerals Peru, Inc. 2009 52

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Minimum distance between center

- CI - - CT -
Minimum distance between center Minimum distance between center
Number to installation (inches) For tension and initial
Belt in V implementation (inches)
All sections
A B C D E All types
26 - 35 0.75 1.00 1.00
38 - 55 0.75 1.00 1.50 1.50
60-85 0.75 1.25 1.50 2.00
90-112 1.00 1.25 1.50 2.50
120 - 144 1.00 1.25 1.50 2.00 2.50 3.00
158 - 180 1.25 2.00 2.00 2.50 3.50
195 y 210 1.50 2.00 2.00 2.50 4.00
240 1.50 2.00 2.50 3.0 4.50
270 y 300 1.50 2.00 2.50 3.00 5.00
330 - 390 2.00 2.50 3.50 6.00
420 to mores 2.25 3.00 1,5% of length belt

Note: It is recommended to use in the twinned straps

transmission systems of pumps, to prevent
vibration and premature wear of bearings

2. Storage of electric motors

This manual covers all asynchronous induction motor with

rotor, this is single phase and three phase motors.

For more information, please contact the nearest supplier.

NOTA: This section provides a general reference

for the care of engines to be found in each
particular case

© Copyright Weir Minerals Peru, Inc. 2009 53

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

GENERAL INSTRUCTIONS

All professionals who perform services in electrical

equipment, whether at the installation, operation or
maintenance, must be continuously informed and updated
on safety standards and requirements that govern the
services and advice to follow. It is responsible to be
certified before beginning work, that everything was
properly noticed and alert staff to the dangers inherent in
this task.

It is recommended that this service is performed by

qualified persons. As a security measure, the equipment
for fire fighting and first aid notices should not miss in the
workplace should always be visible in local and easily
accessible.

Delivery

Motors before being sent are dynamically balanced with

half key and tested at the factory, ensuring its smooth
functioning.

Andalusia receive recommended care and inspection,

verifying the existence of any damage caused by
transportation.

If this has occurred, immediately notify the carrier and the

nearest representative.

Storage

Engines must not be erected by the axle, but if the

suspension eyelet located on the housing. The removal or
deposit must be smooth, without bumps, otherwise the
bearings can be damaged.

If the engines are not installed immediately should be

stored in a dry, free of dust, gases, corrosive agents, with
uniform temperature, placing them in a normal position
and support them in other objects.

Engines stored for long periods may suffer decline in

insulation resistance and oxidation in the bearings.

Lubricating bearings and deserve significant care during

the storage period.

While the engine idle, the weight of the rotor shaft tends
to expel the grease out of the area between the sliding

© Copyright Weir Minerals Peru, Inc. 2009 54

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

surfaces of the bearing by removing the film that prevents

metal to metal contact.

As prevention against corrosion by the formation of

contact in bearings, motors shall remain in the vicinity of
machinery causing vibration and the axes must be rotated
manually at least once a month.

It is recommended to store bearings:

The atmosphere must be dry, with relative humidity

not exceeding 60%.
Local clean, temperature between 10 ° C and 30 ° C ..
Stacking up to 5 boxes
Stay away from chemicals and steam pipes, water or
compressed air.
Do not place them on pallets of green wood, not
leaning against a wall or the floor of stone.
Rotate stock bearings older must be used first.
Double shielded bearings can not remain for more
than two years in stock.

In relation to the storage engine:

• For engines armed and stock, must have their axes

rotated regularly at least once a month to renew the
grease in the bearing track.
• With regard to the insulation resistance is difficult to
set rules dictate its true value when it varies with the
type, size, voltage rating, quality and condition of the
insulating material used, construction method and the
background of the construction of the machine.
•  It is recommended that regular entries are made to
be useful as references to draw conclusions of the
state in which the machine is.
• To further the values that are indicated can be
expected from a machine clean and dry at 40 ° C,
when the test voltage is applied for one minute.
• The insulation resistance Rm is given by the formula.

Rm = Un + 1

Where: Rm = Minimum insulation resistance

Recommend in Mohm with the coiling to temperatura
of 40° C.

Un = Nominal tensiono f machina in Kv

© Copyright Weir Minerals Peru, Inc. 2009 55

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

If the test is done at different temperature, it will be

necessary to correct the temperature to 40 ° C, usi ng
a curve of variation of insulation resistance as a
function of temperature, up to the machine itself.

If you do not have this curve, you can use the

correction given by the approximate curve of Figure
2.1 is noted here that the resistance to virtually
doubles every 10 ° C which reduces the temperature
of isolation.

On new machines, many times lower values can be

obtained due to the presence of solvents in paints
insulators subsequently volatilized during normal
operation. This does not necessarily mean that the
machine is not operating conditions, once the
insulation resistance will rise after a period in service.

In old machines in service, can often be obtained

much higher values. The comparison with values
obtained in earlier tests on the same machine under
similar conditions of load, temperature and moisture
serve as a better indication of the isolation that the
value obtained in a single trial, be considered suspect
any large or sudden reduction.

Generally the insulation resistance is measured with a

MEGGER.

If the insulation resistance is lower than the values

obtained by the formula above, the engines will have
to be subjected to a drying process. We recommend
using a stove as a source for dehumidification, the
rate of temperature increase should not exceed 5 ° C
per hour and reach the final temperature of 110 ° C

© Copyright Weir Minerals Peru, Inc. 2009 56

06/2009 -3
 Weir Minerals │ 5000 Serie Vertical Pump Manual

Motor Manual

© Copyright Weir Minerals Peru, Inc. 2009 57

06/2009 -3
Recommend Spare Parts
Lubrication Schedule for all Motors