Wilfley EMW Series User manual

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EMW®SLURRY PUMP
Metallic Pump
Installation, Operation, and Maintenance Manual
IM-EMW-M
WWW.WILFLEY.COM

5870 E. 56th Avenue, Commerce City, CO 80022 USA • Toll Free: 1-800-525-9930 • Phone: [phone] • Fax: [phone] • www.wilfley.com • [e-mail]
1 IM-EMW-M - rev 6
TABLE OF CONTENTS
1.0 CONSIDERATIONS ...............................................2
1.1 SAFETY SUGGESTIONS ......................................3
Apparel.......................................................................3
Maintenance...............................................................3
2.0 HANDLING..................................................................4
Bare Pump.................................................................4
Pump and Overhead Assembly .................................4
2.1 STORAGE...................................................................5
Long-Term Storage....................................................5
Pump Storage............................................................5
Individual Parts Storage.............................................5
Motor and Seal Storage.............................................5
3.0 INSTALLATION...........................................................5
Inspection upon Arrival...............................................5
Choosing Pump Location...........................................5
Foundation.................................................................5
Alignment...................................................................5
Piping.........................................................................5
Discharge Piping........................................................6
Suction Piping............................................................6
Packing / Seal Flush Piping .......................................6
3.1 INSTALLATION ALIGNMENT ...........................................6
3.2 COUPLING..................................................................7
3.3 SAFETY GUARDS......................................................7
3.4 ROTATION CHECK.......................................................7
4.0 START-UP CHECKS ..................................................8
STARTING........................................................................8
4.1 ENSURING PROPER NPSHA .......................................8
4.2 STARTING THE PUMP AND ADJUSTING FLOW..................8
4.3 OPERATION TO PREVENT FREEZING..............................9
4.4 SHUTDOWN CONSIDERATIONS......................................9
5.0 GENERAL SERVICING ..............................................9
5.1 PERIODIC MAINTENANCE ...........................................10
5.2 VISUAL INSPECTIONS.................................................10
5.3 EXTERNAL CLEANING ................................................10
5.4 GREASE LUBRICATION...............................................10
5.5 OIL LUBRICATION......................................................10
6.0 PUMP DESIGNATION..................................................11
6.1 EMW SLURRY PUMP DETAILS ...................................11
Pump Casing............................................................11
Impeller....................................................................11
Bearing Cartridge.....................................................11
Sealing System........................................................11
Dynamic Seal with Expeller..................................12
Expeller with Packing Seal...................................12
Packing Seal ........................................................12
Mechanical Seal...................................................12
Diaphragm Seal with Expeller ..............................12
7.0 GENERAL ASSEMBLY INFORMATION...................12
7.1 SPECIALIZED TOOLS .................................................12
Impeller Tool............................................................12
Shaft Wrench...........................................................13
Shaft Handling Tool .................................................13
Radial Bearing Alignment Tool.................................13
8.0 POWER END ASSEMBLY........................................14
9.0 WET END ASSEMBLY ................................................19
9.1 Solidlock®Static Seal.........................................19
9.2 Expeller with Packing.........................................23
9.3 Packing Seal......................................................27
9.4 Mechanical Seal.................................................31
9.5 SUCTION COVER ASSEMBLY –UP TO SIZE 150 ...........34
9.6 SUCTION COVER ASSEMBLY -- SIZE 200 AND LARGER .35
9.7 FLANGE ASSEMBLY...................................................36
10.1 SETTING CLEARANCES -SIZE 150 AND SMALLER.......37
10.2 SETTING CLEARANCES -SIZE 200 AND LARGER ........38
10.3 SEAL GUARD ASSEMBLY .........................................39
10.4 WEAR ADJUSTMENT................................................39
10.5 DISASSEMBLY NOTES..............................................40
IMPELLER REPLACEMENT. ...............................................40
LOCK OUT.....................................................................40
BEARING CARTRIDGE......................................................40
FLANGES.......................................................................40
10.6 SPARE PARTS.......................................................41
11.0 FORCES AND MOMENTS ..........................................42
11.1 NOISE LEVELS........................................................43
11.2 ACCESSORIES ........................................................43
11.3TORQUE VALUES (UNLESS OTHERWISE SPECIFIED).....44
11.4CASE/SUCTION COVER HARDWARE TORQUE VALUES 44
12.0 TROUBLESHOOTING............................................45
13.0 REVISION HISTORY..............................................46
APPENDIX 1...................................................................46

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2 IM-EMW-M - rev 6
1.0 Considerations
It is extremely important that this entire manual
be read prior to installation or operation of the
pump.
Any warranty of the operating reliability and safety of
the pump/unit supplied is only valid if the machine is
operated in accordance with its designated use. The
limits stated in the data sheet must not be exceeded
under any circumstances.
Warranty is only valid when genuine Wilfley parts
are used. Modifications of the pump and/or pump
parts are only permitted with approval from the
manufacturer. Contact your authorized Wilfley
representative for basic warranty information and
before making any changes.
A.R. Wilfley and Sons, Inc. shall not be liable for
damage or delays caused by a failure to observe
the instructions that are contained in this manual.
Proper pump selection should be made for
applications based on conditions of service, material
compatibility, solids content, fluid temperature,
footprint size, as well as motor speed and energy
considerations. Improper selection or improper use of
pumps could risk injury or damage. For maximum
safety and reliability, use only factory-supplied parts
and closely follow all operating instructions and
maintenance recommendations.
Every centrifugal pump has the potential to be
dangerous, because of the following factors:
•Parts are rotating at high speeds.
•High pressures may be present.
•High temperatures may be present.
•Highly corrosive and/or toxic chemicals.
NOTE
Always coordinate repair activity with operations
personnel and follow all applicable safety
requirements and health safety regulations.
The following list is provided only as a guide of the
types of misuse that can damage a pump and cause
injury. A.R. Wilfley shall not be liable for physical
injury, damage or production delays caused by a
failure to comply with the instructions contained in this
manual. Below are examples of misuse that will void
all relevant warranties.
1. Do not lift the pump by its case only.
2. Do not connect the pump to the drive system
without first checking to see that the drive system is
running in the correct direction.
3. Do not rely on the factory’s alignment of the pump
and the drive system. Alignment may have changed
during shipment.
4. Do not operate a pump with the coupling guard
removed. Make sure the guard fits snugly around
the coupling so there are no openings.
5. Do not run equipment dry or start the pump without
the proper prime (Casing Flooded).
6. Do not run a pump with the discharge valve closed
or below minimum rated flow.
7. Do not run a pump in the reverse direction.
8. Do not start a pump that is “wind-milling” in the
reverse direction (fluid flowing back down the
discharge pipe).
9. Do not continue to operate a pump when there are
indications that something is rubbing, binding or
knocking.
10. Do not continue to run a pump that gives an
indication of overheating.
11. Do not exceed the maximum allowable pressure
(“Max. P. @ 38°C” as shown on pump nameplate).
12. Do not operate a pump that is excessively vibrating,
surging, or making abnormal noise.
13. Do not put a cold liquid in or on a hot pump or a hot
liquid in or on a cold pump.
14. Do not hit a pump with any object.
15. Do not work on a pump unless the drive system is
locked out and the pump is disconnected from the
drive system.
16. Do not examine a pump without using proper eye
and face protection.
17. Do not stick hands, arms, legs or any other object
into the discharge, suction, or any other opening of
a pump.
18. Do not use worn or faulty parts.
19. Do not weld attachments to the pump.
20. Do not apply external heat to the pump.

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3 IM-EMW-M - rev 6
Paying constant attention to safety is always
extremely important. However, there are often
situations that require special attention. These
situations are indicated throughout this book by the
following symbols:
DANGER
DANGER –Immediate hazards that WILL result in
severe personal injury or death.
WARNING
WARNING –Hazards or unsafe practices that
COULD result in severe personal injury or death.
CAUTION
CAUTION - Hazards or unsafe practices that COULD
result in minor personal injury, product, or property
damage.
NOTE
Always coordinate repair activity with operations
personnel and follow all plant safety requirements
and applicable safety and health laws and
regulations.
1.1 Safety Suggestions
Always follow best practices for safety—including but
not limited to:
Apparel
•Insulated work gloves when handling hot
bearings or using bearing heater
•Heavy work gloves when handling parts with
sharp edges, especially impellers
•Safety glasses (with side shields) for eye
protection, especially in machine shop areas
•Steel-toed shoes for protection when handling
parts, heavy tools, etc.
•Other personal protective equipment to protect
against hazardous/toxic fluids.
•Always lockout/tagout power circuits
•Ensure pump is isolated from electrical system
and pressure is relieved before disassembling
any pressure containing parts
•Use proper lifting and supporting equipment to
prevent serious injury.
•Observe proper decontamination procedures.
•Know and follow company safety regulations.
•Never apply heat to remove impeller.
•Observe all cautions and warnings highlighted
in pump instruction manual.
Maintenance
•The operator is responsible for ensuring that
all maintenance, inspection, and installation
work is performed by authorized and qualified
personnel who understand the application.
•Work on the machine must only occur at
standstill. The shutdown procedure described
in this manual must be followed.
•All safety/protective devices must be re-
installed and/or reactivated immediately
following completion of the work.
•Please observe all instructions described in
Commissioning (Section 6) before returning
the machine to service.
•Always lockout or tag out power.
•Ensure pump is isolated from system and
pressure is relieved before disassembling
pump, removing plugs, or disconnecting
piping.
•Use proper lifting and supporting equipment to
prevent serious injury.
•Observe proper decontamination procedures.
•Know and follow company safety regulations.
•Never apply heat to remove impeller.
•Observe all cautions and warnings highlighted
in pump instruction manual.

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4 IM-EMW-M - rev 6
2.0 Handling
Following proper transport and storage practices
prevents damage to pumping units. Proper lifting
and safety practices must always be observed.
Caution should be taken when lifting the pump as
the center of gravity is not in the physical center of
the unit. Units should be secured properly on a skid
or crated box.
Lifting should only be done by trained personnel
using the appropriate skid assembly. Pumps and
motors often have integral lifting eyes or eye bolts.
These are intended for use in lifting the individual
piece of equipment, not the entire assembly.
Care should be taken to ensure all lifting lines
are properly installed to prevent a load shift. A
load shift may result in injury, death, or property
damage.
Before lifting the equipment, always be sure that the
hoist and strapping method can lift the entire
assembly weight.
Bare Pump
Attach straps on pump case and pedestal to form a
three-point lift as shown. The sling lengths should be
adjusted to balance the load before lifting. Do not
use the bearing cartridge or shaft as a lift point.
Pump and Overhead Assembly
Use the same technique as described with the bare
pump. Do not lift pump and overhead assembly
with the motor mounted on the overhead. See
image shown below.
The tapped hole in the top of the bearing
cartridge is for a lifting eye used to handle the
bearing cartridge assembly by itself. It is not to
be used for lifting a pump.
WARNING
!
CAUTION
!

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5 IM-EMW-M - rev 6
2.1 Storage
If the pump is inoperative for a long period of time, it
is recommended that the pump be flushed and
thoroughly dried to minimize corrosion. It is also
advisable to drain the pump interior if there is any
possibility of freezing. If the pump is to be stored for
more than 15 days, the pump should be rotated once
a month (with lubrication) for the bearings.
Long-Term Storage
The following guidelines should be followed when the
pump or parts will be idle for a period of one month or
more.
Pump Storage
1. All machined metal surfaces should be coated
with a suitable corrosion inhibitor to ensure the
integrity of these surfaces at the time of
installation.
2. All openings must be covered with suitable
covers to protect against contaminants and
moisture.
3. Storage of the Components and Assemblies
should be kept away from all potential
vibration sources. (i.e., motors, rotating
pumps, engines, etc.). This is to prevent
unwanted vibration and possible damage to
the bearings.
4. Components and assemblies are required to
be stored indoors in a dry location.
Temperature range should be between 40
degrees and 100 degrees Fahrenheit. If the
environment is excessively humid (more than
70%), a suitable desiccant should be used.
5. If the pump is to be stored for more than 15
days, the pump should be rotated once a
month (with lubrication) for the bearings.
Individual Parts Storage
Not all parts are packaged in a suitable manner from
the factory for long-term storage. To ensure
satisfactory part performance, all parts must be
protected from corrosion and contamination.
Motor and Seal Storage
Refer to the manufacturer’s manuals for storage
instructions for these items.
3.0 Installation
Inspection upon Arrival
Inspect the assembled pump upon arrival for any
damage that may have occurred during shipment.
Report any damage immediately to the carrier or
distributor.
Leave all shipping covers attached to the pump unit
until it is ready for installation. If installation is to be
delayed more than 15 days, the pump shaft should be
rotated by hand once every month with lubrication for
care of the bearings.
To assure proper installation, supervision from an
authorized Wilfley representative is recommended.
Choosing Pump Location
The following recommendations may be helpful when
choosing the best location for your pump:
1. Locate the pump as close to the liquid source
as practical so the suction pipe is short and
direct with a minimum of elbows, fittings and
valves.
2. Place the pump in a location so the unit is
accessible for inspection during operation as
well as for maintenance operations involving
removal and disassembly.
Foundation
The foundation should be sturdy enough to absorb
any vibration and to form a permanent, rigid support
for the baseplate. This is important to maintain the
correct alignment of the direct connected unit. A
concrete foundation on a solid base is satisfactory.
Foundation bolts of the proper size should be
embedded in the concrete.
Alignment
Alignment of the motor and pump is necessary after
the complete unit has been leveled and tightened
onto the foundation. See alignment procedures
Piping
Both suction and discharge pipes should be
supported independently near the pump so when the
flange bolts are tightened no strain will be transmitted
to the pump casing. The customer is responsible for
proper suction and discharge pipe design and layout
to avoid flow induced problems.

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6 IM-EMW-M - rev 6
Discharge Piping
A valve should be installed in the discharge line to
prevent fluid from flowing back through the pump
when it is shut down. The valve should block the
discharge line during maintenance.
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
Suction Piping
Care should be taken in sizing and locating suction
piping to prevent cavitation. A valve should be
installed in the suction line to prevent fluid from
flowing into the pump when it is shut down.
To avoid NPSH and suction problems, suction pipe
sizes must be at least greater than the pump suction
connection. Never use pipe or fittings on the suction
that are smaller in diameter than the pump suction
size.
The ideal piping configuration should have a
minimum of 10 pipe diameters between the source
and the pump suction. In most cases, horizontal
reducers should be eccentric and mounted with the
flat side on top or up with a maximum of one pipe size
reduction. Never mount eccentric reducers with the
flat side down. Horizontally mounted concentric
reducers should not be used if there is any possibility
of entrained air in the process fluid. Vertically
mounted concentric reducers are acceptable. In
applications where the fluid is completely de-aerated
and free of any vapor or suspended solids, concentric
reducers are preferable to eccentric reducers.
Avoid the use of throttling valves and strainers in the
suction line. Start-up strainers must be removed
shortly after start-up. When the pump is installed
below the source of supply, a valve should be
installed in the suction line to isolate the pump and
permit pump inspection and maintenance. However,
never place a valve directly on the suction nozzle of
the pump.
Packing / Seal Flush Piping
An external connection should be made at the pump
so flush flow can be varied as required by valves
and the pressure can be monitored. Pipe fittings and
gauges must be corrosion resistant to the fluid being
pumped.
Piping Forces: Take care during installation and
operation to minimize pipe forces and/or
moments on the pump casing.
Refer to the Hydraulic Institute Standards for
centrifugal pumps for additional piping information.
3.1 Installation Alignment
Accurate alignment of the equipment must be
obtained and sustained. Trouble-free operation can
be accomplished by following the proper
procedures.
A properly installed base plate will be leveled with
shims, retained in place with anchor bolts, set in
concrete, and grouted with a low shrinkage grout.
When a direct drive pump and motor is mounted to a
common base plate at the factory, the coupling is
installed and aligned at that time. However,
coupling alignment must be verified before operating
the pump and motor.
Proper coupling alignment can be verified by placing
a straight edge axially across the coupling halves.
The distance between the straight edge and the
shaft should be the same within 0.1 mm (0.004
inches). Also, the angular distance between the
coupling halves should be consistent within 0.1 mm
(0.004 inches). At a minimum coupling alignment
should be checked once every 90 degrees of shaft
rotation (12:00, 3:00, 6:00 and 9:00).
When checking a v-belt motor connection, the
parallel and offset alignment of the sheave(s) to
each other must be within 1.0 mm (0.040 inches).
After connecting piping, rotate the pump drive shaft
clockwise (viewed from motor end) by hand several
complete revolutions to be sure there is no binding
and that all parts are free. Recheck shaft alignment.
If piping caused unit to be out of alignment, correct
piping to relieve strain on the pump.
After making all piping connections verify pipe
strains haven’t altered alignment. If changes have
occurred, alter piping to remove pipe strains on
pump flanges.
Operate the pump for at least an hour or until it
reaches final operating temperature. Shut the pump
down and recheck alignment while the pump is hot.
Piping thermal expansion may change the
alignment. Realign the pump as necessary.
WARNING
!
WARNING
!

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7 IM-EMW-M - rev 6
See the following table for possible alignment
issues.
PROBLEM
POSSIBLE
CAUSE
RECOMMENDED
REMEDY
Unable to
obtain
horizontal
(side to
side)
alignment,
angular, or
parallel.
Driver feet
bolt bound.
Loosen pump hold
down bolts and slide
pump and driver until
horizontal alignment
is achieved.
Baseplate
not leveled
properly,
possibly
twisted.
Determine which
corner(s) of the
baseplate are high or
low and remove or
add shims at the
appropriate corner(s)
and realign.
Unable
obtain
vertical
alignment,
angular, or
parallel.
Baseplate
not leveled
properly,
possibly
bowed.
Determine if center
of baseplate should
be raised or lowered
and correct by
evenly adding or
removing shims.
3.2 Coupling
The coupling should be installed as advised by the
coupling manufacturer. If the spacer has been
installed to facilitate alignment, then it must be
removed prior to checking rotation. Remove
3.3 Safety Guards
Power must never be applied to the driver when
the coupling guard is not installed.
Coupling guards are safety devices intended to
protect workers from inherent dangers of the rotating
pump shaft, motor shaft, and coupling. It is intended
to prevent entry of hands, fingers, or other body
parts into a point of hazard by reaching through,
over, under, or around the guard.
No standard coupling guard provides complete
protection from a disintegrating coupling. The
coupling conforms to the U.S.A. standard ASME
B15.1, “Safety Standard for Mechanical Power
Transmission Apparatus.”
Never remove safety guards except for when repairs
or maintenance are required. Always reinstall as the
guards are intended to prevent a safety hazard by
covering rotating parts from contact.
The Wilfley coupling guard conforms to the U.S.A.
standard ASME B11.19, “Performance Requirements
for Safeguarding.”
3.4 Rotation Check
CAUTION
A direction arrow is cast on the front of the
casing. Make sure the motor rotates in the same
direction before coupling the motor to the pump.
It is essential that the rotation of the motor be checked
before connecting the shaft coupling. Incorrect
rotation of the pump, for even a short time, can
dislodge the impeller, which may cause serious
damage to the pump. All Wilfley pumps turn clockwise
as viewed from the motor end, or conversely,
counterclockwise when viewed from the suction end
Pump with Direction of Rotation Arrow and
optional case orientations
WARNING
!

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8 IM-EMW-M - rev 6
4.0 Start-Up Checks
Prior to pump operation, it is essential that the
following checks be made.
•Visually check all main and auxiliary piping to
ensure that all connections have been
properly made.
•Check voltage, fuse, starter amperage ratings
and frequency on the motor nameplate against
the electrical supply characteristics.
•Visually inspect all electrical connections to
the motor and control circuit.
•Check the rotation of the motor by
momentarily starting the motor with motor
disconnected from the pump assembly.
Direction of rotation must be as shown by the
arrow on the pump case and the direction of
rotation plate on the top of the frame. Starting
or running pump backwards will cause
damage.
•Pump and motor are properly secured to the
baseplate.
•All fasteners tightened to the correct torques.
•Coupling guard in place and not rubbing.
•Impeller clearance setting.
•Bearing lubrication.
•Pump instrumentation is operational.
•Pump is primed.
As a final step in preparation for operation, it is
important to rotate the shaft by hand to be certain that
all rotating parts move freely and that there are no
foreign objects in the pump casing.
Starting
Before starting the pump, it is advisable to have the
pump casing and suction line filled with liquid. It is
normal to have the discharge valve momentarily
closed when the pump is started since much less
horsepower is required under these conditions.
DO NOT OPERATE THE PUMP IN A DEAD-HEAD
(NO FLOW) CONDITION.
4.1 Ensuring Proper NPSHA
Net Positive Suction Head –Available (NPSHA) is the
measure of the energy in a liquid above the vapor
pressure. It is used to determine the likelihood that a
fluid will vaporize in the pump. It is critical because a
centrifugal pump is designed to pump a liquid, not a
vapor. Vaporization in a pump will result in damage to
the pump, deterioration of the generated head and
possibly a complete stoppage of pumping.
Net Positive Suction Head –Required (NPSHR) is the
decrease of fluid energy between the inlet of the
pump and the point of lowest pressure in the pump.
This decrease occurs because of friction losses and
fluid accelerations in the inlet region of the pump. The
value for NPSHR for the specific pump purchased is
given in the pump data sheet and on the pump
performance curve. For a pump to operate properly,
the NPSHA must be greater than the NPSHR. Good
practice dictates that this margin should be at least 3
ft (1 m) or 20%, whichever is greater.
CAUTION
Ensuring that NPSHA is larger than NPSHR by the
suggested margin will greatly enhance pump
performance and reliability. It will also reduce the
likelihood of cavitation, which can severely damage
the pump.
4.2 Starting the Pump and Adjusting Flow
1. Open the suction valve to the fully open
position. It is very important to leave the
suction valve open while the pump is
operating. Any throttling or adjusting of flow
must be done through the discharge valve.
Partially closing the suction valve can create
serious NPSH and pump performance
problems or even severe damage.
DANGER
Never operate pump with both the suction and
discharge valves closed. This could cause an
explosion.
2. A standard centrifugal pump will not move
liquid unless the pump is primed. A pump is
said to be “primed” when the casing and the
suction piping are completely void of air. Open

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9 IM-EMW-M - rev 6
the discharge valve a slight amount. This will
allow any entrapped air to escape and will
allow the pump to prime if the suction source
is above the pump. When a condition exists
where the suction pressure drops below the
pump’s capability, it is advisable to add a low-
pressure control device to shut the
pump/motor down when the pressure drops
below a predetermined minimum value.
3. All cooling, heating and flush lines must be
started and regulated.
4. Start the driver (typically an electric motor).
5. Slowly open the discharge valve until the
desired flow is reached, keeping in mind the
minimum flow restrictions listed above.
DANGER
It is important that the discharge valve be
opened within a short interval after starting the
driver. Failure to do this could cause a
dangerous build-up of heat and possibly an
explosion.
Reduced capacity
Avoid running a centrifugal pump at drastically
reduced capacities or with the discharge valve
closed for extended periods of time. Operating
in this capacity could result in the liquid in the
pump reaching its boiling point. If this occurs,
the seal may be damaged, as it will have no
lubrication and may score or seize to the
stationary parts. It is also possible that it can
create an explosive condition. If the suction
valve is simultaneously closed, there is an even
greater risk of a catastrophic failure.
Thermocouples may be used to safeguard
against overheating by shutting down the pump
at a predetermined temperature
Pump safeguards should also be used to
prevent operation with a closed discharge
valve. This may be accomplished by installing
a bypass back to the suction source. The size
of the bypass line and the required bypass flow
rate is a function of the input horsepower and
the allowable temperature rise.
Reduced Head
Note that when discharge head drops, the
pump’s flow rate usually increases rapidly.
Check motor for temperature rise as this may
cause an overload in flow. If flow overloading
occurs, adjust the discharge valve.
Surging Condition
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement is recommended in the piping.
4.3 Operation to prevent Freezing
When using the pump in sub-freezing conditions
especially if the pump is periodically idle, special
attention should be given to the temperature. The
pump should be properly drained or protected with
thermal insulating devices which will keep the liquid
in the pump from freezing.
4.4 Shutdown Considerations
When the pump is being shut down, the procedure
should be the reverse of the start-up procedure. First,
slowly close the discharge valve, shut down the driver
and then close the suction valve. Remember, closing
the suction valve while the pump is running is a safety
hazard and could seriously damage the pump and
other equipment.
5.0 General Servicing
It is recommended that the pump be inspected at
regular intervals. It is also suggested that a service
record be kept for the pump. A procedure for keeping
accurate maintenance records is a critical part of any
program to improve pump reliability. There are many
variables that can contribute to pump failures.
Analyzing these variables through pump
maintenance records can only solve often-long term
and repetitive problems.
General service and maintenance should be carried
out by authorized and trained operators who are
familiar with these operating instructions.
The electrical connections must be disconnected
and locked out. Make sure the pump cannot be
switched on accidentally.
WARNING
!

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10 IM-EMW-M - rev 6
Liquids posing health hazards must be
decontaminated and disposed of ensuring that there
are no risks to persons or to the environment.
5.1 Periodic Maintenance
All flow, pressure, and temperature gauges should
be monitored to ensure that the pump is operating
within specified limits. If the frame temperatures are
monitored, this temperature generally should not
exceed 71°C (160°F).
The following table contains recommended service
checks that should be performed on a periodic
basis.
Initial
Start-
Up
Weekly
Monthly
Flow, Pressure,
Temperature
X
X
Visual
X
X
Noise Vibration
X
X
Lubricate
X
X
X
5.2 Visual Inspections
Periodic visual inspection should be made of the
pump and its installation.
This inspection should include the following:
1. All mounting supports should be secure.
2. All external nuts, bolts, and fittings should be
tight.
3. All suction and discharge piping should be
secure.
4. All surfaces and joints should show no signs of
leakage.
5.3 External Cleaning
Periodic maintenance can involve the use of high
pressure sprays to remove excess dirt and debris.
When using such equipment, it is essential to ensure
the bearing isolators are not sprayed in order to
prevent liquid penetration into the bearing frame. If
this occurs, simply drain, and re-lubricate.
5.4 Grease Lubrication
Grease lubrication is standard on EMW pumps. The
grease base oil may be mineral or synthetic with
synthetic base oil being preferred for bearing
temperatures above 93°C (200°F). The consistency
should be a NLGI grade 2, with a lithium or lithium
complex thickener (soap).
Bearings in pumps shipped from the factory come
with the bearings pre-packed with grease. When
replacing bearings, pack the bearings 100% full of
grease, and fill the pump housing cavity around the
bearing 30% to 50% full of grease.
Re-lubrication intervals are difficult to determine.
Once intervals are established through plant
practices or experiences, regular lubrication intervals
should be maintained. In the absence of pre-
existing practices, refer to Appendix 1 for guidelines.
5.5 Oil Lubrication
The optional oil lubrication is a less common feature
of the EMW pumps. Recommended oil change
interval is once every three months when used in
continuous operation. Viscosity grade
recommendations are listed in the following table:
ISO Grade
Temperature
VG68
63°C to 76°C
145°F to 170°F
VG150
77°C to 92°C
171°F to 199°F
VG220
9°C to 121°C
200°F to 250°F
The bearing unit should be filled until the sight glass
indicates the oil level approximately in the middle:
Size
Oil Level
Liters (Quarts)
50 (2x2)
0.6 (0.6)
75 (3x3)
0.7 (0.8)
100 (4x3)
1.0 (1.1)
150 (6x4)
1.3 (1.4)
200 (8x6)
2.1 (2.2)
250 (10x8)
4.6 (4.8)
300 (12x10)
5.9 (6.2)
350 (14x12)
5.6 (6.0)

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11 IM-EMW-M - rev 6
6.0 Pump Designation
Example: EMW 150M 6x4
Pump: EMW
Suction Nozzle (in mm):
50 through 350
(See the table below)
Hydraulic Type:
Metal (M)
Rubber (R)
Imperial Size (suction x discharge):
Pump
Type
Suction
mm (in)
Discharge
mm (in)
50
M/R
50 (2)
50 (2)
75
M/R
75 (3)
75 (3)
100
M/R
100 (4)
75 (3)
150
M/R
150 (6)
100 (4)
200
M/R
200 (8)
150 (6)
250
M/R
250 (10)
200 (8)
300
M
300 (12)
250 (10)
350
M
350 (14)
300 (12)
6.1 EMW Slurry Pump Details
Designed as a class III heavy duty end suction slurry
pump, the EMW pumping chamber, impeller and
expeller are constructed with high chrome, hard iron
materials. The wet end construction of the EMW
pump is built to last and features components
with double the thickness of comparable medium
duty slurry pumps. This type of design,
combined with Wilfley's proprietary MAXALLOY® 5A
hard iron and rubber liners, creates the
ideal slurry pump for high wear applications.
Pump Casing
The extra heavy wall thickness and special volute
design extends wear life. The front of the case is
open to allow inspection of or removal of the impeller
from an installed pump. The casing may be rotated
in 45 degree increments (90 degrees for the size 75
and 50 pumps) to accommodate a variety of
discharge requirements.
Impeller
The impeller with its extra thick shrouds and vanes
and wide-open flow passages for handling large
objects, maintains excellent performance
characteristics throughout its wear life. A closed
type impeller is used with all sizes except the size 50
(2x2) pump, which uses a semi-open type impeller.
Bearing Cartridge
The shaft is constructed from high strength alloy
steel, mounting paired taper roller thrust bearings
and a spherical roller radial bearing protected by
labyrinth isolators. The bearing cartridge assembly is
designed for long life in the harshest conditions and
is available with either grease or oil lubrication.
Sealing System
The seal chamber is designed for easy
maintenance, equipped with large openings for all
around accessibility.
The following seal systems are available.
•Dynamic Seal with expeller
•Expeller with Packing Seal
•Packing Seal
•Mechanical Seal
•Diaphragm Seal with expeller

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12 IM-EMW-M - rev 6
Dynamic Seal with Expeller
The dynamic seal is a flush-less proprietary sealing
solution that uses an expeller to create an air pocket
to seal the pump while rotating, and a specially
designed static seal that can be adjusted to open
and close specifically at the application speeds and
pressures.
Operating the pump at other than the specified
conditions for which it was built could result in
unsatisfactory performance, excessive wear, and/or
premature failure. For additional information, review
the Solidlock® User manual, IM-SL.
Expeller with Packing Seal
The expeller provides a positive hydraulic sealing
arrangement when the pump is running. The
packing provides a static seal when the pump is not
running. The expeller will keep slurry from coming in
contact with the packing when the pump is running,
so abrasive wear on shaft sleeve is greatly reduced.
However, the packing must be lubricated to
compensate for the pumping action of the expeller,
which will tend to dry out the seal chamber. Grease
is the recommended lubricant for applications where
the use of a liquid lubricant is undesirable. Graphite
packing is standard.
Packing Seal
The Packing seal provides a simple alternative
solution to either an expeller seal or mechanical
seal. Graphite packing is standard. A packing flush
is always recommended; however, in some
applications, dry running packing (packing that is
lubricated solely by the liquid being pumped) will
also work.
Mechanical Seal
The EMW pump seal chamber is designed to
accommodate select mechanical seals. Consult with
a Wilfley Representative for mechanical seal use
with the EMW Slurry pump.
Diaphragm Seal with Expeller
A flush-less diaphragm seal is possible with the EMW
slurry pump. The expeller creates suction in the seal
chamber that pulls open the diaphragm while rotating,
and the diaphragm will push back against a rotating
seal face when stopped.
Expeller seal and dynamic seal performance is
highly dependent upon suction pressure and pump
rotational speed as well as properly adjusted internal
clearances.
7.0 General Assembly Information
The EMW pump is metric by design. Metric
fasteners are used throughout with the select
exceptions. All pipe fittings use imperial National
Pipe Threads (NPT). On EMW metal pumps
produced in the U.S.A. the square head bolts and
nuts used to assemble the case are imperial. The
flat washers used with these fasteners, however, are
metric. Imperial washers are too large to register
correctly in the case and bracket counter bore reliefs
and should not be substituted here.
In general, parts should be cleaned to remove
debris, dirt, or rust inhibitor coatings. Use this
opportunity to visually inspect for damage. If
reconditioned or existing parts are going to be used,
inspect them for wear before installing. All sealing
surfaces should be inspected for cleanliness and
damage. Replace any damaged fasteners with new
fasteners coated with an anti-seize lubricating
compound prior to using.
When bolted joints are encountered care should be
taken to incrementally tighten all fasteners in a
crossing pattern until metal to metal contact is
achieved between the mating parts.
Exception: A gap, approximately 1 mm (0.040
inches) wide, will exist between the thrust bearing
cap and the bearing cartridge when properly
assembled. This bearing cap should not be over
tightened.
7.1 Specialized Tools
Impeller Tool
On all but the smallest size pumps, an impeller lifting
fixture that registers in the eye of the impeller is

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13 IM-EMW-M - rev 6
required for inserting an impeller into or removing an
impeller from a case. If a crane will be used, a “C”
shaped bent frame lifting fixture with a lifting point
located above the impeller center of gravity when
the impeller is in a horizontal position is
recommended.
Shaft Wrench
A shaft wrench keyed to fit the drive end of the shaft
is recommended for aiding with the tightening or
releasing of an impeller. Contact AR Wilfley for
details on this tool.
Shaft Handling Tool
A 12 mm tapped hole in the end of the shaft
provides a location for a hoisting attachment such as
an eyebolt to assist with vertical positioning of the
shaft for insertion into or removal from a bearing
cartridge.
Radial Bearing Alignment Tool
A tool to align the radial bearing outer race during
vertical insertion or removal of a shaft assembly into
or from a bearing cartridge is required. A tool that
shoulders against the radial bearing outer race, slip
fits over the drive end of the shaft and is secured in
the keyway by a set screw is recommended. To
avoid damaging the shaft, the set screw should only
be tightened against the shaft keyway flat.

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14 IM-EMW-M - rev 6
8.0 Power End Assembly
Shaft assembly. Preheat the Thrust Bearings (16) and Radial Bearing (18) onto the Shaft (6) using an induction
heater. The temperature will allow the bearings to slip onto the shaft against the appropriate shoulder. Be sure that
the bearings are cooled before moving on to the next step.
NOTE
The thrust bearing outer race (for the inner bearing) will have to be
placed on the shaft before installing the thrust bearings. The thrust
bearings are located on the threaded side of the shaft. The radial
bearing is located on the keyed side of the shaft
Shaft Insertion. Next, install the shaft with bearings into the
Bearing Cartridge (99). If the bearings are grease lubricated, the
space directly inboard from the bearings should be packed with
grease before inserting the shaft assembly into the bearing
cartridge. The best way to do this is to install the assembly
vertically down and into the cartridge. Use the threaded hole in
the shaft and a lifting eye for safe maneuvering.
NOTES
Note the orientation and bearing fits - the side that has a lip in the
bore is the thrust bearing side (the side that the shaft is inserted
into). Be careful when lowering the thrust bearing into the cartridge
such that the outer races are inserted squarely.

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15 IM-EMW-M - rev 6
Bearing Cartridge.
1. Press fit the bearing isolaters (47) and (49) into the bearing caps (35) and (37) respectively.
2. Next install the o-rings (35B) into the thrust bearing cap (35), and (37A) into the radial bearing cap (37).
The bearing caps are assembled onto their respective sides using hardware (35A) and (37A). If the bearings
are grease lubricated, the area directly outboard from the bearings should be packed with grease prior to
assembling the bearing caps. When installing the bearing caps, it may be difficult to push the o-ring over
the shaft shoulder, so it is recommended to use the cap screws to pull the bearing cap evenly into place.
NOTE
When installing the thrust bearing cap (35), a gap of approximately 1mm (0.040 inches) will be visible
between the bearing cartridge and bearing cap. The bearing cap screws (35A) and (37A) should be
tightened slowly in a star pattern. Do not over tighten this bearing cap.
3. If the pump is grease lubricated, thread two grease fittings (99E) into the top of the bearing cartridge and
give each bearing a shot of grease. If the pump is oil lubricated, assemble the oil drain plug (99B), oil sight
glass (143), and temperature gauge (144) into the holes on the side of the cartridge, and install the oil fill
plug (99A) on the top of the bearing cartridge.
Grease Lube Cartridge
Oil Lube Cartridge

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16 IM-EMW-M - rev 6
Pedestal Assembly.
1. Install the clearance adjustment bolt (149), nuts (149B), and washers (149C) into the pedestal (53).
2. Bolt the pedestal to a rigid base or structure to prevent it from tipping forward when the wet end of the pump
is assembled.
3. On pumps size 100 and smaller, assemble the bracket (71) with socket head cap screws (71F). On pumps
size 150 and larger, assemble the bracket (71) with hex-head screws (71F) and flat washers (71G).
Power End Assembly.
1. Lower the bearing cartridge assembly onto the pedestal assembly making sure the threaded side of the
shaft is on the side of the pedestal with the bracket (71).
2. Loosely install the bearing cartridge clamps (54) using hardware (54A), (54B), and (54C). Remove the
lifting eye from the bearing cartridge and replace it with a hex cap screw and washer as this lifting eye
location is not designed to lift the full pump weight.

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17 IM-EMW-M - rev 6
Shaft Sleeve assembly.
1. Install the o-ring (119B) into the inner groove in the shaft sleeve (14). Slide the shaft sleeve, chamfered
end first, onto the front end of the shaft (6). Lubrication of grease will help the oring to start sliding against
the shaft. The sleeve will stop on contact with the bearing isolator. Be sure to push the shaft sleeve
completely on, until it seats against the thrust bearing (16).
Correctly installed shaft sleeve
(Shoulders against thrust bearing)
Incorrectly installed shaft sleeve
(Shoulders against thrust bearing isolator o-ring
Pumps Size 150 and Smaller

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18 IM-EMW-M - rev 6
Release Collar Sleeve Assembly.
1. Install the o-ring (36A) in the inner in the release collar sleeve (36B). Slide the release collar sleeve,
chamfered end first, onto the shaft (6).
2. Slide the release collar cover (36C) onto the release collar shaft sleeve past the groove and loosely install
the square head set screw (36D) into the cover (36C).
3. If the release collar (36) is not already in two pieces, cut the release collar into two halves at the two scored
locations and notch to 45 degrees as shown. Orient the two halves so that the O-ring grooves are facing
out. Position on the shaft as shown.
4. Slide the release collar cover (36C) over the two halves of the release collar (36) and tighten the square
head screw (36D) so that it bottoms out in the groove on the release collar sleeve (36B).
NOTE
The release collar is split to allow removal and
reinstallation on a fully assembled pump. Removing the
release collar will relieve the pressure on the impeller
threads so the impeller can be removed easily after use.
To remove a release collar from a fully assembled pump,
loosen the square head set screw (36D). Slide the release
collar cover (36C) towards the bearing cartridge to expose
the release collar (36) and use the notches in the release
collar as pry points to work the collar out.
Pumps Size 200 and Larger

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19 IM-EMW-M - rev 6
9.0 Wet End Assembly
Seal Assembly.
There are a variety of seals available for the EMW pump. Please navigate to the appropriate page in table 6-1
based on which seal is installed in your pump.
Table 6-1: Seal Assemblies by Page
Seal
Section
Page
Solidlock® Dynamic Seal
See IM-SL
19-21
Expeller with Packing
9.2
22-26
Packing
9.3
27-20
Mechanical Seal
9.4
30-33
Solidlock® Lite (Diaphragm Seal)
Contact Wilfley Representative
9.1 Solidlock®Static Seal
The recommended seal for use in EMW slurry pumps is the Solidlock® Static seal. For applications with abrasives
and some degree of solids or particulates that tend to crystalize, the Solidlock® seal is an excellent solution. The
two seal faces operate as a dynamic seal in tandem with the pump’s expeller.
No flushing plan is required and the Solidlock®seal may operate dry without issue, such as if a tank level is dropped
accidentally. The cartridge design allows the units to be installed easily as well as set in a few quick steps. An
optional flushing port is also available for the flexibility of that feature.
Please review the Solidlock® Instruction manual IM-SL for additional detail regarding this sealing solution.
The instillation of the Solidlock® seal components consist of the expeller (4), expeller plate (71B), case plate o-ring
(71C), stationary seal subassembly, stationary seal o-ring (S1C), rotary seal subassembly, stationary seal o-ring
(S1C), shaft sleave (14), expeller to shaft sleave o-ring (119A), and shaft sleave o-ring (119B).
1. Install expeller to shaft sleave o-ring (119A) in grove on the shaft sleave towards the wet end. Then install
o-ring (119B) in the groove inside the shaft sleave on the power end.
2. Apply the lubrication to the o-rings outlined in the Solidlock® instruction manual IM-SL and slide the shaft
sleave on to the pump shaft till shaft sleave bottoms on the inboard bearing. Slide the Solidlock® rotary
subassembly over the shaft sleave.