ICS Mill Master ICSHDMMB215 User manual

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ASSEMBLY, OPERATING,
MAINTENANCE AND TESTING
INSTRUCTIONS
ICS Mill Master Slurry Pumps
MANUAL FOR:
METAL AND RUBBER PUMP SIZES:
• ICSHDMMB215
• ICSHDMMC32
• ICSHDMMC43
• ICSHDMMD43
Issue Date: April 2008
Revised November 2019

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SAFETY
ICS Wear Group Inc. slurry pumps have been designed for safe and reliable operation. A pump is a pressure-
containing device with rotating parts that could be hazardous. Operators and maintenance personnel must
realize this and follow the necessary safety measures. All statutory requirements relating to this equipment must
be complied with at all times and site safety procedures strictly adhered to.
ICS shall not be liable for damage or delays caused by a failure to observe either the instructions in this manual
or the usual industry safety procedures.
CAUTION
Never completely restrict the discharge flow. It may result in adverse temperature increase and possible
explosion (as applicable to all centrifugal pump brands).
Never apply heat to the impeller to assist removal from shaft. Heating may result in shattering the impeller
RESULTING IN INJURY OR EQUIPMENT DAMAGE
Direction test driven WITHOUT belt drives or couplings fitted. The impeller is threaded and incorrect rotation
may cause personnel injury or equipment damage.
If pump is operating with a very hot or very cold liquid, gradually change pump temperature to prevent damage
by thermal shock. Thermal shock may cause personnel injury or equipment damage
NOTE
Proper alignment is essential for long pump life.
GENERAL PRECAUTIONS
• Warning: Personal injuries will result if procedures outlined in this manual are not followed.
• Never work on the pump set with the power connected.
• Never work on the pumpsets without the appropriate work tags (eg ‘Danger Tags’) fitted in compliance
with site safety procedures.
• Never operate pump without drive guard correctly installed.
• Never operate pump beyond the rated conditions for which the pump was sold.
• Never run pump below the recommended minimum flow or when dry.
• Never operate pump without safety devices installed.
• Never operate pump with discharge valve closed.
• Never use heat to disassemble pumps due to risk of explosion from trapped liquid.
• With the pump disconnected from the driver, check the motor rotation. Incorrect motor rotation can
cause the impeller to back off of its threads and rupture the casing. It may also cause personal injury.
WHERE AUXHILIARY EQUIPMENT IS ASSOCIATED WITH A PUMP (eg. MOTORS, DRIVE BELTS,
DRIVE COUPLINGS, SPEED REDUCERS, VARIABLE SPEED DRIVES, ETC), ALL RELEVANT
INSTRUCTION MANUALS SHOULD BE CONSULTED, AND RECOMMENDED PROCEDURES
IMPLEMENTED, DURING INSTALLATION, OPERATION AND MAINTENANCE OF THE PUMP
SYSTEM.

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Table of Contents
SAFETY .................................................................................................................................................. 2
1. INTRODUCTION ........................................................................................................................... 7
2. IDENTIFICATION OF PARTS .................................................................................................... 7
3. BEARING ASSEMBLY – ASSEMBLY AND MAINTENANCE ................................................. 7
4. PUMP ASSEMBLY INSTRUCTIONS .......................................................................................... 8
4.1 FRAME ASSEMBLY .................................................................................................................. 8
4.1.1 FITTING BEARING ASSEMBLY TO BASE – Ref Fig 1 ................................................... 8
4.1.2 FITTING FRAME PLATE AND COVER PLATE BOLTS – Ref Fig 2 ............................ 10
4.2 SEAL ASSEMBLY .................................................................................................................... 12
4.2.1 GLAND SEAL ASSEMBLY - Ref Fig 4 ............................................................................. 12
4.2.2 EXPELLER SEAL ASSEMBLY -Ref Fig 8 ........................................................................ 16
4.2.3 MECHANICAL SEAL ASSEMBLY ................................... Error! Bookmark not defined.
4.3 PUMP CASING ASSEMBLY .................................................................................................. 18
4.3.1 TWO PIECE RUBBER LINERS-Ref Fig 9 ......................................................................... 18
4.4 MISCELLANEOUS FITTINGS - Ref Fig 13 ......................................................................... 23
5. IMPELLER ADJUSTMENT - Ref Fig 12 .................................................................................. 24
6. DISMANTLING PUMP AND REMOVAL OF IMPELLER ..................................................... 25
APPENDIX A ........................................................................................................................................ 26
GLAND SEALING WATER FLOWRATE ......................................................................................... 26

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PARTS INDEX
NOTE:
• Stuffing boxes are designed as ICSMM ** SBOX, the Stars represent the size for example, A
stuffing box to suit a 6x4 E frame pump would be ICSMMESBOX.
• * Represent not present on all sizes or select layouts, consult ICS for your pumps specific bill
of materials.
Bearing Assembly:
Description
ICS Part Number
Bearing
MMBR
Bearing Drive End
MMBRD
Bearing Housing
MMBH
Bearing V-Seal
MMBRS
End Cover
MMECV
Laby Seal
MMLBL
Laby Seal
MMLBS
Piston Ring
MMPIST
Shaft
MMSFTM
Shaft Key
MMSFK
Shim Set
MMSHM
Expeller Seal Kit:
Description
ICS Part Number
Expeller
MMEXP
Expeller Ring
MMEXR
Gland
MMGS
Gland Bolt
MMGB
Grease Cap Adaptor
MMGCA
Impeller O-Ring
MMIOR
Lantern Ring
MMLTR
Neck Ring
MMNKR
Packing
MMPAK
Seal Ring
MMSLR
Shaft O-Ring
MMSOR
Short Shaft Sleeve
MMSSLV

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Stuffing Box Seal Kit:
Description
ICS Part Number
Gland
MMGS
Gland Bolt
MMGB
Grease Cap Adaptor
MMGCA
Impeller O-Ring
MMIOR
Lantern Restrictor
MMLTRR
Long Shaft Sleeve
MMLSLV
Packing
MMPAK
Seal Ring
MMSLR
Shaft O-Ring
MMSOR
Shaft Sleeve Spacer *
MMSTS
Stuffing Box
MMSBOX
Metal Wet End Kit and Frame Assembly
Description
ICS Part Number
Adjusting Screw
MMAB
Base
MMBAS
Clamp Bolt
MMCLB
Clamp Washer
MMCLW
Cotters
MMCOT
Cover Plate
MMCP
Cover Plate Bolt
MMCPB
Discharge Seal Ring
MMDJR
Frame Plate
MMFP
Frame Plate Liner Insert
MMFPLI
Frame Plate Liner Stud
MMFPLIS
Frame Plate Stud
MMFPS
Impeller
MMIMP
Impeller Release Collar *
MMIRC
Intake Joint Ring
MMINJR
Keeper Plates
MMKP
Retaining Ring *
MMRR
Throat Bush
MMTRB
Throat Bush Stud
MMTBS
Volute
MMVOL
Volute Liner Seal
MMVLS

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Rubber Wet End Kit and Frame Assembly
Description
ICS Part Number
Adjusting Screw
MMAB
Base
MMBAS
Clamp Bolt
MMCLB
Clamp Washer
MMCLW
Cotters
MMCOT
Cover Plate
MMCP
Cover Plate Bolt
MMCPB
Cover Plate Liner
MMCPL
Cover Plate Liner Stud
MMCPLS
Discharge Seal Ring
MMDJR
Frame Plate
MMFP
Frame Plate Liner
MMFPL
Frame Plate Liner Insert *
MMFPLI
Frame Plate Liner Stud
MMFPLS
Frame Plate Stud
MMFPS
Impeller
MMIMP
Impeller Release Collar *
MMIRC
Intake Joint Ring
MMINJR
Retaining Ring *
MMRR
Throat Bush
MMTRB
Throat Bush Stud
MMTBS
Volute
MMVOL
Volute Liner Seal
MMVLS

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1. INTRODUCTION
This manual is applicable for ICS Heavy Duty Mill Master slurry pumps from the 6x4 to 12x10. The Mill
Master line of pumps feature a wide choice of replaceable abrasion resistant metal or molded elastomer casing
liners and impellers, which are all interchangeable within a common casing assembly.
The pumps may be fitted with a range of seal types depending on the particular duty requirements: a water-
flushed packed gland seal (standard); an expeller; or an ICS Patented Mechanical Seal.
If problems are experienced during pump operation, reference should be made to the ICS Fault Detection Chart.
If operating problems are not rectified by following instructions in the Chart, assistance should be sought from
the nearest local representative or via our technical support e-mail (detailed in the footer).
Important design features of this range of ICS Heavy Duty Mill Master Slurry Pumps include:
• Cartridge type upgraded ICS Bearing Assembly for extended life compared to competitors’ pumps.
• Replaceable casing liners (hard metal, rubber or urethane can be site retrofitted).
• Heavy duty screw thread Impeller attachment.
• Through-bolt design throughout for easier maintenance.
• Self-setting and self-aligning Patented Slurry Seals.
• Minimum number of casing bolts
2. IDENTIFICATION OF PARTS
Each part has a basic part identification. Parts with the same name have the same basic part abbreviation,
regardless of pump size. For example, all stuffing boxes are designed as SBOX forwarded by a specific letter to
the size. A stuffing box to suit a 4x3 D frame pump would be MMDSBOX.
Refer to the Sectional Arrangement Drawing for the appropriate size of ICS Pump for complete identification and
description of component parts.
In all communication with ICS, or its distributors, and particularly when ordering spare parts, the correct
component names and Part Numbers should be used at all times to avoid supply of incorrect parts.
3. BEARING ASSEMBLY – ASSEMBLY AND MAINTENANCE
The Bearing Assembly is assembled and maintained as described in separately available ICS manuals.

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4. PUMP ASSEMBLY INSTRUCTIONS
Reference to a Sectional Arrangement Drawing provided by ICS for the particular pump being assembled will be
of assistance in the instructions outlined in the following sections.
All parts dismantled during pump overhaul should be inspected to determine suitability for reuse,
and identification of new parts should be checked.
Parts suitable for re-use should be cleaned and if necessary re-painted. Matching faces should be free of rust,
dirt, and burrs, and have a coating of anti-seize compound applied prior to assembly, so that the pump remains
easy to fix in future overhauls.
Small standard fasteners should preferably be replaced, and all threads coated with suitable compound (such as
anti-seize) before assembly.
Replacement of all elastomer seals (such as O rings and joint rings) is recommended at major overhauls, as
these materials usually deteriorate with use. Direct exposure to sunlight causes accelerated deterioration of
elastomers and will result in more frequent changing of parts.
4.1 FRAME ASSEMBLY
4.1.1 FITTING BEARING ASSEMBLY TO BASE – Ref Fig 1
Figure 1 -Bearing Frame Assembly in Base.

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(i) Insert Adjusting Bolt in Base from drive end. Fix Adjusting Bolt into Base by screwing on one nut and
fully tighten. Fit the additional two nuts supplied with the Adjusting Bolt and separate with two flat
washers. These nuts should remain loose on Adjusting Screw and spaced well apart so that the Bearing
Assembly will slot into place.
(ii) Apply anti-seize compound to semi-circular machined surfaces on the bottom of the Bearing Housing
and onto the mating support cradle in the Base. This helps reduce corrosion in this area (which is
important for maintaining low maintenance costs for packing and expellers).
(iii) Approximately match the Bearing Housing ears with the hold down bolt holes in the base then lower the
Bearing Assembly into the Base and ensure the lug has fitted over the Adjusting Screw and between the
nuts and washers.
(iv) Fit Clamp Bolts through Base from below. Mount a Clamp Washer on each bolt (domed side up) then
screw on the nuts. Fully tighten Bolts on the left hand side of Base as viewed from the impeller end. At
this stage the Clamp Bolts on the other side should remain finger tight only, to maintain alignment but
allow axial movement of the Bearing Assembly.
(v) Apply anti-seize compound to Shaft. This will assist fitting and removal of shaft components, and prevent
damage to Shaft surfaces by moisture.
(vi) If not repaired in-situ, fit an appropriate assembly cradle (such as two blocks of timber with coach
screws), to underside of Base to prevent the pump from tipping forward during assembly of the wet end,
as shown in Fig 1. Ensure that the Base is high enough above the floor for the frame plate and components
to be assembled.

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4.1.2 FITTING FRAME PLATE AND COVER PLATE BOLTS – Ref Fig 2
Figure 2 - Assembling Frame Plate and Cover Plate Bolts
(i) Apply anti-seize compound to the recesses in the base where the Frame Plate spigot engages. Fit Frame
Plate to Base, ensuring that the Frame Plate locating spigot engages with the corresponding Base arms.
For pumps 6x4 and larger, Frame Plates are provided with either radially tapped holes for eyebolts or
lifting lugs to assist fitting.
(ii) Insert Frame Plate Studs or Frame Plate Bolts, depending on pump size. Fit and fully tighten nuts.
Depending on the pump size, the Frame Plate is bolted externally using studs. whilst others use bolts
which are inserted from within the Frame Plate. In most pump sizes, the Frame Plate can be rotated to
provide eight alternative angular discharge positions.
(iii) Ensure the cover plate bolts are clean, and remove any burrs. Cover threads with anti-seize. Fit Cover
Plate Bolts Through Frame Plate lugs.

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Screw on nuts, and tighten bolts in the manner and sequence below.
Figure 3-Tightening Sequence
Bring the parts of the joint into full contact by tightening sufficient bolts to achieve a “snug-tight”
condition. The “snug-tight” condition is 10% of the bolt’s full tension or yield tension. This is achieved to
reasonable accuracy and repeatability by the full effort of an average man (approximately 70kg) using a standard
podger spanner, or by a few impacts from an impact wrench, after initial slackness in the nut has been taken up.
Make corresponding permanent marks on the nut and the protruding thread of the bolt, from which subsequent
rotation of the nut or bolt can be measured. Then using the appropriate turns in Figure 3, turn the bolts/nuts,
according to the tightening sequence shown in Figure 3, if appropriate, to achieve 70% of yield tension in the
bolts.
Bolt Size (mm)
Shank Length Between
Load Faces Of Bolt and
Nut (mm)
Final Torsional Displacement
Between Bolt and Nut (turns)
M16 – M22
<120
>120
0.5
0.75
M24 – M36
<160
>160
0.5
0.75
M38 – M64
<200
>200
0.5
0.75

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4.2 SEAL ASSEMBLY
ICS Pumps are supplied as standard with a flushed gland assembly. Refer to ICS or our nearest agent to determine
the most appropriate method of sealing in your specific application.
4.2.1 STUFFING BOX SEAL ASSEMBLY - Ref Fig 4
Figure 4-Assemble Gland Seal
For longevity, ALL gland packed pumps require a reliable external water flush as detailed in Appendix A. The
standard ICS supply incorporates a Lantern Restrictor which is located at the impeller end of the stuffing box.
‘Low Flow’ lantern restrictors are available as an option, however when pumping abrasive slurries these reduce
are not as effective as the ‘Full Flow’ standard version. Refer Figure 5, 6 and 7 for arrangement options.

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FULL FLOW – STANDARD
Used for normal slurry applications with positive suction head or suction lifts to approx 2m.
Figure 5-Full Flow Arrangement
LOW FLOW
As full flow except lantern restrictor has reduced clearance on sleeve. Used on pumps with suction lifts greater
than 2m or where full flow flush is not possible.
Figure 6 - Low Flow Arrangement

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ULTRA LOW FLOW
Used where slurry dilution is not desirable and can be used on high suction lifts.
Figure 7- Ultra Low Flow Arrangement
To assemble stuffing box seal:
I. Place Stuffing Box flat on surface, wet end side down.
Full Flow & Low Flow Packed Glands
1. Place Lantern Restrictor, small ID down, into stuffing box bore
2. Stand Shaft Sleeve on its end with small ID down, and slide through Lantern Restrictor
3. Fit first Packing Ring to fill the Stuffing Box
4. Fit Packing Rings, staggering joints and flattening each ring separately, until they almost
completely fill the Stuffing Box chamber
Ultra-Low Flow Packed Glands
1. Place Neck Ring into stuffing box bore
2. Place Lip Seal into stuffing box bore, with flat side of lip seal facing upwards
3. Stand Shaft Sleeve on its end with small ID down, and slide through Lip Seal
4. Fit Lantern Ring
5. Fit Packing Rings, staggering joints and flattening each ring separately, until they almost
completely fill the Stuffing Box chamber
II. Fit Gland Assembly over Shaft Sleeve and press to engage bore of Stuffing Box. Press down to
compress Packing Rings. Fit Gland Bolts to recesses in Stuffing Box, engaging holes in Gland
Assembly, fit washers and nuts, and tighten just sufficiently to hold Shaft Sleeve (final adjustment will
be made when running the pump). A cable tie or similar may be used to secure bolts in position.

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III. Refer to the Sectional Arrangement Drawing supplied with the pump to schematically view the order of
components from the bearing spacer to the impeller. For pumps to 4x3 in size the order is as follows:
• Shaft O Ring
• Shaft Sleeve
• Impeller O Ring
• Impeller
IV. Apply anti-seize to recess in Frame Plate where the Stuffing Box will sit to assist future removal.
Remember to fit shaft O ring (and if applicable Impeller Release Collar) to the pump shaft, then fit the
Stuffing Box you have assembled to the Frame Plate, engaging Shaft Sleeve with Shaft, and tap into
position in Frame Plate with a soft mallet.
Push the Shaft Sleeve back until all components on the shaft from the bearing spacer onwards are
firmly in position.
V. Check that all Shaft O-Rings are correctly positioned in grooves and have not been damaged during
assembly.
VI. Fit remaining O-Rings. Using heavy grease that is compatible with the O ring material will assist
keeping the O ring in its correct location during assembly.
VII. Ensure the shaft thread is clean and free of burrs and sharp edges. Using gloves apply anti-seize
compound liberally to Shaft thread.

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4.2.2 EXPELLER SEAL ASSEMBLY -Ref Fig 8
ICS pumps are supplied with metal Expeller Ring’s. On corrosive applications they can be lined with urethane.
The gland of Expeller Ring is normally fitted with packing, but can also be used with Lip Seals.
Alternative assembly methods are described below for the centrifugal seal depending upon pump and frame size.
Please contact an ICS Wear Group representative to discuss you site specific requirements.
Figure 8- Assemble Expeller Sealed Pump
The following instructions describe the procedure to pack the gland of the metal or urethane lined Expeller
Ring, which differs according to the pump frame size.
I. Place Expeller Ring flat on bench, gland side up
II. Push Neck Ring into gland bore
III. Stand Shaft Sleeve on end, and slide through Neck Ring.
IV. Insert first Packing Ring into the Expeller Ring (or Lip Seal if not using Packing).
V. Insert Lantern Ring and press down to flatten first Packing.
VI. Insert remaining Packing (or Lip Seal if not using packing).

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VII. Fit Gland Seal over Shaft Sleeve, until it slots into the bore of Expeller Ring. Press down to compress
Packing Rings. Fit Gland Bolts to recesses in Expeller Ring, with the bolts extending through the holes
in GLAND ASSEMBLY, fit washers and nuts, and finger tighten to hold Shaft Sleeve (final adjustment
will be made when running pump). A cable tie may be used to secure bolts in position.
VIII. Apply anti-seize to recess in Frame Plate where the Expeller Ring will sit to assist future removal. Fit
the Expeller Ring you have assembled to the Frame Plate, and tap into position with a soft mallet.
IX. Locate Expeller Ring with the grease inlet connection at the top.
X. Check that all Shaft O-Ring before the Sleeve is correctly positioned in groove and have not been
damaged during assembly.
XI. Fit second Shaft O-Ring on end of sleeve protruding through Expeller Ring.
XII. Fit Expeller to Shaft, and push to ensure there is contact of all components mounted back to the bearing
spacer.
XIII. Fit Impeller O-Ring to groove in Expeller using thick compatible grease to ensure it does not move
when screwing on impeller.
XIV. Ensure the shaft thread is clean and free of burrs and sharp edges. Using gloves apply anti-seize
compound liberally to Shaft thread.
XV. Fit Grease Nipple to Expeller Ring. Apply grease to Nipple with grease gun, to charge Lantern Ring
cavity.

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4.3 PUMP WET END ASSEMBLY
Pumps described in this manual, to the 4x3 in size, have two-piece metal, urethane or elastomer liners.
Liner configuration is independent of Bearing Assembly size. Metal and Elastomer liners can be retrofitted into
the same wet ends and a mix of Metal and Elastomer liners is also possible where mixing the components will
extend component life.
4.3.1 TWO PIECE RUBBER LINERS-Ref Fig 9
Figure 9- Assembling Two Piece Liners
4.3.1.1 ASSEMBLE FRAME PLATE LINER
I. Fit and tighten Frame Plate Liner Studs to tapped bosses in Frame Plate Liner. If Studs are not square to
the face of the Liner, screw a nut on the thread, and straighten by tapping lightly with a hammer.
II. Lift Liner in position, line up the Studs with holes in the Frame Plate, then push into Frame Plate. Fit
Nuts to Studs, then finger tighten plus a quarter of a turn. These studs are only required to hold the part
in place and prevent collapse if the pump is under vacuum. DO NOT OVER TIGHTEN.
III. Place the impeller, suction down on a flat surface, check to ensure the thread is clean and free of burrs,
using gloves liberally apply anti-seize compound to thread, and screw Impeller to Shaft.
IV. Fit Shaft Key in Shaft keyway, and using a shaft locking device (Shaft Wrench recommended) turn the
Impeller with a bar between vanes until it locks firmly to the shaft, but do not over tighten. Ensure that
the various O-Rings on the Shaft are not damaged, and are in their correct O ring seat.

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4.3.1.2 ASSEMBLE COVER PLATE LINER AND COVER PLATE
I. Fit and tighten Studs to tapped bosses in Cover Plate Liners (4x3 and 3x2 ICS Mill Master pumps
only). If Studs are not square to the face of the Liner, screw a nut on the thread, and straighten by
tapping lightly with a hammer.
II. Place two blocks of wood on the floor spaced so that they are secure but towards the edge of the suction
inlet of the Cover Plate. Apply generous amounts of rubber lubricant or soap to the intake flange and
intake surface of the Cover Plate.
III. Place Cover Plate Liner, suction side down with corresponding holes lining up with the Cover Plate
(3x2 and 4x3 pumps only), then push elastomer intake flange through the Cover Plate bore. Press down
until the Cover Plate Liner firmly engages with the Cover Plate and the elastomer intake flange
protrudes. This may require force and use of a small tire lever, or similar, between intake flange and
Liner. Fit Nuts to Studs, and tighten finger tight plus quarter of a turn (max). These studs are only
required to prevent collapse if the pump is under vacuum. DO NOT OVER TIGHTEN.
IV. Lift Cover Plate, with Liner fitted, and align holes with Cover Plate Bolts assembled in the Frame Plate.
Fit Nuts to Cover Plate Bolts, and tighten evenly, and in accordance with the tightening sequence
indicated above in figure 3 and ensure that the Cover Plate lugs engage firmly with shoulders on Cover
Plate Bolts.
V. Fit gland flushing or grease connections.
VI. The pump is now ready for fitting of Joint Rings (if provided for pump configuration) and Impeller
adjustment.

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4.3.2 TWO PIECE METAL LINERS – Fig 10
Figure 10- Assembling Two Piece Metal Liners
I. Fit ‘C’-section Seal Ring to the outside spigot of the Stuffing Box or Expeller Ring, preferably using
compatible thick grease to hold Seal Ring during assembly.
II. The Volute Liner Seal comprises an O-ring for these small sizes, except the 4x3 which has a ‘C’-section
seal.
III. Fit Frame Plate Liner Insert. The Frame Plate Liner Insert is clamped in position by engagement of its
tapered periphery with a corresponding tapered surface on the Volute Liner. Radial alignment of the
Insert is provided by engagement of a spigot on the Insert with a recess in the Frame Plate (1.5x1,
2x1.5, and 3x2 pumps). In the 4x3 ICS pump, radial alignment of the Insert is provided only by
engagement with the Volute Liner and its Frame Plate Liner Insert studs are simply to assist holding it
in place during assembly.