Centrifugal Pump Minerals

200 HVCC Bare Shaft Pump

Operation and Maintenance Manual

Operation and Maintenance Manual

Copyright © 2017, Weir Minerals Australia Ltd trading as Weir Minerals Australia. All rights reserved.
MULTIFLO, VACTRONIC and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd. This
document contains information which is confidential to Weir Minerals Australia Ltd. It should not be disclosed
in whole or in part to parties other than the recipient without the express written permission of Weir Minerals
Australia Ltd. authorized personnel.
Document Number: WMM-ENG-IOM-0057 UNCONTROLLED DOCUMENT
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 Centrifugal Pump Minerals

200 HVCC Bare Shaft Pump

Operation and Maintenance Manual

PUMP COMPONENTS ARE ONLY RATED

FOR THEIR INTENDED USE.

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 Centrifugal Pump Minerals

200 HVCC Bare Shaft Pump

Operation and Maintenance Manual

Revision History

Revision Description Reviewed Authorised Date

1.0 Initial release Bob Turner Multiflo® 12/05/2017

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 Centrifugal Pump Minerals

200 HVCC Bare Shaft Pump

Operation and Maintenance Manual

Contact Details

Australia
Queensland (QLD):
Head Office Rockhampton
Weir Minerals Australia Authorised Service Provider
15 Dacmar Road Weir Minerals Service Centre
Coolum Beach Qld 4573 80 McLaughlin Street
Ph: 07 5449 3032 North Rockhampton QLD 4701
Fax: 07 5446 4304 Ph: 07 4924 7700
Email: [email protected] Fax: 07 4924 7799
Email: [email protected]

Western Australia (WA):

Kimberly, Pilbara, Mid- Local contact details: Kalgoorlie & Goldfields Perth Metro
West, Murchison Region South West Region Authorised Service Authorised Service
Weir Minerals Australia Ltd. Authorised Service Provider Provider
WA Head Office Provider Weir Minerals Australia Ltd. Weir Minerals Australia Ltd.
41 Kewdale Road Weir Minerals Australia Ltd. Kalgoorlie Service Centre Henderson Service Centre
Kewdale, WA, 6105 Bunbury Service Centre 30 Atbara Street 20 Stuart Drive
Ph: 08 9366 2700 1 Shanahan Road Kalgoorlie WA 6430 Henderson WA 6166
Fax: 08 9366 2766 Bunbury WA 6230 Ph: 08 9021 1454 Ph: 08 9419 7500
Ph: 08 9726 2301 Fax: 08 9021 1468 Fax: 08 9410 7510
Fax: 08 9726 2303

New South Wales (NSW):

Hunter Valley
Authorised Service Provider
Weir Minerals Australia Ltd.
Beresfield Service Centre
9 Arunga Drive
Beresfield NSW 2322
Ph: 02 4032 9412
Fax: 02 4032 9497

Indonesia

PT Weir Minerals Australia Tanjung Branch Office Sangatta Branch Office

Jl. Mulawarman Rt. 020 No. 020 Jl.Ahmad Yani Km 7.5 RT.01 Jl.Yos Sudarso iv rt.23 No.25
Kelurahan Manggar, Balikpapan Maburai. Desa Teluk Lingga, Kecamatan
76117, Kecamatan Murung Pudak, Sangatta Utara.
East Kalimantan Tanjung - Kabupaten Kutai Timur, Sangatta –
Indonesia Tabalong, South Kalimantan East Kalimantan.
Ph: 62 542 746098 Ph: +62 526 - 2712267 Ph: +62 549 25584
Fax: 62 542 746099

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Bare Shaft Pump
Table of Contents
Revision History................................................................................................................................................................ ii
Contact Details ................................................................................................................................................................. iii
Australia............................................................................................................................................................................ iii
Indonesia .......................................................................................................................................................................... iii
Table of Contents............................................................................................................................................................. iv
List of Figures ................................................................................................................................................................ viii
List of Tables .................................................................................................................................................................... ix
1 Introduction .......................................................................................................................................................... 1-1
1.1 Scope of the Manual ........................................................................................................................................ 1-1
1.2 Intended Audience ........................................................................................................................................... 1-1
1.3 Disclaimer ........................................................................................................................................................ 1-1
1.4 Copyright .......................................................................................................................................................... 1-2
1.5 Chapters in the Manual .................................................................................................................................... 1-2
2 Safety .................................................................................................................................................................... 2-3
2.1 Safety Symbols ................................................................................................................................................ 2-4
2.2 Important Information ....................................................................................................................................... 2-6
2.3 General Guidelines .......................................................................................................................................... 2-9
2.4 Operating Conditions ..................................................................................................................................... 2-10
2.5 Personnel Qualification and Training ............................................................................................................. 2-10
2.6 Handling Components ................................................................................................................................... 2-10
2.7 Efficient Use and Intended Use ..................................................................................................................... 2-10
2.8 Unintended Use ............................................................................................................................................. 2-11
2.9 General Safety ............................................................................................................................................... 2-11
2.10 Qualified Workers .......................................................................................................................................... 2-11
2.11 Safe Working on Pumps ................................................................................................................................ 2-11
2.12 Markings and Approvals ................................................................................................................................ 2-12
2.13 Safety Equipment ........................................................................................................................................... 2-12
2.14 Fire Fighting ................................................................................................................................................... 2-12
2.15 Emergency Procedures ................................................................................................................................. 2-12
3 Technical Data ................................................................................................................................................... 3-14
3.1 Bare Shaft Pump Data ................................................................................................................................... 3-14
3.2 Dimensions, Centre of Gravity and Mass Properties of the Bare Shaft Pump .............................................. 3-15
3.3 Pump Identification ........................................................................................................................................ 3-16
3.3.1 Discharge Positions ............................................................................................................................... 3-16
3.4 Bearing Power Capacity ................................................................................................................................ 3-17
3.5 Bolt Torques ................................................................................................................................................... 3-17
3.6 Materials......................................................................................................................................................... 3-17
4 Description ......................................................................................................................................................... 4-18
4.1 Introduction to the 420EXHVCC Bare Shaft Pump ....................................................................................... 4-18
4.2 Pump Component Description ....................................................................................................................... 4-18
4.2.1 Bearing Assemblies and Frames ........................................................................................................... 4-18
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Bare Shaft Pump
4.2.2 Shaft Seals ............................................................................................................................................. 4-18
5 Transport and Storage ...................................................................................................................................... 5-19
5.1 Transportation ................................................................................................................................................ 5-19
5.1.1 Transport Safety .................................................................................................................................... 5-19
5.1.2 Chain of Responsibility .......................................................................................................................... 5-19
5.1.3 Load Restraint ........................................................................................................................................ 5-19
5.1.4 Load Restraint Tools .............................................................................................................................. 5-20
5.1.5 Packing and Delivery ............................................................................................................................. 5-21
5.1.6 Receiving ............................................................................................................................................... 5-21
5.1.7 Loading and Unloading .......................................................................................................................... 5-21
5.1.8 Shaft Locking ......................................................................................................................................... 5-22
5.2 Tie-down Instructions ..................................................................................................................................... 5-23
5.3 Lifting Instructions .......................................................................................................................................... 5-23
5.4 Storage........................................................................................................................................................... 5-23
5.4.1 Standard Storage Instructions ............................................................................................................... 5-24
5.4.2 Short Term Storage (<12 Months) ......................................................................................................... 5-24
5.4.3 Medium-term Storage (>12 Months) ...................................................................................................... 5-25
5.4.4 Long-term Storage ................................................................................................................................. 5-26
5.4.5 Inspection during Storage ...................................................................................................................... 5-26
6 Installation .......................................................................................................................................................... 6-27
6.1 Installation Safety ........................................................................................................................................... 6-27
6.2 Pump Installation ........................................................................................................................................... 6-27
6.2.1 Foundations ........................................................................................................................................... 6-27
6.2.2 Alignment of Direct Coupled Pumps ...................................................................................................... 6-27
6.2.3 Pipework ................................................................................................................................................ 6-29
6.2.4 Flanges .................................................................................................................................................. 6-30
6.2.5 Intake Conditions ................................................................................................................................... 6-31
7 Operation ............................................................................................................................................................ 7-32
7.1 Operation Safety ............................................................................................................................................ 7-32
7.2 Shaft Seal....................................................................................................................................................... 7-33
7.3 Priming ........................................................................................................................................................... 7-33
7.4 Normal Startup ............................................................................................................................................... 7-33
7.5 Abnormal Startup ........................................................................................................................................... 7-34
7.5.1 Blocked Intake Pipe ............................................................................................................................... 7-34
7.5.2 Air Entering Gland .................................................................................................................................. 7-34
7.6 Operating Faults ............................................................................................................................................ 7-34
7.6.1 Overloading ............................................................................................................................................ 7-34
7.6.2 Low Pit Level .......................................................................................................................................... 7-34
7.6.3 Blocked Intake Pipe ............................................................................................................................... 7-35
7.6.4 Blocked Impeller .................................................................................................................................... 7-35
7.6.5 Blocked Discharge Pipe ......................................................................................................................... 7-35
7.7 Pump Shutdown ............................................................................................................................................. 7-35

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Bare Shaft Pump
7.8 Bearing and Impeller Tip Speeds .................................................................................................................. 7-35
8 Maintenance ....................................................................................................................................................... 8-36
8.1 Maintenance Safety ....................................................................................................................................... 8-36
8.2 Running Maintenance .................................................................................................................................... 8-36
8.2.1 Gland Adjustment .................................................................................................................................. 8-36
8.2.2 Repacking Gland ................................................................................................................................... 8-37
8.2.3 Gland Packing Adjustment..................................................................................................................... 8-38
8.2.4 Tightening Nuts and Bolts ...................................................................................................................... 8-38
8.2.5 Labyrinth Grease Purging ...................................................................................................................... 8-38
8.3 Overhaul Maintenance ................................................................................................................................... 8-39
8.3.1 Pump Disassembly ................................................................................................................................ 8-39
8.4 Disassembly Procedure ................................................................................................................................. 8-40
8.4.1 Removal of the Volute............................................................................................................................ 8-42
8.4.2 Removal of Impeller ............................................................................................................................... 8-46
8.4.3 Removal of the Bearing Assembly ......................................................................................................... 8-48
8.4.4 Adaptor Plate and Back Liner Removal ................................................................................................. 8-52
8.4.5 Disassembly of Bearing Assembly ........................................................................................................ 8-54
8.5 Inspection after disassembly.......................................................................................................................... 8-67
8.6 Replacement of Wearing Parts ...................................................................................................................... 8-68
8.6.1 Reassembling the Pump after Overhaul ................................................................................................ 8-68
8.7 Assembly Procedure ...................................................................................................................................... 8-69
8.7.1 Bearing Barrel Assembly ....................................................................................................................... 8-69
8.7.2 Assembly of the Adaptor Plate............................................................................................................... 8-80
8.7.3 Fitting the Bearing Assembly into the Pedestal ..................................................................................... 8-84
8.7.4 Fitting the Impeller ................................................................................................................................. 8-89
8.7.5 Assembling the Volute ........................................................................................................................... 8-91
8.7.6 Setting the Impeller to Front Door Gap .................................................................................................. 8-95
8.7.7 Fitting Gland Packing ............................................................................................................................. 8-98
8.7.8 Finalising Assembly ............................................................................................................................. 8-100
8.8 Assembly of BSP to the Engine ................................................................................................................... 8-102
8.9 Routine General Maintenance ..................................................................................................................... 8-108
9 Commissioning ................................................................................................................................................ 9-109
9.1 Commissioning Safety ................................................................................................................................. 9-109
9.2 Commissioning Steps .................................................................................................................................. 9-110
9.2.1 Impeller Adjustment ............................................................................................................................. 9-110
9.2.2 Pipework .............................................................................................................................................. 9-110
9.2.3 Fasteners ............................................................................................................................................. 9-110
9.2.4 The following are the commissioning steps normally done with clean water: ....................................... 9-110
9.2.5 Monitor Performance ........................................................................................................................... 9-111
9.2.6 Turn the Pump OFF ............................................................................................................................. 9-111
9.2.7 Avoidance of Impeller Loosening – Runback and Reverse Rotation .................................................. 9-111
9.3 Motor Rotation Check (Bump) ..................................................................................................................... 9-114

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Bare Shaft Pump
9.4 Gland Seal ................................................................................................................................................... 9-114
9.5 Impeller Adjustment ..................................................................................................................................... 9-115
9.6 Tightening Nuts and Bolts ............................................................................................................................ 9-116
9.7 Labyrinth Grease Purging ............................................................................................................................ 9-116
9.8 Bearing Assembly Lubrication ..................................................................................................................... 9-116
10 Lubrication ..................................................................................................................................................... 10-117
10.1 Lubrication Safety ...................................................................................................................................... 10-117
10.2 Recommended Intervals for Labyrinth Grease Purging ............................................................................ 10-117
11 Decommissioning and Disposal .................................................................................................................. 11-118
11.1 Decommissioning Safety ........................................................................................................................... 11-118
11.2 Decommissioning ....................................................................................................................................... 11-119
11.3 Disposal ..................................................................................................................................................... 11-120
12 Troubleshooting ............................................................................................................................................ 12-121
12.1 Gland Packing Problems ........................................................................................................................... 12-121
13 Special Tools ................................................................................................................................................. 13-122
13.1 C-Spanner .................................................................................................................................................. 13-122
13.2 Shaft Locking Clamp .................................................................................................................................. 13-122
13.3 Shaft Lifting Nut ......................................................................................................................................... 13-123
14 Appendices .................................................................................................................................................... 14-124
14.1 Fault Finding Chart .................................................................................................................................... 14-124

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Bare Shaft Pump
List of Figures
Figure 3-1: Key dimensions and centre of gravity ................................................................................................... 3-15
Figure 3-2: Pump identification markings ................................................................................................................. 3-16
Figure 3-3: Pump discharge positions ...................................................................................................................... 3-16
Figure 5-1: Load Restraint .......................................................................................................................................... 5-19
Figure 5-2: Over-centre load chain binder ................................................................................................................ 5-20
Figure 5-3: Shaft locking clamp ................................................................................................................................. 5-22
Figure 6-1: Concentric and eccentric reducers ........................................................................................................ 6-29
Figure 6-2: Flange loading .......................................................................................................................................... 6-30
Figure 8-1: Gland packing removal tool .................................................................................................................... 8-36
Figure 8-2: Suction cover plate severe damage from recirculation ....................................................................... 8-67
Figure 9-1: Impeller Tightening ................................................................................................................................ 9-112
Figure 9-2: Impeller Loosening ................................................................................................................................ 9-112
Figure 13-1: C-Spanner ........................................................................................................................................... 13-122
Figure 13-2: Shaft Locking Clamp.......................................................................................................................... 13-122
Figure 13-3: Shaft Lifting Nut ................................................................................................................................. 13-123

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Bare Shaft Pump
List of Tables
Table 1-1: Manual Organisation ................................................................................................................................... 1-2
Table 2-1: Safety Colours .............................................................................................................................................. 2-4
Table 2-2: Safety Symbols ............................................................................................................................................ 2-5
Table 3-1: Bare Shaft Pump Data ............................................................................................................................... 3-14
Table 3-2: Dimensions, Centre of Gravity and Mass Properties of the Bare Shaft Pump .................................... 3-15
Table 3-3: Bearing Assembly Power Ratings ........................................................................................................... 3-17
Table 3-4: Torque Settings for Metric Bolts .............................................................................................................. 3-17
Table 9-1: Bearing Housing Clamp Bolt Torque ..................................................................................................... 9-115
Table 10-1: Grease Quantities for Labyrinth Grease Purging ............................................................................. 10-117
Table 12-1: Packed Gland Troubleshooting .......................................................................................................... 12-121

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Bare Shaft Pump Introduction

1 Introduction
ction
The purpose of this manual is to aid and instruct installers, operators and repairers of the Weir Minerals
heading
Australia pump unit in the recommended safety, installation, operation and maintenance of associated
equipment.
The Weir Minerals Australia pump unit is of robust construction and is designed to be used as a mine
dewatering pump in accordance with the pump performance data contained in this manual. When correctly
installed and appropriate training is undertaken as per the IOM instructions, the pump unit will achieve high
levels of reliability. To meet the consistent high performance that the Pump unit is designed to achieve, it is
important that the instructions contained in the Pump units manuals are understood and carried out by all
users of this product.
Following all recommended instruction is paramount to ensure long life, trouble-free operation and
consistent high performance. All content incorporated in this manual must be strictly followed, read and
understood by all persons responsible for the safety, operation, installation and maintenance of the pump
unit. It is recommended that the full extent of this manual be understood prior to commissioning in order to
understand instructions for the undertaking of periodic maintenance of the pump unit.
Weir Minerals Australia Pumps
 Excellence Through Design
 Excellence Through Engineering
 Excellence Through Performance

1.1 Scope of the Manual

The manual must be used only as a reference in conjunction with Weir Minerals Australia product-specific
training. For further information contact Weir Minerals Australia.

1.2 Intended Audience

This manual is intended for:
 Weir Minerals Australia service personnel.
 The personnel who have a relevant basic level of trade/professional competency.

CAUTION
PERSONNEL INJURY
The pump or pump unit must be installed, operated and maintained only by personnel who
are trained and have sufficient knowledge about the hazards that may occur during
operation.

1.3 Disclaimer
Despite of the care taken to compile all information and illustrations in this document, neither the author nor
the publisher can be held liable for any consequential damages resulting from possible errors in this
publication.

The English language was used to write the original manual. Any versions in other languages are a
translation of the original manual instructions. These translated versions may contain information that differs
from the original due to interpretation of the content and meaning of the original text. In the case of such
discrepancies, the original English language instructions will be considered the sole authentic source for the
purpose of determining the content and meaning of the text.

Weir Minerals Australia reserves the right to make changes to technical and design specifications at any
time without prior notice.

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Bare Shaft Pump Introduction

1.4 Copyright
ction
Weir Minerals Australia Pty. Ltd. 2017.
heading
This document is subject to copyright. Use or copying of this document in whole or part without the written
permission of Weir Minerals Australia constitutes an infringement of copyright.

1.5 Chapters in the Manual

Table 1-1: Manual Organisation

Chapter Description

Contains an introduction to the Weir Minerals Australia bare shaft pump and
Introduction
the scope of the manual.
Lists the safety guidelines that must be adhered to while installing, operating
Safety
and maintaining the pump.

Technical Data Contains the technical aspects of the pump.

Description Describes the working principle and different components of the pump.

Provides information on safety guidelines and procedures to follow while

Transport and Storage delivering the pump to a customer location, bringing the pump to workshop
for maintenance, and storing the pump.

Installation Lists the procedures to install the pump.

Provides information on initial checks and settings to be done, before putting

Commissioning
the pump into operation.
Contains the information on pump pre-start up procedures, pump startup,
Operation problems that may occur during the pump startup, and shut down
procedures.

Maintenance Lists running and overhaul maintenance procedures.

Contains details about the lubrication requirements, specifications,

Lubrication
lubrication checks and service intervals.
Decommissioning and Provides guidelines regarding taking a pump out of service, and disposing or
Disposal selling.
Provides information regarding various problems that may occur during
Troubleshooting
pump operation and respective solutions.

Special Tools Lists special tools that are required for assembly and disassembly.

Contains additional information such as tie-down instructions, lifting

Appendix
instructions, check lists, and graphs.

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Bare Shaft Pump Safety

2 Safety
The instructions within this chapter must be followed and carried out accordingly to ensure a safe and
efficient operation.
The Weir Minerals Australia Pump unit is designed to be used as a mine dewatering pump in accordance
with the pump performance data contained in this manual. It is the user’s responsibility to be aware of and
comply with all federal and state occupational health and safety requirements.
The Weir Minerals Australia Pump unit has been designed to provide a safe working environment for the
operators, maintenance personnel and others. Improper operation, installation, maintenance or repair of this
equipment could results in injury or death.
Good, Robust Health, Safety and Environmental Systems, Process and Practices are undoubtedly an
important aspect of operating safely.
 Do not operate or perform any operation, installation, maintenance or repair on this product, until you
have read and understood the operation, installation and maintenance and repair information
contained in the supplied documentation.
 Personal Protective Equipment (PPE) must be used when installing, operating, servicing, maintaining
and repairing this equipment.
 It is the user’s responsibility to be aware of and comply with all federal and state occupational health
and safety requirements.
 Use trained competent people to assess all site OHSE risks involved with the installation of this
equipment in accordance with the Installation and Operations Manual (IOM) supplied by Weir Minerals
Australia.
 Use the correct, safe and appropriate equipment related to the site conditions.
SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THIS SECTION. FAILURE TO HEED THESE
WARNINGS AND PRECAUTIONS MAY RESULT IN PERSONAL INJURY AND/OR DEATH TO YOURSELF
AND/OR OTHERS ALONG WITH THE RESULTS OF EQUIPMENT AND ENVIRONMENTAL DAMAGES.

Living by our five key safety values and commitment to following safety procedures will enable us all to
make the work place a safer environment.
Our Five Key Safety Values are:
 My colleagues and my own safety are paramount;
 No task is so important or urgent that it cannot be undertaken safely;
 I will not only undertake tasks that I am trained, competent and properly prepared for;
 I will never cut corners, nor take shortcuts at the expense of safety; and
 I will stop the job if I believe it is unsafe to continue.
Any aspect of the installation, which the Customer is unsure of, we advise the customer to discuss
with a Weir Minerals Australia representative.

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Bare Shaft Pump Safety

2.1 Safety Symbols

The safety colours incorporated in this manual are indicated in Table 2-1. These colours serve as a guide to
the associated risk with the given safety symbols.
Table 2-1: Safety Colours

Signal Warning Level Description

Indicates a hazard with high level of risk

DANGER Danger which, if not avoided, could result in
death or catastrophic equipment damage.

Indicates a hazard with a medium level of

risk which, if not avoided, could result in
WARNING Warning
serious or moderate injury, or serious
equipment damage.

Indicates a hazard with a low level of risk

which, if not avoided, could result in
CAUTION Caution
moderate or minor injury, or moderate
equipment damage.

Indicates important information for the

NOTICE Notice user.

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Bare Shaft Pump Safety

The documentation supplied with the Weir Minerals Australia Pump unit utilises the following safety symbols
listed in Table 2-2 to highlight potential harmful situations to personnel, equipment and the environment as
per ISO 9001:2008.
Table 2-2: Safety Symbols

Symbols Definitions Consequences

Imminent risk of fatal Fatal or crippling injuries likely to result from any
or crippling injuries exposure.

Possibility of a
Minor or slight injuries possible
harmful situation

Mandatory Failure to follow may lead to fatality, injuries or

instructions damage to property and environment.

Possible damage to the product, equipment or

Prohibited activities
property.

Warning of electrical Fatal or crippling injuries likely to result from any

shock exposure.

Mandatory Personal
Fatal or crippling injuries likely to result if the
Protective Equipment
correct PPE is not worn.
(PPE)

Explosion warning Possibility of explosion if instructions not followed.

Application hints and

other useful
information

Refer to
User has to refer accompanying manuals or
accompanying
external documents.
documents

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Bare Shaft Pump Safety

2.2 Important Information

DANGER
EXPLOSION
 Weir Minerals would like to bring to your attention the potential hazard caused by the
continued operation of centrifugal pumps when the intake and discharge are blocked.
 Extreme heat is generated leading to vaporization of the entrapped liquid. This can
result in a life threatening explosion if operation is continued.
Contact your local Weir Minerals representative to provide methods to eliminate and/or
minimise the risk of explosion.

DANGER
PUMP BLOCKAGE
 The operation of centrifugal pumps in slurry applications can increase this potential
hazard due to the nature of the material being pumped.
 In slurry applications, there is the possibility of solids blocking the pump intake and/or
discharge and remaining undetected. Blockage of the pump discharge has been
known in some instances to lead to the intake side of the pump also becoming
blocked with solids.
 The continued operation of the pump under these circumstances can be extremely
dangerous.
If the installation is prone to this occurrence, Weir recommends that measures be adopted
to prevent any blockage situations.

DANGER
VAPORISATION
Personnel injury and equipment damage could result from the high temperature and
pressures created if the pumping liquid vaporises.

DANGER
PUMP OPERATING AT ZERO FLOW
Do not operate the pump at low or zero flow conditions, or under any circumstances that
cause the pumping liquid to vaporise.
This must not be done under any circumstances for any significant period of time (more
than 6 minutes) due to the risk of heat/vaporisation of pumped fluid in the casing that may
cause subsequent explosion.

DANGER
PUMP OPERATING AT LOW FLOW (BELOW 25% QBEP)
 This has a number of problems and is not generally recommended:
 If the pump/system is operating at normal flow and then throttled to less than 25%
QBEP, there is a possibility of the particles settling in the inlet and outlet pipes and
plugging the flow that would cause heat/vaporization inside the pump with subsequent
explosion as zero flow.
 Discharge and suction recirculation may cause vibration and cavitation that impacts
bearing and wetted component life in a high energy pump at low flow (below 25%
QBEP).
 The pump energy efficiency is poor at low flow (below 25% QBEP) and higher axial
loading on the impeller may impact bearing and gland or mechanical seal life.
The pump head performance curve may be unstable at low flow (below 25% QBEP)
causing flow surging and hunting of the pump operating point.

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Bare Shaft Pump Safety

DANGER
OVERPRESSURE IN PUMP
 Pumps that are not fitted with an over pressure relief device are at risk of generating
 Excessive pressures and temperatures when run with restricted or no discharge flow,
such as against a closed discharge valve.
 The system design must include suitable pressure relief measures and operation with
restricted discharge flow must be limited such that the static pressure limit of the
pump is not exceeded.
 Running the pump with the discharge valve closed (while necessary at shut down)
produces heat and pressures build up in the pump. The time between closing the
valve and pump shut down must be minimized to reduce the risk of exceeding the
pumps temperature and pressure limits.
Suitable pressure relief must be included in the pipe work.

DANGER
IMPELLER SHATTERING
 Do not apply heat to the impeller boss or nose in an effort to loosen the impeller
thread prior to impeller removal. Do not use heat to expand or cut an impeller from the
shaft.
 Personnel injury and damage to equipment occurs as a result of an explosion or the
impeller shattering.
 A shaft wrench is available to assist impeller removal.
In some cases, an impeller release collar has also been provided to assist impeller
removal.

DANGER
PUMP ISOLATION
 Never carry out maintenance work when the unit is connected to power. The pump
must be fully isolated before any maintenance work, inspection or troubleshooting
involving work on sections which are potentially pressurised (casing, gland, connected
pipework)or involving work on the mechanical drive system (shaft, bearing assembly,
coupling).
 Battery and Starter Motor must be isolated, tagged out and tested for dead.
Ensure that the intake and discharge openings are totally isolated from all potentially
pressurised connections and that they are, and can only be exposed to atmospheric
pressure.

DANGER
THERMAL SHOCK
Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal
shock may cause damage to the internal components and rupture the pump casing.

DANGER
LIFTING DEVICE SAFETY
 Use lifting devices to lift heavy or awkward components.
 The lifting devices must be in good condition, certified and tagged.
 The lifting devices must be of adequate capacity and must be used whenever they
are required.
Personnel must never work under suspended loads.

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Bare Shaft Pump Safety

DANGER
LIFTING POINT SAFETY
 Refer to Multiflo® lifting instructions at all times.
Tapped holes (for eye-bolts) and lugs (for shackles) on Multiflo® parts are for lifting
individual parts only. Some heavy parts of the pump have threaded holes for lifting. During
assembly, eye bolts are screwed into holes to engage the crane. After assembly, the eye
bolts must be removed and the holes filled with RTV silicon to protect the thread of the
holes for further use.

DANGER
FAILURE DUE TO CASTING REPAIRS
Castings made from A series Weir Minerals materials, for example, A05, A61, etc. are
brittle and have low thermal shock resistance. Attempts to repair or rebuild by welding
causes catastrophic failure. Repairs of such castings using these methods must not be
attempted.

DANGER
IMPELLER INSPECTION
 Impellers must be routinely inspected for fatigue. Failure to inspect routinely may
result in catastrophic pump failure.
 For impellers with low wear applications, other non-visual methods of inspection are
required.
Contact your local Weir Minerals representative for more information.

DANGER
TOXIC VAPOURS FROM GLAND
Vapours can leak past gland guards. Appropriate risk assessment must be made
regarding the nature of the product in the pump and necessary safety precautions put in
place to protect from exposure to product vapours.

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Bare Shaft Pump Safety

2.3 General Guidelines

Multiflo® dewatering pumps are designed, developed and manufactured with state of the art technologies in
modern facilities. The unit is produced with great care and commitment to continuous quality control, utilising
sophisticated quality techniques, and safety requirements.
Weir Minerals Australia is committed to continuous quality improvements and being at service for any further
information about the product in its installation and operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate familiarisation with the product and its permitted use. Operating
the product in compliance with these instructions is important to help ensure reliability in service and avoid
risks. The instructions may not take into account the local regulations; ensure such regulations are observed
by all, including those installing the product. Always coordinate repair activity with operations personnel, and
follow all plant safety requirements, applicable safety and health laws/regulations.
For the safety of operating personnel, please note that the information supplied in this manual only applies
to the fitting of genuine Multiflo® parts and Multiflo® recommended bearings to Multiflo® pumps.
Weir Minerals Australia manufactures products to exacting International Quality Management system
Standards as certified and audited by external quality assurance organisations. Genuine parts and
accessories have been designed, tested and incorporated into the products to help ensure their continued
product quality and performance in use. As Weir Minerals Australia cannot test parts and accessories
sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect
the performance and safety features of the products. The failure to properly select, install or use authorised
parts and accessories is considered misuse. Damage or failure caused by misuse is not covered by our
warranty. In addition, and modification of Weir Minerals Australia products or removal of original
components may impair the safety of these products in their use.

CAUTION
Information in these User Instructions is believed to be reliable. In spite of all the efforts to
provide sound and all necessary information, the content of this manual may appear
insufficient and is not guaranteed as to its completeness or accuracy.

CAUTION
This pump must not be operated beyond the allowable limits of pressure, temperature and
speed specified for the application. These limits are dependent on the pump type,
configuration and materials used. If there is any doubt as to the suitability of the product for
the application intended, contact Weir Minerals Australia for advice, quoting the serial
number.

NOTICE
These Instructions must always be kept close to the product’s operating location or directly
with the product. These Instructions should be read prior to installing, operating, using and
maintaining the equipment in any region worldwide. The equipment must not be put into
service until all the conditions relating to safety noted in the instructions have been met.

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Bare Shaft Pump Safety

2.4 Operating Conditions

The standard ambient operation temperatures recommended are 0°C to +40 °C. If the operating range is
outside this contact your local Weir Minerals representative for more information.

NOTICE
OPERATING RANGES FOR MATERIALS
Contact your local Weir Minerals representative for specific information on the operating
temperature ranges of bare shaft pump materials.
CAUTION
FAILURE DUE TO OPERATING CONDITIONS
If the pump is operated outside the recommended temperature range it may cause
mechanical failure leading to safety issues.

2.5 Personnel Qualification and Training

NOTICE
Personnel Qualification and Training
All personnel involved in the operation, installation, inspection, and maintenance of the
Bare shaft pump must be qualified to carry out the work involved. If the personnel in
question do not already possess the necessary knowledge and skill, appropriate training
and instruction must be provided. If required, the operator may commission the
manufacturer/supplier to provide applicable training. Always coordinate repair activity with
operations and health and safety personnel, and follow all plant safety requirements and
applicable safety and health laws and regulations.
2.6 Handling Components
CAUTION
Worn pump components can have sharp or jagged edges. Caution must be taken in
handling worn parts to prevent damage to slings or personal injury. To lift heavy pieces
above 25 kg (55 lb) use a crane appropriate for the mass and in accordance with current
local regulations. Tapped holes (for eyebolts) and cast-on lugs (for shackles) on
MULTIFLO® parts are for lifting INDIVIDUAL PARTS ONLY. Lifting devices of adequate
capacity must be used whenever they are required. Safe workshop practices must be
applied during all assembly and maintenance work. Personnel must never work under
suspended loads.
2.7 Efficient Use and Intended Use
The Multiflo® pump is designed to be used only as a mine dewatering equipment in accordance with the
pump performance data contained in this manual.
The pump’s application is to move liquids (non-corrosive and non-explosive). The specific gravity of the
liquid should be less than or equal to 1.05. The maximum liquid temperature is 70 oC (150 F). The
operational pH range for the pump is 5 – 9. For further information on the operational range of the pump
model, please contact your nearest Weir Minerals Australia representative for more information.
It is the user’s responsibility to ensure that pump as a whole or any of its components are not used for any
other purpose other than the intended usage mentioned in this manual. The procedures followed must be in
line with the technical data and instructions provided in this manual. The pump should not be used in an
environment with an explosive atmosphere (ATEX).
It is forbidden to physically modify any components of the pump or the pump as a whole. Weir Minerals
Australia does not take responsibility if the pump was used after such modifications. If the conditions of
service on the purchase order are going to be changed (for example liquid pumped, temperature or duty), it
is requested that the user seek the manufacturer’s written agreement before startup.

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Bare Shaft Pump Safety

2.8 Unintended Use

The pump is not designed to pump flammable and/or explosive substances. Therefore it is not permitted to
have working fluids that are outside the allowable types stated by the manufacturer. The pump must also not
work in an environment in which there is a danger of fire and/or explosion. The pump should not be used in
an environment with an explosive atmosphere (ATEX).
The pump must only be used for applications that are listed in the intended use section of this manual. It is
not permitted to use the pump for any applications and/or field of activity other than that for which the pump
was originally specified and installed without written permission from Weir Minerals Australia. Weir Minerals
Australia Installation, operation and maintenance (IOM) manual must be studied carefully and followed. Note
that the information contained in this manual applies only to the fitting of genuine parts and recommended
bearings.

CAUTION
Weir Minerals Australia is not responsible for incorrect application of the pump. If the pump
is used outside of this operating range, premature failure could occur. Pumping of corrosive
or abrasive mediums without appropriate countermeasures will lead to premature failure. If
the pumps have not been designed to meet a duty outside of the customer specification,
the customer will be liable for any damages due to misuse of the pump.

2.9 General Safety

Legal requirements and local regulations may differ substantially with regard to particular safety
requirements and may be regularly modified by relevant authorities without notice. As a consequence,
applicable laws and regulations must be consulted to ensure compliance. The following cannot be
guaranteed for its completeness or continuing accuracy.
These instructions are intended to facilitate familiarisation with the product and its permitted use. Operating
the product in compliance with these instructions is important to help ensure reliability in service and avoid
risks. The instructions may not take into account local regulations. It is the responsibility of the purchaser of
the product to ensure such regulations are observed by all, including those installing the product. Always
coordinate repair activities with operations personnel and follow all plant safety requirements, applicable
workplace health and safety laws and regulations.
These instructions must be read prior to installing, operating, using and maintaining the equipment in any
region, worldwide. The equipment must not be put into service, until as a minimum, all the conditions
relating to workplace health and safety in the instructions, are met. Information in these user instructions is
believed to be reliable. In spite of all the efforts to provide correct and necessary information, the content of
this manual may appear insufficient and is not guaranteed as to its completeness or accuracy.

2.10 Qualified Workers

All personnel involved in the operation, installation, inspection, and maintenance of the pump must be
qualified to carry out the work involved. If the personnel in question do not already possess the necessary
knowledge and skill, appropriate training and instruction must be provided. If required, the operator may
engage the manufacturer/supplier to provide applicable training. Always coordinate repair activities with
operations and workplace health and safety personnel, and follow all plant safety requirements and
applicable workplace health and safety laws and regulations.

2.11 Safe Working on Pumps

The Weir Minerals Australia is a piece of rotating equipment which contains pressure under service
conditions. All standard safety precautions for such equipment must be followed before and during
installation, operation, and maintenance. Drain the pump and isolate pipework before dismantling the pump.
The appropriate workplace health and safety precautions must be taken where the pumped liquids are
hazardous.

WARNING
ROTATING PARTS
Personnel injury or illness may result from contact with rotating parts, seal leakage or
spray from the rotating shaft.
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Bare Shaft Pump Safety

Mixing of new and worn pump components may increase the incidence of premature pump wear and
leakage. All metal mating faces must be cleaned of dirt, rust, paint and other adhering substances prior to
pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to
catastrophic failure of parts.
Avoid contamination:
 Leakage in excess of the specified packing lubrication requirements from pump shaft seals and/or
leakage from worn pump components or seals, causes water and/or soil contamination.
 Liquid waste disposal from servicing of pumps or stagnant water from pumps stored for long periods,
causes water and/or soil contamination.
2.12 Markings and Approvals
It is a legal requirement that machinery and equipment put into service within certain regions of the world
must conform to the applicable marking directives and standards such as CE marking directives covering
machinery and, where applicable, low-voltage equipment, EMC, PED, and ATEX.
Where applicable, the directives and any additional approvals cover important workplace health and safety
aspects relating to machinery and equipment and the satisfactory provision of technical documents and
workplace health and safety instructions.
Where applicable, this document incorporates information relevant to these directives and approvals. To
confirm the applying approvals, and if the product is CE marked, check the serial number plate markings
and the certification.

2.13 Safety Equipment

Do not operate the pump without properly installed seal, v-belt and coupling guards in place. If guards are
removed during maintenance or gland adjustment, they must be replaced prior to operating the pump.
During gland seal adjustment the fixed guard needs to be removed while the pump is operational. When the
guard is removed, the rotating shaft is exposed. Additional safety management measures must be
implemented to manage this specific hazard, and only suitable trained and qualified personnel must work on
gland adjustment. The guard must be replaced when adjustment is complete.

WARNING
GLAND ADJUSTMENT
During gland seal adjustment the fixed guard needs to be removed while the pump is
operational. When the guard is removed, the rotating shaft is exposed. Additional safety
management measures must be implemented to manage this specific hazard and only
suitable trained and qualified personnel must work on gland adjustment. The guard must
be replaced when adjustment is complete.
For auxiliary equipment (motors, belt drives, couplings, gear reducers, variable speed drives, mechanical
seals, etc.), standard workplace health and safety precautions must be followed and appropriate instruction
manuals consulted before and during installation, operation, adjustment, and maintenance.
2.14 Fire Fighting
A number of possible emissions or leakage of hazardous substances may be possible depending of the
product being pumped. Ensure you are familiar with site and local procedures and requirements.
2.15 Emergency Procedures
Ensure you are familiar with site and local procedures and requirements. If there is an emergency, follow
site and local procedures.
Emergency shutdown is usually forced by a complete power failure. Another emergency, which is less likely,
is a major bursting of the pipeline and a loss of head resulting in increased flow from the pumps. Typically,
this causes the power drawn to increase rapidly and the electrical controllers would cause all or most pumps
to trip the safety switches.
There is little that can be done in either of the above cases for a simple or controlled system. If all power
fails, the gland water pumps will also stop. Before pumps are restarted, it is recommended that the gland
packing be inspected and possibly replaced as slurry will enter the glands with no GSW. If the pumps stop
but the GSW pumps continue to operate, then there will be minimum effects on the glands, probably.
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Bare Shaft Pump Safety

For systems fitted with an automatically opening dump valve, this is activated and some of the pipeline
contents are dumped. Runback and major flooding of the pump and the sump is thereby minimised. The
effects of runback are also minimised, if slow acting non-return valves are fitted.
Intake sumps can be sized with reserve capacity to take the runback in emergencies.
Where possible:
 Clear blockages
 Barricade the pump, where head is present to minimize slurry spillage.
 Do not cool the pump with water.
After an emergency, stop and check for blockages and then follow the commissioning procedure.

CAUTION
BLOCKED IMPELLER
Do not operate the pump if solids have settled and the rotating element cannot be turned
by hand.

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Bare Shaft Pump Technical Data

3 Technical Data
This section describes the:
 Pump identification, nameplate, size, frame and bearing sizes, type, and part identification.
 Power requirements for bearings
 Torque settings for bolts
 Materials used for construction of slurry pumps.
3.1 Bare Shaft Pump Data
Table 3-1: Bare Shaft Pump Data

Pump Designation : Multiflo® 10/6 FFY MF-420EXHVCC Bare Shaft Pump

Bare Shaft Pump Material : H7A SS

Impeller Material : H7A SS

Suction (mm) : 250 mm (10”)

Discharge (mm) : 150 mm (6”)

Impeller Type : Closed

Impeller Diameter (mm) : 660 mm

Number of Impeller Vanes : 4

Min. Passage Size (mm) : 50 mm

Max RPM : 1700 RPM

Best Efficiency (%) : 70%

Total Dynamic Head @ BEP (m) : 189 m

Flow Rate @ BEP (l/s) : 305 l/s

Pump Power Required @ BEP (kW) : 807

Shaft Sleeve Material : Refer IOMM parts list

Shaft : SS1045

Suction Flange : 250 NB 8 Holes ∅19 on 324 P.C.D.

Discharge Flange : 150 NB

Weight : 2,114.6 kg

NOTE: For specific information on the pump units performance characteristic at the required duty point, refer
to the following pump curve.

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Bare Shaft Pump Technical Data

3.2 Dimensions, Centre of Gravity and Mass Properties of the Bare Shaft Pump
Table 3-2: Dimensions, Centre of Gravity and Mass Properties of the Bare Shaft Pump

Model 10/6 FFY 200HVCC Bare Shaft Pump

Measurement Units
1501 mm
200HVCC
59.1 inch
2114.6 kg
Mass
4662 lbs

Figure 3-1: Key dimensions and centre of gravity

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 Bare Shaft Pump Technical Data

3.3 Pump Identification

To identify a full part number and description, refer to the appropriate spare parts lists that are used in the
appendices at the end of the Unit IOMM. In all correspondence with Weir Minerals Australia or their
representatives, it is advisable to use correct part names as well as full part numbers to prevent
misunderstandings or inaccurate deliveries. This is especially true when ordering spare parts. To eliminate
uncertainty, the pump serial number should be quoted along with the correct part names and full part
numbers. The physical pump markings and identification information is shown as per the figure below.

Bearing
assembly
identification Information labels
and serial
number

Pump
identification and
serial number

Figure 3-2: Pump identification markings

3.3.1 Discharge Positions
Based on the position of the discharge pipework, the frame plate and cover plate can be fitted to the frame
in any of the eight possible positions, as per the figure below.

Figure 3-3: Pump discharge positions

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Bare Shaft Pump Technical Data

3.4 Bearing Power Capacity

The values provided in the following tables are for reference only. Sometimes, power exceeds the limit.
Consult your Weir Minerals Australia representative, when the power exceeds the limit.
Table 3-3: Bearing Assembly Power Ratings

Bearing Assembly Power Rating (kW)

FF ±425 (Belt Driven)

NOTE: Bearings are rated higher for direct drive applications – please consult Multiflo® engineering
for further information.

3.5 Bolt Torques

Table 3-4: Torque Settings for Metric Bolts

Recommended Torque
Metric Bolt Size
(±10%) (Nm)
M12 25
M16 50
M20 90
M24 150
M27 220
M30 300
M33 400
M36 520
M42 850
M48 1200
M64 1500

3.6 Materials
A major advantage of the Weir Minerals Australia slurry pump is the number of optional materials available.
This enables the construction of a pump with the most appropriate materials, specifically to meet the duty
requirements. It also allows adapting the existing pumps in service to meet changed duty conditions by
changing individual parts. For any assistance with the selection of specific material, consult your nearest
Weir Minerals Australia representative.

NOTICE
PUMP WEAR IS AFFECTED BY SLURRY PROPERTIES
Large variations in slurry properties, increases the rate of wear and corrosion of pump
components.
 Wear increases exponentially with velocity and slurry particle size.
 Corrosion rate doubles for every 10 °C increase in slurry temperature.
Corrosion rate increases exponentially as slurry pH decreases.

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Bare Shaft Pump Description

4 Description
4.1 Introduction to the 420EXHVCC Bare Shaft Pump
The Multiflo® MF-420EXHVCC pump is a centrifugal pump. The pump discharge can be orientated in almost
any position through 360° depending on mounting as shown previously. The main features of the Multiflo®
MF-420EXHVCC pumps are as follows:
 All Multiflo® standard seal options are available.
 Designed for a wide range of erosive and/or corrosive applications.
 The centrifugal pump operates by increasing pressure from the inlet (lower pressure) to the outlet
(higher pressure).

4.2 Pump Component Description

4.2.1 Bearing Assemblies and Frames
Bearing assemblies are oil lubricated, and are selected according to the duty of the pump. Frames are
cradles sized to suit the different types and arrangements of bearing assemblies. The Multiflo® MF-
420EXCC pump is a modified basic FF bearing/frame size.

4.2.2 Shaft Seals

The Multiflo® MF-420EXHVCC pump uses a gland packing arrangement.

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Bare Shaft Pump Transport and Storage

5 Transport and Storage

This section provides the instructions to follow during:
 Transportation of the pump
 Tie-down
 Lifting
 Storage of the pump

5.1 Transportation
5.1.1 Transport Safety
The transport vendor must pack the freight such that it:
 Ensures any instructions required to lift or re-tether the load are fully visible.
 Does not cause any hazard to the supply staff, transport personnel, and the general public.
 Complies with all legal requirements including mass, dimension, and load restraint requirements.
 Can withstand high-speed road transport over rough terrain.
 Can be safely loaded/unloaded from the transport vehicles.
 Minimises the risk of injury to all personnel involved in the freight transportation.
 Minimises the risk of damage to the freight.
 Minimises the risk of damage to other freight and the general public.
 Has packing labels that specify the weight of the items and details of the recipient.
 Have appropriate protection for tie-downs over painted areas to minimise paint damage.
 Secures the loose items.
5.1.2 Chain of Responsibility
Under COR regulations, all parties with some control in the supply chain have legal responsibilities to ensure
compliance with relevant heavy vehicle road laws, including mass, dimension and load restraint laws. This
includes people involved in consigning, loading, packing and receiving freight as well as drivers of those
vehicles (for example, in relation to speeding and fatigue management).
5.1.3 Load Restraint
The securement systems must withstand the forces associated with the following four deceleration/
accelerations, applied separately.

Figure 5-1: Load Restraint

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Bare Shaft Pump Transport and Storage

Key requirements for load security are:

1. Ensure that the load platform, bodywork, and any load securing equipment are in a serviceable
condition before loading the vehicle.
2. Secure the cargo such that it cannot shove away, roll-over, wander because of vibrations, fall off the
vehicle, or make the vehicle tip over.
3. Determine the securing method(s) best adapted to the characteristics of the cargo (locking, blocking,
direct lashing, top-over lashing, or a combination of these).
4. Ensure that the vehicle and blocking equipment manufacturers’ recommendations are adhered to.
5. Ensure that the cargo securing equipment is commensurate with the constraints it encounters during
the journey. Ensure that the securing equipment can withstand the following conditions, which are
considered as normal circumstances that may occur during journey:
 Emergency braking
 Strong cornering to avoid an obstacle
 Bad road or weather conditions
6. Inspect the cargo and check for overload and/or poorly balanced weight distribution before starting
when cargo is loaded, unloaded, or redistributed each time. Ensure that the cargo is distributed in such
a way that the centre of gravity of the total cargo lies as close as possible to the longitudinal axis and
is kept as low as possible (heavier goods below, lighter goods above).
7. Use equipment which supports the cargo securing such as friction mats, walking boards, straps, edge
beams, etc. wherever possible.
8. Ensure that the securing arrangements do not damage the goods transported.
5.1.4 Load Restraint Tools
The basic safety principles related to the load restraint tools are:
 A qualified and experienced person who is familiar with applicable safety and transportation legislation,
site requirements, and best practices must undertake the securing of any pump. This person must be
able to assess the load, create a plan, and then apply it safely.
 Inspect tensioners, chains, straps, and other restraint mechanisms regularly, to make sure that they
are suitable to secure the proposed load.
 Do not use ropes or over-centre load chain binders (dogs) (refer to Figure 5-2), when you secure loads
for collection or delivery from Weir Minerals Division.

Figure 5-2: Over-centre load chain binder

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Bare Shaft Pump Transport and Storage

5.1.5 Packing and Delivery

Each order or shipment is double checked before leaving the factory. All parts, pieces and components are
listed item by item on our packing list, which accompanies each order. The number and description of each
item, package, container, etc., is listed on the bill of lading.
IN SIGNING THE BILL OF LADING, THE CARRIER ASSUMES FULL RESPONSIBILITY FOR SAFE
DELIVERY OF ALL GOODS TO DESTINATION IN THE SAME ORDER AS TENDERED BY THE
SHIPPER.
In the event of damage or shortage, have the transportation company note the same on the freight bill.
A packing list is attached to all the shipment for the items contained. Check each item against the list. Check
by description, item/tag no., document reference, quantity, etc. Should there be any discrepancies, notify
Weir Minerals Australia immediately. Small parts and items such as bolts, washers, bushings and keys are
just as important to an installation as the larger parts. Make sure these are located and checked before
disposing of any containers or packing equipment. Weir Minerals Australia is not responsible for the loss of
items that are listed and included on our packing list.

NOTICE
Illustrations used are only suggestive. Not Actual.

NOTICE
Refer to the detailed packing list attached with the pump unit for more details.

Each shipment is sent through approved transport companies. Containers are used for overseas transport
while trucks can be used for local transport. Depending on the size and number of components present, the
unit can be disassembled if required and packed in suitable containers. The components are packed in such
a way so that the integrity of the components is not damaged during shipment.
Heavier components are left free standing in the truck/container. However timber or any suitable equipment
may be used to prop them. These structures will sometimes be steel strapped to the base of the vehicle if
required. Smaller items are bundled with nylon ropes or similar binding material or packed with appropriate
packing material such as dunnage or timber in wooden crates. The wooden crates are sealed using duct
tape or nylon tape. The wood packing material used on pump is heat treated.

5.1.6 Receiving
Upon arrival, carefully check the pump for any signs of defects or damage that may have occurred during
transport. Check the bill of lading and certify to match with the shipment.
If any damage is observed or incomplete shipment, report to the transporter straight away. The transporter
must immediately note this on the shipping documentation.

5.1.7 Loading and Unloading

The pump unit is loaded onto the truck/container using appropriate lifting equipment. Consideration is given
to the mass, dimensions of the unit while selecting the lifting equipment. Use designated lifting points while
lifting the components.
The wooden crates and smaller components are loaded using a fork lift. Dimensions and mass are taken
into consideration while selecting a suitable fork lift.
The user must unload the components using appropriate lifting & unloading procedures and equipment. The
pump dimensions and mass are shown in the technical data. After unloading, strapping tape on the crates
can be removed using appropriate cutting equipment.

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Bare Shaft Pump Transport and Storage

5.1.8 Shaft Locking

To transport the Multiflo® pumps, lock the bearings using the shaft clamp to prevent vibration and
consequent damage.

CAUTION
To eliminate the possibility of brinelling of the pump and bearings, shaft locking devices
may be employed. These should be removed and the free rotation at the pump should be
checked before use.
Before Transportation:
1. Attach the shaft clamp to the shaft.
2. Adjust the set screw nuts on the clamp, so the bolt head is secured hard against the pump pedestal
base.
3. Once the bolt head is secured against the pedestal, tighten the clamp adjusting bolts until the drive
shaft is secure.
Before commissioning the pump:
1. Loosen the clamp adjusting bolts to free the shaft clamp from the drive shaft.
2. Rotate the shaft manually in clockwise direction using the shaft clamp. This makes sure that the
impeller turns without any restriction within the pump.
3. Refer to the information on the assembly procedure in this manual for adjustment of the impeller and
front door clearance gap.
4. Remove the shaft clamp.

Figure 5-3: Shaft locking clamp

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Bare Shaft Pump Transport and Storage

5.2 Tie-down Instructions

The tie-down instructions indicate the points on the bare shaft pump that are safe to use as tie-down points
for the bare shaft pump.

DANGER
TIE DOWN POINT FAILURE
No other points on the pump or pump baseplate must be used other than those indicated in
the tie-down instructions. If other lifting points are used they may be damaged which can
lead to a dropped load.
The Multiflo® bare shaft pump should only be secured using the designated pedestal securing footings. This
is appropriate during transportation or fitting the bare shaft pump to the pump unit frame.

5.3 Lifting Instructions

DANGER
TIE DOWN POINT FAILURE
No other points on the pump or pump baseplate must be used other than those indicated in
the tie-down instructions. If other lifting points are used they may be damaged which can
lead to a dropped load.

CAUTION
 Qualified and experienced personnel to lift the pump unit.
 Refer to site procedures for lifting, personnel and equipment requirements.
 Only uses certified lifting equipment with an adequate lifting capacity and always lift
directly above. Lifting from an angle can lead to dangerous situations. Authorized
personnel to lift the pump unit.
 Neither the lifting eye on the engine nor the lifting eye of the pump may be used for
transport of the pump unit.
 Always disconnect all connections before moving the pump unit.
 Never walk under a raised load. This can result in a life-threatening situation.

5.4 Storage
Keep the pumps clean. Pumps taken out of service should be flushed with water and dried before storage.
Indoor storage is recommended or in a manner where the bare shaft pump is not exposed to the
environment. Too much heat can artificially age certain materials and renders it unserviceable. For pumps
stored outside, it is recommended to cover the unit(s) with a tarpaulin rather than plastic so that air can
circulate.
It is best to cover flanges. Remove transport clamps and loosen gland to release pressure on the packing.
Turn the shaft of the pump 10 turns by hand once per week. In this way all the bearing rollers in turn are
made to carry static loads and external vibrations. Ensure that the rust preventing coat of the shaft drive end
is maintained.
To store the pumps for prolonged periods:
 Weir Minerals recommends to drain the oil filled assemblies leaving some oil in to cover the lowest
bearing rollers. This procedure helps to prevent the following two risks:
 Environmental damage from leaking oil
 Corrosion
 Plug the ports. If the assembly is stored in an open area with major temperature fluctuations, it is
preferable to install a desiccant breather instead of one plug.
 If the stand-by assemblies/pumps are idle for long periods, it is advisable to turn their shafts a quarter
turn by hand, once in a week. In this way, all the bearing rollers are made to carry static loads and
external vibration.
 Do not store spare bearing assemblies near vibration or in a damp area.

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Bare Shaft Pump Transport and Storage

NOTICE
PUMP STORAGE
It is possible for operational and storage problems to arise due to environmental conditions
the pump is subjected to. These problems must be corrected at the owner’s expense prior
to operation. Weir Minerals will accept no responsibility for these problems. These
provisions are applicable to Weir Minerals proprietary items only. For the appropriate
storage procedures for non-Weir Minerals items refer to specific requirements from the
manufacturer.

5.4.1 Standard Storage Instructions

To store the pump:
 Weir Minerals Australia recommends indoor storage when the bare shaft pump is not in operation.
 If stored outside, protect the equipment from extreme temperature, humidity, exposure to excessive
dust, moisture, and vibration. For outdoor or excessively unfavourable environment including dust and
rain, cover the equipment with some type of protective sheeting that allows air circulation.
 Remove the transport clamps from pumps and fit shaft wrench to turn the pumps by hand. Turn each
pump shaft at least 10 revolutions once a week.
 To prevent hardening of packing, loosen all glands to release pressure on the gland packing’s.
 Once in every six months, purge the labyrinth with grease to prevent dirt and/or moisture
contamination of the bearings. In a dusty environment, the labyrinth must be purged once a month.
 Cover the suction and discharge flange openings unless the pump is installed and connected to the
pipework. Avoid removal of intake and discharge protection covers, while in storage.
 Removal of intake and discharge protection covers may allow ingress or tramp material, water or
harmful substances to the pump head which may damage components when commissioning.
 All external machined surfaces are factory coated with a rust preventative prior to dispatch. Maintain
the protective coating on machined surfaces.
 Maintain written records of labyrinth purging and shaft rotation intervals, when the storage period
exceeds six months from the time of dispatch. The records must be available for Weir Minerals
Australia inspection upon request.
 Maintain the oil level at maximum level for oil lubricated bearings. Turn the shaft 10 times once in a
week. Completely drain and refill the bearing assembly every six months with new recommended oil
lubricant.
 If the pumps are stored for more than 18 months since the time of dispatch, additional provisions are
required. In such cases, to prevent void of all warranty provisions, obtain prior agreement from Weir
Minerals.
 These provisions are applicable to Weir Minerals Australia proprietary items only. For the appropriate
storage procedure of non- Weir Minerals Australia items, refer to the specific requirements of the
manufacturer.

5.4.2 Short Term Storage (<12 Months)

 As much as possible, store the bare shaft pump in a location that minimizes exposure to the elements.
 Drain and refill the bearing assembly with recommended oil and re-purge the labyrinths prior to
returning unit to regular service.

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Bare Shaft Pump Transport and Storage

5.4.3 Medium-term Storage (>12 Months)

If you do not plan to operate the used pump for more than two months, do the following within a day of shut
down:
1. Flush the pump with process water for one hour to flush out the pumps, pipes, and associated
equipment.
2. Drain the pump. Leave all drain valves open.
3. Remove suction pipe and cover plate.
4. Hose inside of the pump using clean water to remove all traces of solids which may form hard deposits
and process water which may contain high levels of dissolved salts or corrosive fluids.
5. Ensure that the suction pipes are clean.
6. Dismantle the pump head to allow complete cleaning and drainage if water or residual solids are
corrosive, or likely to deposit.
7. Check operation of all valves, remove solids built-up and lubricate according to the valve
manufacturer’s instructions. Put emphasis on suction valve operation.
8. Ensure that the pump shaft rotates freely and readjust the impeller if required. For more information on
Impeller adjustment, refer to impeller adjustment section of this manual.
9. While rotating the pump by hand, grease labyrinths through the end cover nipples at both ends of the
bearing assembly, until grease is expelled beyond the labyrinths.
10. Cover exposed ends to keep the ends clean and moisture free.
11. Protect the bare shaft pump from extreme temperature, humidity, and exposure to excessive dust,
moisture, and/or vibration.
12. Rotate the shaft 10 turns every week, and inspect the general condition of the pump and equipment.
13. Every six months, purge the labyrinth with grease to prevent dirt and/or moisture contamination of the
bearings.
14. Cover the suction and discharge flange openings.
15. Indoor storage is recommended.
16. For outdoor or excessively unfavourable environment, cover the pump with some type of protective
cover which allows proper air circulation.
NOTICE
WARRANTY REQUIREMENT
Maintenance records of labyrinth purging and shaft rotation intervals is mandatory during
warranty period, to maintain warranty validity.

WARNING
ROTATING PARTS
Personnel injury or illness may result from contact with rotating parts, seal leakage or spray
from the rotating shaft.

WARNING
HAZARDOUS CHEMICALS
During disassembly, personnel may come in contact with hazardous chemicals. These
chemicals must be identified before disassembly, and the correct MSDS must be made
available and appropriate safety management precautions put in place.

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Bare Shaft Pump Transport and Storage

5.4.4 Long-term Storage

To store and safely keep the new and stand-by pumps for long-term:
 Limit the long-term storage to a maximum of 24 months.
 Do not stack other pieces of equipment on top of the pumps.
 Touch up any scratches before storage.
 Flush and clean the pumps with clean water when you remove a pump from service, for storage.
 Wipe the inner side of the pump to dry any water present in it.
 Due to the design, the pump does not have a drip tray, therefore, dismantle the pump, and dry all parts
of excess water.
5.4.5 Inspection during Storage
Inspection must be conducted whilst pump unit is in storage to check for any evidence of engine fluid leaks,
lubrication leaks or electrical wiring damage.

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Bare Shaft Pump Installation

6 Installation
This section describes the:
 Factors that affect the installation of the pump.
 Pre-startup procedures for bearing assembly.

6.1 Installation Safety

DANGER
LIFTING POINT SAFETY
 Refer to the Multiflo® lifting instructions at all times.
 Tapped holes (for eye-bolts) and cast-on lugs (for shackles) on Multiflo® parts are for
lifting individual parts only.
Some heavy parts of the pump have threaded holes for lifting. During assembly, eye bolts
are screwed into holes to engage the crane. Remove the eye bolts after assembly.

WARNING
TIPPING OR FALLING
The pump can tip over or fall, if the lifting points are offset from the recommended lifting
points.

6.2 Pump Installation

6.2.1 Foundations
Efficient pump service can be obtained only by installing the pump on adequate foundations. Steel frame
foundations should be robust, concrete foundations heavy. Both should be designed to take all loads from
the pump and to absorb any vibrations. Fully tighten all holding down bolts.
The pump should be located such that the length of the intake pipe is as short as possible. Adequate space
to provide access for installation and dismantling to replace worn components should be allowed.
Where a pump base is mounted directly onto a steel framework or base, design it with sufficient strength to
withstand normal pumping operational stress and to ensure that there is no distortion to the base frame
when the pump is installed and operated.

6.2.2 Alignment of Direct Coupled Pumps

NOTICE
ALIGNMENT OF DIRECT-COUPLED PUMPS
The following is recommended as a basis for alignment of direct-coupled pumps. Contact
your local Weir Minerals representative for more information on a specific product.
In a direct-coupled drive, misalignment causes unnecessary vibration and wear on the bearings. Avoid rigid
couplings (that is, couplings that bolt directly together without any flexible member in between) and do not
use them without consultation with Weir Minerals Division.
The following procedures outline a suggested practice for checking shaft alignment. This method is
independent of the coupling or shaft and is therefore not affected by angled coupling faces or eccentricity of
the outside diameter of the coupling.

CAUTION
INCORRECT SHAFT ALIGNMENT
Ensure that no damage occurs when the shaft of the driven unit is turned.

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Bare Shaft Pump Installation

Before starting the alignment procedures:

1. Isolate the drive unit from the power supply.
2. Rotate each shaft independently to check that the shaft and bearings turn without undue friction and
that shaft is true to within 0.04 mm or better as measured on a dial indicator.
 Check with the engine manufacturer for this procedure if connecting the pump to a diesel engine.
3. Ensure that the couplings are loosely coupled, that is, each half must move freely relative to the other.
4. Otherwise, it results in incorrect dial indicator readings.
5. Where tightly fitting pins or springs prevent loose coupling:
 Remove the pins or springs.
 Scribe a line across both half couplings and take the readings only when both the half couplings are
aligned.
6. On couplings with a serrated rim, ensure that as the couplings are rotated, the gauge plungers do not
fall into a groove and become damaged.

6.2.2.1 Angular Shaft Alignment

To ensure proper angular shaft alignment:
1. Rotate the couplings until the gauges are in line vertically, and set the gauges to read zero.
2. Rotate the couplings through half a revolution (180 degrees) and record the reading on each dial
indicator. The readings must be identical though not necessarily zero because of possible end floats.
Either positive or negative readings are acceptable provided they are equally positive or equally
negative
3. Rotate the couplings until the gauges are in line horizontally and reset the gauges to read zero.
4. Adjust the unit position until the correct tolerance is achieved and no further adjustment is necessary.
Repeat this step as required.

6.2.2.2 Radial Shaft Alignment

To ensure proper radial shaft alignment:
1. Clamp a dial indicator to one half coupling or to the shaft, with the plunger resting on the rim of the
other half coupling.
2. Set the gauge to read zero.
3. Rotate the couplings and note the reading at each quarter revolution (90 degrees). Any variation in the
readings indicates a deviation from alignment. In such cases, adjust the position of one of the units
until the readings at each quarter revolution are identical or within the tolerance.
NOTICE
PROVISIONAL ALIGNMENT
Provisional alignment can be carried out with the unit cold. However, where the working
temperature of the pump can raise the centre line of one machine relative to the other,
allowances must be made. The units must then be realigned when each have attained their
correct operating temperature.

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Bare Shaft Pump Installation

6.2.3 Pipework
The guidelines for pipework are:
 Align the pipelines and valves correctly with pump flanges.
 Ensure the pipelines and valves are supported independently of the pump.
 Ensure all pipe designs are on the basis of zero pump flange loading. If this condition cannot be
achieved, consult your local Weir Minerals representative to obtain values for the maximum allowable
external loads and moments on the pump flanges.
 Use appropriate Weir Minerals Australia joint rings (when required) at the pump flanges. The joint rings
form an effective seal between pipework and pump casing.
 Note that the removal of the intake pipe is facilitated if a flexible joint is used in the place of the flanged
connection.
 Ensure that all pipe joints are airtight for correct priming of the pump.
 Consult your local Weir Minerals representative for recommendations and procedures related to inter-
stage piping of multi-stage installations.
NOTICE
INTAKE PIPE LENGTH
A removable piece of pipe must be used on the intake side of the pump. This pipe must be
of sufficient length to allow removal of the pump cover plate or casing and to enable access
to pump wearing parts and impeller.

6.2.3.1 Observations
1. Do not use a concentric reducer on the pump suction as this may cause an air lock. Suction Pipe Size
- The diameter of the suction pipe must be sized according to the flow and allowable head loss in any
case it must be equal to or larger than the diameter to the pump inlet connection. If a pipe larger than
the pump inlet is to be used, good practice stipulates that an eccentric reducer must be fitted to avoid
the possibility of air pockets.

Figure 6-1: Concentric and eccentric reducers

2. All pipe work must be correctly aligned and independently supported, pump flanges are not to be
overloaded. Pipe work restraints must be saddles, rather than stands, restraining axial and radial
movements.
3. Shim material selection to ensure that they do not corrode or compress.
4. Area must be kept clean to ensure safe working environment and effective use of pump set.
5. Never tamper with pump set construction. Modifications to pump set components result in catastrophic
failure.
6. Always use cross pattern (180 degrees) for tightening bolts, for even pressure. Repeat sequence two-
three times. Use calibrated torque wrench for correct tension.
7. Apply grease or anti-seize to bolts to allow easier removal when required.

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Bare Shaft Pump Installation

6.2.4 Flanges
Check the maximum allowable external loads and moments on Weir Minerals Australia pump flanges.
Alternatively, check if actual loads and moments are within the allowable values by submitting the actual
values to your local Weir representative for comparison against the allowable values.
Units:
 Unit of force is newton (N)
 Unit of torque and moment is newton meter (Nm). Y
My
Mxz
X
Z B
Z

Mxy

A X

X Mz

Y Z

Figure 6-2: Flange loading

Nozzle Load = Hydraulic load + Flange Load

Hydraulic Load = P×A
Intake Flange
Fz = Axial Load along z-z axis. Into or out of the pump through A
Fxy = Force in the x-y plane. Any direction through A parallel and level with flange face
Mz = About z-z axis through A. Torsional moment on flange
Mxy = About any axis in x-y plane through A. Acts parallel and level with flange face
Discharge Flange
Fy = Axial Load along y-y axis. Into or out of the pump through B
Fxz = Force in the x-z plane. Any direction through B parallel and level with flange face
My = About y-y axis through B. Torsional moment on flange
Mxz = About any axis in x-z plane through B. Acts parallel and level with flange face
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Bare Shaft Pump Installation

NOTICE
LOADS AND MOMENTS
 Allowable values depend on whether the pump is lined or unlined. Values are
independent of the position of the discharge flange.
 Allowable loads and moments take into consideration the effects of casing distortion
and shaft misalignments.
 The x-y and x-z planes contain the outside faces of the intake and discharge flanges
respectively.
 External loads acting on the pump must be less than the allowable. To minimize the
loads.
 Ensure that pipes are aligned with the pump flanges and supported independent of the
pump and as close to the pump as practical. Use approximate Weir Minerals Australia
joint rings at the pump flanges.
 All allowable loads and moments can act concurrently. Consult your local Weir
Minerals representative for the following:
 Conditions that are not listed in this document
 Axial and radial flange forces (Fz, Fy, Fxy, Fxz) are assumed to act at the bolt PCD circle
of the flange.
 When designing plinths and holding down bolts, assume that the full value of the
allowable flange loads and moments are acting on the pump. Include static and
dynamic loads where appropriate as follows:
 Static load = Total mass of pump set including the pump, drive, and baseplate
 Dynamic Load = Factor × Static Load
 (Factor = 2.0 for pumps with Intake diameters < 300 mm)
 (Factor = 2.5 for pumps with Intake diameters > 300 mm)
 The dynamic load takes into consideration the unbalanced loads from the
pump, motor and couplings or V-belts.
 Actual loads and moments can be checked against the allowable values. In some
installations not every load and moment as defined above will necessarily occur in
practice. In such cases, it is possible to increase the allowable loads and moments that
do act without exceeding the overall allowable. Please consult with your local Weir
Minerals Australia representative in such cases.
For high pressure pumps, multi-stage pump installations or for any pumps not listed,
contact local Weir Minerals Australia representative.

6.2.5 Intake Conditions

The diameter of the intake pipe required depends upon its length and bears no fixed relationship to the
diameter of the intake branch of the pump. The size of the pipe must be such that the velocity is kept to a
minimum, but above the solids particle critical settling velocity to reduce friction losses, that is a long intake
pipe, (or one with numerous bends) which passes a given quantity of liquid must be of larger bore than a
short straight one passing the same quantity of liquid.

CAUTION
AIR TIGHT PIPEWORK
When the bore of the intake pipe is increased to a size larger than that of the pump intake
branch, the form of taper pipe used must not allow the formation of air pockets.
To avoid air pockets, the installation of intake pipework must be arranged with as few
bends as possible and the pipework must be completely airtight.

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Bare Shaft Pump Operation

7 Operation
This section describes the:
 Safety guidelines to be followed while operating the pump.
 Procedures to be followed before pump startup, such as priming.
 Pump startup procedures.
 Problems that may occur during pump startup.
 Pump shut down procedures.
 Information on glands, impeller adjustment, maximum allowable pressures, and bearing fault
frequencies.
The principal requirements for operation of Weir Minerals Australia pumps are:
 Priming arrangements to raise water in the intake pipe and fill the pump.
 Impellers adjusted to maintain minimum clearance with front door.
 Wearing parts replaced when performance falls below required operating pressure.
 Grease purged labyrinths (where used) lubricated regularly to prolong bearing life by removing dust
and dirt from the bearing assembly.

7.1 Operation Safety

DANGER
MONITORING PUMPS
Lack of monitoring, temperature, flow, pressure and vibration can lead to catastrophic failure
of the pumps. Weir Minerals recommends following ISO standards.

WARNING
LARGE PUMPS
The operation and maintenance of the large pumps has an increased risk due to the size
and weights of components as well as the physical size of the complete pump unit.

WARNING
ENTRAPMENT
With the guard removed the rotating shaft is exposed and there is potential for entrapment.
Additional safety management measures must be implemented to manage this specific
hazard.

CAUTION
SOLIDS IN SLURRY INCREASE PUMP WEAR
Large foreign objects or tramp entering a pump will increase the incidence of higher wear
and/or damage to the pump.

CAUTION
ENSURE IMPELLER HAS NOT LOOSENED FROM THE SHAFT
Ensure that the impeller is tight on the shaft before any startup. All components on the
shaft between the impeller and the wet-end bearing must butt metal to metal against each
other without any gap.
Gaps may form when the pump experiences duty conditions conducive to unscrewing of
the impeller, such as excessive runback, high intake pressure, motor braking, etc.

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Bare Shaft Pump Operation

7.2 Shaft Seal

DANGER
MONITORING PUMPS
Lack of monitoring, temperature, flow, pressure and vibration can lead to catastrophic failure
of the pumps. Weir Minerals recommends following ISO standards.

DANGER
TOXIC VAPOURS FROM GLAND
Vapours can leak past gland guards. Appropriate risk assessment must be made regarding
the nature of the product in the pump and necessary safety precautions put in place to
protect from exposure to product vapours.

WARNING
GLAND ADJUSTMENT
During gland seal adjustment the fixed guard needs to be removed while the pump is
operational. When the guard is removed, the rotating shaft is exposed. Additional safety
management measures must be implemented to manage this specific hazard and only
suitable trained and qualified personnel must work on gland adjustment. Replace the guard
when adjustment is complete.

7.3 Priming
Arrangements for raising water in the intake pipe and filling the pump must be provided in preparation to
starting up.
7.4 Normal Startup
CAUTION
BLOCKED IMPELLER
Do not operate the pump if solids have settled and the rotating element cannot be turned by
hand.

The normal startup procedure is as follows:

1. Check once more that all the bolts are tight and that the impeller turns freely.
2. Start pump and run-up to speed, if pump is on suction lift; execute priming procedure for facilities
provided. When the pump is primed, isolate priming facilities.
3. Check gland leakage - If leakage is a constant flow, tighten the gland nuts until the flow is dripping at
the required rate. If leakage is insufficient and the gland shows signs of heating, then try loosening the
gland nuts. If this is ineffective and the gland continues to heat up, stop the pump and allow gland to
cool. Do not loosen the gland nuts to such an extent that the gland follower is allowed to disengage
the stuffing box.
WARNING
GLAND ADJUSTMENT
During gland seal adjustment the fixed guard needs to be removed while the pump is
operational. When the guard is removed, the rotating shaft is exposed. Additional safety
management measures must be implemented to manage this specific hazard and only
suitable trained and qualified personnel must work on gland adjustment. Replace the guard
when adjustment is complete.

NOTICE
HOT GLAND LEAKAGE WATER
It is normal for gland leakage water to be hotter than the supply because it is transferring
away the heat generated by friction in the gland.

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Bare Shaft Pump Operation

At low pressures (single stage operation) very little leakage is required and it is possible to operate with only
a small amount of water issuing from the gland. It is not essential to stop a pump because of gland heating
unless steam or smoke is produced.
This difficulty is normally only experienced on initial startup on gland sealed pumps. When initial heat up of
the gland is encountered, it is only necessary to startup - stop - cool and start the pump two or three times
before the packing beds-in correctly and the gland operates satisfactorily.
It is preferable at start to have too much leakage than not enough. After the pump has run for 8 to 10 hours,
gland bolts can be adjusted to give optimum leakage. If heating of the gland persists, remove the packing
and repack the gland.
Weir Minerals Australia pumps are normally packed with non-asbestos packing, for general duties and
pressures up to 2,000 kPa.

7.5 Abnormal Startup

If the pump fails to operate, one or more of the following faults may be the cause.

7.5.1 Blocked Intake Pipe

When the pump has not been operated for some time, it is possible for slurry to settle in the intake pipe or
around it if operating from a pit and thereby prevent water flow to the pump.

7.5.2 Air Entering Gland

If one of the following conditions applies, air may have entered into the pump through the gland. This may
prevent the pump from priming or cause it to lose its suction during operation.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
 High suction lift causes air intake through the gland.
Inspection of the gland will reveal above faults.

7.6 Operating Faults

The major faults that can occur are described in this section.

7.6.1 Overloading
Overloading can occur when the pump is discharging into an empty system as the delivery head will be
temporarily lower and the throughput will be in excess of that for which the pump is designed. Careful
regulation of the delivery valve until the system is fully charged will prevent this. For more information refer
to the fault finding charts in this manual.

DANGER
OVER PRESSURING IN THE PUMP
 Pumps that are not fitted with an over pressure relief device are at risk of generating
excessive pressures and temperatures when run with restricted or no discharge flow,
such as against a closed discharge valve.
 The system design must include suitable pressure relief measures and operation with
restricted discharge flow must be limited such that the static pressure limit of the pump
is not exceeded.
Running the pump with the discharge valve closed produces heat and pressure builds up in
the pump.

7.6.2 Low Pit Level

Pumps (or first stage pumps in a multi-stage installation) may lose suction if air enters through the gland.
Pumps may also lose their suction if the water level in the pit falls sufficiently low to allow air to enter into the
pump intake by vortex action.
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Bare Shaft Pump Operation

7.6.3 Blocked Intake Pipe

It is possible during operation of a pump for a piece of foreign material to be drawn across the strainer and
thereby cause a partial obstruction. Such an obstruction may not be sufficient to stop operation completely
but will result in a reduced output from the pump. It will also cause a drop in discharge pressure and motor
current or engine load, and will increase the vacuum reading on the pump intake. Rough running and
vibration of the pump may also occur due to the high induced suction causing cavitation within the pump.
7.6.4 Blocked Impeller
Impellers are capable of passing a certain size particle. If a particle larger in size enters the intake pipe it
may become lodged in the eye of the impeller thereby restricting the output of the pump. Such an
obstruction will usually result in a drop in motor current and a drop in both discharge pressure and intake
vacuum readings. Pump vibrations will also occur due to the out of balance effects. Do not operate Multiflo®
pumps without an appropriately sized strainer.
7.6.5 Blocked Discharge Pipe
Blocked discharge pipe may be caused by abnormally high concentration of coarse particles in the pump
discharge pipe or by the velocity in the discharge pipe being too low to adequately transport the solids. Such
a blockage will be shown up by a rise in discharge pressure and a drop in motor current or engine load and
intake vacuum readings.
7.7 Pump Shutdown
The normal shut down procedure is as follows:
1. Flush the pump with clean water.
2. Isolate the flushing water from the pump.
3. Shut down the pump.
4. Close the discharge valve.
5. De-pressurise the pump suction.

7.8 Bearing and Impeller Tip Speeds

Contact your local Weir Minerals Australia representative for maximum bearing and impeller tip speeds.

DANGER
MAXIMUM ALLOWABLE PUMP SPEEDS
For recommended maximum allowable pump speeds, refer to the specific pump
performance curve which takes into consideration the impeller and liner materials and the
maximum allowable peripheral velocity.

WARNING
LUBRICATION OR OVER TEMPERATURE PROBLEMS
Pumps operating within 25% of the maximum bearing speed must generally be reserved for
lightly loaded applications (for example, single stage pumps) to avoid possible lubrication or
over temperature problems. High speed multi-stage applications involving high axial thrust
loads must generally be limited to 50%-70% of the tabulated maximum speeds.

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Bare Shaft Pump Maintenance

8 Maintenance
This section provides the:
 Safety guidelines to be followed while performing maintenance procedures.
 Maintenance checkpoints on the pump.
 Routine maintenance intervals.
 Maintenance procedures to be performed while the pump is in operation.
 Maintenance procedures to be performed when components need to be replaced.

8.1 Maintenance Safety

CAUTION
ISOLATE PUMP COMPLETELY BEFORE MAINTENANCE
 Never carry out maintenance work when the pump is connected to power. Power to
the electric motor or engine must be isolated locked out, tagged out and tested for
dead.
 Ensure that the intake and discharge openings are totally isolated from all potentially
pressurized connections and that they are, and can only be exposed to atmospheric
pressure.
 Drain the pump and isolate pipework before dismantling the pump. The appropriate
safety precautions must be taken where the pumped liquids are hazardous.

8.2 Running Maintenance

This section contains information on the maintenance procedures to perform while the Weir Minerals
Australia pump is in operation. Weir Minerals Australia pumps are of robust construction and when correctly
assembled and installed, they provide long trouble-free service with a minimum amount of maintenance. The
maintenance required for pumps are:
 Gland adjustment
 Repacking gland
 Tightening nuts and bolts
 Labyrinth grease purging
 Bearing assembly lubrication
 Impeller adjustment
For more information on the maintenance of the Weir Minerals Australia pump units, refer to the MF -
420EXHVCC Installation, Operation and Maintenance Manual.

8.2.1 Gland Adjustment

The gland must be checked and adjusted to maintain the leakage at the required flow rate. For gland
adjustment procedure, refer to the gland adjustment section of this manual.

Figure 8-1: Gland packing removal tool

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Bare Shaft Pump Maintenance

8.2.2 Repacking Gland

When gland packing has deteriorated to such an extent that adjustment cannot be obtained by tightening the
gland follower, all the packing must be removed and replaced with new ones.

CAUTION
GLAND PACKING ADJUSTMENT
One new ring of packing on top of the old rings must not be inserted to correct the
adjustment.

When the gland follower has reached the limit of its travel, remove all the old packing from the gland and
repack the gland with new packing. There are 5 packing rings in total and it is recommended that Flurograph
193 or equivalent gland packing’s are to be used. To repack a gland:
1. Remove the gland bolts and gland clamp bolts and the two halves of the gland follower from the pump.
2. Remove the old packing.
3. Clean the stuffing box recess.
4. Place the rings of new packing in position and tamp them home one at a time. Ensure that the ends of
each ring come hard together and joints in successive rings are staggered around the stuffing box.
5. Replace the gland halves. Secure the gland halves with clamp bolts and nip them with gland bolts.
6. Back off the nuts of gland bolts. Keep the nuts finger tight, until the pump is started. After startup,
glands may be adjusted until leakage is at the required flow rate.
These glands are designed for water lubrication and some leakage is necessary during operation to
lubricate and cool the packing and shaft sleeve. Gland leakage must be clean and free from solids at all
times. If there is any sign of slurry leaking from a gland then one of the following must be occurring:
 Gland packing and/or shaft sleeve requires replacement.
When a gland is being repacked during a complete pump overhaul it is easier to pack the stuffing box and
assemble the gland while the stuffing box is out of the pump. The packing gland may be assembled into the
stuffing box with the shaft sleeve in position in the stuffing box. The stuffing box, assembled gland, and shaft
sleeve may then be fitted to the pump as one unit.

NOTICE
STAGGERING PACKING JOINTS
Keep the packing joints away from the water injection hole. This can be achieved by
staggering the joints of each row of packing so that all the packing’s are not in the same
row.
To put the packing in the stuffing box:
1. Put the packing around the shaft sleeve and bring the scarf ends together.
2. Push the joint into the annulus between the stuffing box and shaft sleeve.
3. Push the remaining packing into the annulus by starting near the joint and working around the
opposite side of the ring.
4. After the packing ring starts:
a) Push evenly all the way around the packing.
b) Push gently to the bottom keeping the packing as a ring.
c) Use a gland follower to push the packing down square.
After pump has been started, the glands must be adjusted to provide reasonable leakage. When water
pressure is at a minimum the gland should leak slightly, therefore when this pressure rises, leakage will
necessarily be excessive.
If the gland is adjusted to provide optimum leakage at higher pump rpm (high pressure), insufficient leakage
will occur when the rpm falls or is less from the point of adjustment.

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Bare Shaft Pump Maintenance

The gland sealing water should be as clean as possible, as large amounts of abrasive material can quickly
wear the gland components. Always maintain a very small amount of water leakage along the shaft by
regularly adjusting the gland. As well as lubricating and cooling the gland, the water escaping from the gland
also prevents the ingress of air when the pressure at the shaft falls below atmospheric. E.g. when a vacuum
is required.
If one of the following conditions applies, air may be inducted into the pump through the gland. This may
prevent the pump “picking up” its prime or cause it to lose its prime during operation.
 Packing has insufficient tension.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
 Inspection of the gland will reveal if any of the above faults are occurring.

8.2.3 Gland Packing Adjustment

After pump has started, the glands must be adjusted to provide reasonable leakage. When water pressure is
at a minimum the gland should leak slightly, therefore when this pressure rises, leakage will be excessive. If
the gland is adjusted to provide optimum leakage at higher pump rpm (high pressure), insufficient leakage
will occur when the rpm falls or is less from the point of adjustment.
As well as lubricating and cooling the gland, the water escaping from the gland also prevents the ingress of
air when the pressure at the shaft falls below atmospheric. E.g.: when a vacuum is required.
If one of the following conditions applies, air may be inducted into the pump through the gland. This may
prevent the pump “picking up” its prime or cause it to lose its prime during operation.
 Packing has insufficient tension.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
The starting procedure while undertaking the gland adjustment is as follows:
 Release gland nuts by one (1) full turn.
 Start the unit as per site procedures. Once unit has started, allow to prime. Once primed, check for
water moving past the gland and gland follower. A constant drip is ideal. This will reduce friction and
prevent over heating of the gland.
 If there is no flow of water past the gland or gland follower, stop the pump as per site procedures and
isolate.
 Once unit is isolated, loosen the gland nuts by one more turn. Repeat steps 2 through to 4 until a
constant drip is achieved.
 If the flow of water is too great past the gland follower, stop the pump and tighten the gland nuts by
one turn at a time to ensure that only a constant drip is achieved.

8.2.4 Tightening Nuts and Bolts

For further information, refer the tightening nuts and bolts section of this manual.

8.2.5 Labyrinth Grease Purging

For further information, refer to the labyrinth grease purging section of this manual.

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Bare Shaft Pump Maintenance

8.3 Overhaul Maintenance

This section provides details on the maintenance carried out when components need to be replaced. When
the pump has worn to such an extent that the performance obtained is no longer satisfactory then dismantle
the pump for inspection and/or replace the worn parts. If the bearing assembly requires maintenance, then
dismantle the wet-end before the bearing assembly is removed from the pump.

NOTICE
RECONDITIONING OF BEARING ASSEMBLIES
Bearing assemblies must be reconditioned only in a workshop, preferably in a specific area
set aside for the work. A clean environment is essential.

8.3.1 Pump Disassembly

Isolate the pump from the system and wash it to reduce particle and chemical contamination. Remove drive
items as necessary after noting the alignment of drive. Disassembling can be done at the site if suitable
lifting facilities and working space are available otherwise remove the complete pump unit to a maintenance
workshop.

DANGER
DO NOT HEAT PARTS
Do not apply heat, including welding or hard face coating, to Weir Minerals Australia metal
wear resistant components. This can cause cracks, residual stresses, and changes the
fracture toughness of the parent material.
This may lead to catastrophic failure and could result in personnel injury and equipment
damage even when operating within recommended speed and pressure limits.

The procedure for removing the pump or bearing assembly is a reversal of the assembly procedure for the
pump and bearing assembly. All Multiflo® 420EXHVCC pumps use a thread to fasten the impeller to the
pump shaft.

NOTICE
DISASSEMBLY OF BEARING ASSEMBLIES
 It is recommended to disassemble and overhaul the bearing assemblies only in the
workshop.
 When bearing assembly components are removed from a pump, identify them with
suitable tags so that if they are reused they may be replaced in the same position in
the pump with their correct mating parts.
 Bearing assembly components which are interference fit on the shaft must be
removed only if replacement is necessary.
 Refer to the disassembly procedures outlined in this manual.

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8.4 Disassembly Procedure

CAUTION
QUALIFIED WORKERS
The owner of the pump must ensure that personnel, who are competent and familiar with
the following disassembly procedure, undertake works on this pump. Furthermore, site
safety procedures must be adhered to before any works are undertaken on this pump.

CAUTION
CORRECT TOOLS
Personnel undertaking any maintenance operations on the pump must use appropriate
tools in a safe manner.

CAUTION
CAUTION
Worn pump components can have sharp or jagged edges. Caution must be taken in
handling worn parts to prevent damage to slings or personal injury. To lift heavy pieces
above 25 kg (55 lb) use a crane appropriate for the mass and in accordance with current
local regulations. Tapped holes (for eyebolts) and cast-on lugs (for shackles) on
MULTIFLO® parts are for lifting INDIVIDUAL PARTS ONLY. Lifting devices of adequate
capacity must be used whenever they are required. Safe workshop practices must be
applied during all assembly and maintenance work. Personnel must never work under
suspended loads.
PERSONNEL QUALIFICATION AND TRAINING
All personnel involved in the operation, installation, inspection, and maintenance of the
Bare shaft pump must be qualified to carry out the work involved. If the personnel in
question do not already possess the necessary knowledge and skill, appropriate training
and instruction must be provided. If required, the operator may commission the
manufacturer/supplier to provide applicable training. Always coordinate repair activity with
operations and health and safety personnel, and follow all plant safety requirements and
applicable safety and health laws and regulations.
FAILURE DUE TO CASTING REPAIRS
Castings made from A series Weir Minerals materials, for example, A05, A49, etc. are
brittle and have low thermal shock resistance. Attempts to repair or rebuild by welding
causes catastrophic failure. Repairs of such castings using these methods must not be
attempted.
LIFTING POINT SAFETY
 Refer to Multiflo® lifting instructions at all times.
 Tapped holes (for eye-bolts) and lugs (for shackles) on Multiflo® parts are for lifting
individual parts only. Some heavy parts of the pump have threaded holes for lifting.
During assembly, eye bolts are screwed into holes to engage the crane. After
assembly, the eye bolts must be removed and the holes filled with RTV silicon to
protect the thread of the holes for further use.
LIFTING DEVICE SAFETY
 Use lifting devices to lift heavy or awkward components.
 The lifting devices must be in good condition, certified and tagged.
 The lifting devices must be of adequate capacity and must be used whenever they are
required.
 Personnel must never work under suspended loads.

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Bare Shaft Pump Maintenance

IMPELLER SHATTERING
 Do not apply heat to the impeller boss or nose in an effort to loosen the impeller thread
prior to impeller removal. Do not use heat to expand or cut an impeller from the shaft.
 Personnel injury and damage to equipment occurs as a result of an explosion or the
impeller shattering.
 A shaft wrench is available to assist impeller removal.
 In some cases, an impeller release collar has also been provided to assist impeller
removal.
LIFTING DEVICE SAFETY
No other points on the bare shaft pump must be used other than those indicated in the
lifting instructions. If other lifting points are used they may be damaged which can lead to a
dropped load.
CAUTION
 The lifting of the pump must be undertaken by a qualified and experienced person who
is familiar with lifting safety legislation and practices. This person must be able to
assess the load and lift, create a lifting plan and then apply it safely.
 The mass of the pump is found in the bare shaft pump information.
 The centre of gravity information is found in the bare shaft pump information.
 Use a chock under the wet end of bare shaft pump as it may tip, if the frame is not well
secured.
 Store all lifting equipment in a dry corrosive free environment.
 All lifting points must be routinely inspected and maintained.

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Bare Shaft Pump Maintenance

8.4.1 Removal of the Volute

1. Fix the bare shaft pump on an appropriate jig. Remove discharge flange clamp and coupling guard.
Remove and discard suction and discharge gasket.
Discharge Gasket Discharge Clamp

Coupling Guard

Suction Gasket

2. Remove the top and bottom gland guards.

Top Gland Guard

Bottom Gland Guard

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3. Remove the two square head gland follower bolts.

Gland Follower

RHS square head

gland follower bolts

LHS square head gland

follower bolts

4. Remove both the gland follower clamp bolts.

Gland Follower Gland Follower

Clamp Bolts

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Bare Shaft Pump Maintenance

5. Remove the gland follower.

6. Remove the 5 gland packing rings using the gland packing removal tool.
Gland Packing
Rings

7. Remove all sixteen front door bolts.

Volute
Front Door Bolts

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8. Carefully remove the front door. Remove and discard the front door o-ring.
Front Door
Volute

9. Using an appropriate lifting mechanism offset the weight of the volute.

10. Remove all sixteen adaptor plate bolts.

Cast Lifting Lug

Volute

Front Door
O-Ring

Adaptor Plate Bolts

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11. Lift out the volute, taking care as to not to damage the impeller.
Volute

Impeller

8.4.2 Removal of Impeller

12. Use straps and an appropriate lifting mechanism to secure and offset the weight of the impeller.
13. Loosen the impeller from the shaft and lift away. Impeller thread is right hand thread.

Impeller

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14. Remove the shaft sleeve from the front end.

Adaptor Plate

Shaft Sleeve

Back Liner

Back Liner

Shaft Sleeve

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8.4.3 Removal of the Bearing Assembly

CAUTION
DRAIN OIL FROM THE BEARING ASSEMBLY
Before the bearing assembly is dismantled, it is imperative that personnel drain the oil from
the bearing assembly. Failure to do so will result in oil discharge into the environment.

15. Drain the oil from the bearing assembly. Using an appropriate container and placing it under the drain
hole and unscrew the bearing housing oil drain.

Bearing Housing Oil

Drain

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16. Unscrew the breather assembly from the top of the bearing assembly and plug the hole.

Breather Assembly

17. Loosen (do not remove) the left hand thread nut on the drive end of the bearing assembly, using a C
– Spanner. The shaft will need to be secured to stop it from turning.
18. Remove the locating key from the shaft, take care not to damage the keyway.

Left hand threaded nut

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19. Remove the four bearing housing pedestal securing bolts.

Pedestal Securing Bolts

20. Loosen the bearing housing adjuster nuts as far apart as possible.

Adjusting Nut

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21. Using appropriate lifting equipment and the cast lifting lugs to lift, angle the bearing assembly out of
the adaptor plate drive shaft hole. Place securely on the ground.

Cast Lifting Lugs

Adjusting Nut

22. Remove the neck ring from the stuffing box.

Stuffing Box
Neck Ring

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8.4.4 Adaptor Plate and Back Liner Removal

23. Remove and discard the adaptor plate o-ring.

Adaptor Plate

24. Using appropriate lifting equipment and a sling through the drive hole of the adaptor plate, offset the
weight of the adaptor plate and the back liner.
25. Remove the three adaptor plate pedestal bolts.

Adaptor Plate Adaptor Plate

Pedestal Bolts Pedestal Bolt

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26. Lift the adaptor plate and the back liner. Place the two components on top of wooden block to prevent
damage (liner face down as shown).

Adaptor Plate

Back Liner

27. Remove the four adaptor plate studs.

Adaptor Plate Studs

28. Using appropriate lifting equipment, lift and remove the adaptor plate. With a marker, place a mark on
the adaptor plate and the liner for future alignment in assembly.
Stuffing Box

Back Liner

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29. Using appropriate lifting equipment, lift and remove the liner. With a marker, place a mark on the liner
and the stuffing box for future alignment in assembly.

Back Liner

8.4.5 Disassembly of Bearing Assembly

CAUTION
DRAIN OIL FROM THE BEARING ASSEMBLY
Before the bearing assembly is disassembled, it is imperative that personnel drain the oil
from the bearing assembly. Failure to do so will result in oil discharge into the environment.

30. Secure the bearing assembly to a bench or assembly jig. Remove the lubrication nipples on the
bearing caps.

Drive End
Impeller End

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31. Remove six of the eight bolts on the impeller end that are securing the impeller end bearing cap.
Ensure the bolts are diagonally opposite to each other ensuring the cap is still secured.

Bearing Cap Bolts

Impeller End

Impeller End Bearing Cap

32. Repeat the removal of the six of the eight bolts on the drive end that are securing the drive end
bearing cap. Ensure the bolts are diagonally opposite ensuring the cap is still secured.

Drive End Bearing Cap

Drive End

Bearing Cap Bolts

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33. Remove the locknut (loosened in a previous instruction) from the drive end.

Lock Nut

34. Remove and discard lock nut o-ring and remove with the drive end labyrinth.

Labyrinth

O-Ring

Drive End

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35. Upon removing the drive end labyrinth, ensure that the drive end labyrinth v-ring seal is also removed
with it and discarded.

V-Ring

36. Using appropriate lifting equipment, lift the bearing assembly with a lifting eye on the drive end.
37. Secure the bearing assembly in a vertical position and ensure the drive end is facing upwards.
Drive End

Impeller End

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38. Remove the impeller end labyrinth.

Labyrinth

Impeller End

39. Upon removing the impeller end labyrinth, ensure that the impeller end labyrinth v-ring seal is also
removed with it and discarded.

V-Ring

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40. Remove the remaining two bolts from the impeller end bearing cap and remove it from the assembly.

Bearing Cap Drive End

Bearing Cap Bolts

Impeller End

41. Make sure the o-ring and radial oil seal are removed and discarded.

O-Ring

Radial Oil Seal

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42. Remove and discard bearing cap gasket from the impeller end.

Gasket

Impeller End

43. Remove the oil slinger from the impeller end of the bearing assembly.

Slinger

Impeller End

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44. Remove the remaining two bolts from the drive end bearing cap and remove it from the assembly.

Bearing Cap Bolts

Bearing Cap

Drive End

45. Make sure the o-ring and radial oil seal are removed with the cap and discarded.

O-Ring

Radial Oil Seal

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46. Remove bearing cap gasket from the drive end.

Gasket

Drive End

47. Remove the oil slinger and the o-ring from the impeller end of the bearing assembly.

Slinger

Drive End

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48. Using appropriate lifting equipment, place lifting eyes into two diagonally opposing bearing cap bolt
hole threads and lift the bearing housing gently off the shaft. Secure the bearing housing on a
suitable work bench once it has been removed.

Screw in Lifting Eyes into

Bearing Cap Bolt Holes

Bearing Housing

49. With the bearing housing secure, remove the outer drive end bearing and the drive end bearing
spacer.

Outer Bearing Spacer

Outer Bearing

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50. With the bearing housing removed, secure the shaft on a suitable workbench to prevent it from rolling
off the assembly jig.

Inner Drive Drive Shaft

End Bearing

Bearing Spacer

Impeller End
Bearing

51. Using a hydraulic puller, remove the impeller end bearing, be sure to keep the bearing spacer for
reassembly.
Note: If there has been a bearing failure and the outer of the bearing separates from the inner, it is permissible
to apply light heat to remove the inner bearing. Avoid heating the bearing to the point that the shaft changes
colour. Check the shaft for straightness and machine tolerance once all bearings have been removed.

Bearing Spacer

Impeller End

Impeller End
Bearing

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52. Secure the shaft vertically above a workbench with the drive end facing downwards. Lightly heat the
drive end inner bearing until the bearing falls from the shaft.
Note: Do not heat the shaft or bearing to the point it changes colour. If there has been a bearing failure remove
the bearing and check the shaft for straightness and machine tolerance.

Impeller End

Inner Drive End

Bearing Spacer

Drive End Inner

Bearing

Drive End

53. Once the shaft has cooled from the removal of the drive end inner bearing, the inner drive end
bearing spacer can be removed.

Impeller End

Inner Drive End

Bearing Spacer

Drive End

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54. The shaft should now be bare, secure it to an appropriate workbench or assembly jig. Thoroughly
clean the entire shaft and check all critical tolerances (bearing spigots, threads, etc) for wear,
damage and tolerance compliance).

Impeller End

Drive Shaft

Drive End

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8.5 Inspection after disassembly

CAUTION
Worn pump components can have sharp or jagged edges. Caution must be taken in
handling worn parts to prevent damage to slings or personal injury. To lift heavy pieces
above 25 kg (55 lb) use a crane appropriate for the mass and in accordance with current
local regulations. Tapped holes (for eyebolts) and cast-on lugs (for shackles) on
MULTIFLO® parts are for lifting INDIVIDUAL PARTS ONLY. Lifting devices of adequate
capacity must be used whenever they are required. Safe workshop practices must be
applied during all assembly and maintenance work. Personnel must never work under
suspended loads.
Wetted parts

1. Check impeller tips and expellers for signs of cavitation.

2. Check the cut water for cavitation damage.
3. Check the impeller thread for damage or galling.
4. If the pump has been used in heavy slurry applications check:
 The impeller diameter is within tolerance.
 Check for excessive wear at the eye of the impeller.
 Check the area around the throat on the suction cover plate and the corresponding area of the
impeller for excessive wear.
 Check the stuffing box, shaft sleeve, neck ring, volute and liner for wear.
Note: It is difficult to measure dimensions, recirculation and cavitation look similar and will be a visual check.

Figure 8-2: Suction cover plate severe damage from recirculation

Bearing assembly

1. Measure the bore of the drive and impeller end bearings in the bearing barrel.
2. Check all threads.
3. Check the shaft for correct dimensions, heat damage, straightness and damage to any machined
surfaces or threads.
4. Check the barrel, end caps and labyrinths for corrosion damage blocked lubrication passages and
general damage.
5. Check the mating faces with the pedestal for excessive corrosion.
6. Pedestal.
7. Check the mating faces with the bearing barrel for excessive corrosion.
8. Check the mounts for cracks, corrosion, general damage or signs of metal fatigue.
Note: It is recommended components exposed to the elements are sand blasted and primed at
this point.
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8.6 Replacement of Wearing Parts

DANGER
DO NOT USE REPAIRED WETTED COMPONENTS
Do not weld worn or holed wetted parts or pressure containing casing components as
repairs could lead to catastrophic failure and slurry blow-out at lower than recommended
maximum pressures.

CAUTION
AVOID USING WORN OUT PARTS
Mixing of new and worn pump components may increase the incidence of premature pump
wear and leakage.
All metal mating faces must be cleaned of dirt, rust, paint, and other adhering substances
prior to pump assembly. Failure to clean parts can affect pump assembly and running
clearances and could lead to catastrophic failure of parts.

The wear rate of a solids handling pump is a function of the severity of the pumping duty and of the abrasive
properties of the material handled. Therefore, the life of wearing parts, such as impellers and liners, varies
from pump to pump and from one installation to another.
As pump impellers and liners become worn, the head developed by the pump decreases. As the head
decreases a consequent drop in rate of discharge occurs. When the rate of discharge falls to such a level
that either the required quantity of slurry cannot be discharged or the line velocity is too low for satisfactory
transportation of the slurry, dismantle the pump(s) for inspection of the impeller and liners.
Replacement of the impeller only, results in the pump regaining almost new pump performance. Whether
liners require replacement must be assessed by estimating whether the proportionate thickness remaining
will provide reasonable further life before replacement is required.
Where a pump is used on a particular duty for the first time and especially where failure of a wearing part
during service could have serious consequences, it is recommended to open the pump at regular intervals,
inspect parts, and estimate their wear rate so that the remaining life of the parts may be established.

8.6.1 Reassembling the Pump after Overhaul

When pumps are dismantled for complete overhaul, closely inspect all parts and check new parts for correct
identification.

CAUTION
RUBBER SEALS REPLACEMENT
It is recommended that all rubber seals are replaced during major overhauls as rubber
tends to harden and seals lose their effectiveness.

NOTICE
CORRECT OVERHAULING PROCEDURES
Used parts which are being reused must be thoroughly cleaned and painted. Mating faces
must be free from rust, dirt, and burrs and given a coat of grease before they are fitted
together.
It is preferable to renew small bolts and set screws during overhaul and coat all threads
with graphite grease before reassembly, if high tensile bolts are used, they must not be
reused.

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8.7 Assembly Procedure

CAUTION

CLEAN PARTS BEFORE FITTING

Ensure that all parts are clean and free from debris before fitting.

8.7.1 Bearing Barrel Assembly

1. Lightly lubricate the shaft and using a bearing heater fit the impeller end bearing to the shaft.

Drive End
Impeller End Drive Shaft
Bearing

Impeller End

2. Lightly lubricate the shaft and fit the inner drive end bearing spacer to the shaft.

Inner Drive End Bearing

Spacer

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3. Fit the drive end inner bearing to the shaft.

Drive End Inner Bearing

4. Lightly oil the bearing bore of the barrel on the drive end.
5. Fit the outer bearing spacer and the outer drive end bearing to the bearing housing. Ensure the drive
end bearing identification number is facing outwards.

Outer Bearing Outer Drive

Spacer End Bearing

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6. Lightly oil the bearing recess of the barrel on the drive end. Using lifting eyes in diagonally opposing
holes in the mounting flange for the bearing cap and appropriate lifting equipment lift the bearing
housing and lower it over the shaft.
Screw in Lifting Eyes into
Bearing Cap Bolt Holes

Bearing Housing

7. Fit the drive end oil slinger.

Drive End

Bearing Housing
Slinger

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8. Fit the drive end bearing cap gasket.

Gasket

9. Grease the drive end bearing cap o-ring and radial oil seal grooves. Grease over the o-ring to aid in
fitment of the cap. Fit seal and o-ring to bearing cap.

O-Ring

Radial Oil Seal

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10. Fit the oil bearing cap, apply anti-seize to the bolts and evenly tighten. Ensure that the oil lubrication
port is facing towards the lift eyes of the bearing housing.

Bearing Cap

Bearing Cap Bolts

Oil lubrication
port

11. Grease the drive end labyrinth v-ring seal groove. Fit the drive end v-ring seal to the drive end
labyrinth.

V-Ring

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12. Apply grease to the mating surface of the drive end labyrinth then fit the labyrinth. Grease the o-ring
groove on the labyrinth then fit the o-ring. Apply grease over the lock nut o-ring to stop the o-ring
galling during fitment and to fold the o-ring in place.

O-Ring Labyrinth

13. Apply anti-seize to the thread of the lock nut.

Lock Nut Thread

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14. Fit the lock nut and tighten with the c-spanner.
Note: The lock nut is left hand thread.

Lock nut
(Left hand thread)

15. Using appropriate lifting equipment, lift and secure assembly on a workbench or assembly jig.

Drive End

Bearing Housing

Impeller End

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16. Fit the impeller end bearing spacer.

Bearing Spacer

17. Fit the impeller end oil slinger.

Oil Slinger

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18. Fit the impeller end bearing cap gasket (a light application of grease will keep the gasket in position).

Gasket

19. Grease the impeller end bearing cap o-ring and radial oil seal grooves. Fit the o-ring and seal,
grease over the o-ring to aid in fitment of the cap.

O-Ring

Radial Oil Seal

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20. Fit the impeller end bearing cap to the assembly, lubricate all bolts with anti-seize, fit them to the cap
and tighten. Ensure the oil lubrication port is towards the lift lugs.
Lubrication Port

Bearing Cap Bolts

Bearing Cap

21. Grease the impeller end labyrinth v-ring seal groove. Fit the impeller end v-ring seal to the drive end
labyrinth.

V-Ring

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22. Apply grease to the mating surface of the impeller end labyrinth and fit the labyrinth.

Labyrinth

Impeller End

23. The bearing assembly should now be complete. A corrosion inhibitor such as CRC softseal should
be applied to the mating face between the bearing assembly and the pedestal.

Air Breather

Breather Adaptor

Drive End Bearing Housing

Impeller End

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8.7.2 Assembly of the Adaptor Plate

24. Remove any dirt and debris from all machined faces on the liner.
Back Liner

25. Apply Loctite 272 to the back liner stud threads that are going to be fitted to the liner. Fit all 4 studs to
the liner.
26. Apply grease to the machined o-ring face on the liner.

Machined O-Ring Face

Stud
Back Liner

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27. Clean the o-ring groove and all machined surfaces on the stuffing box and apply grease to the o-ring
groove. Once greased fit the o-ring and grease over the o-ring.
Stuffing Box

O-Ring Groove O-Ring

28. Using appropriate lifting equipment, lift the stuffing box onto the back liner. Ensure the gland
lubrication port on the stuffing box is facing upwards and at 450 to the studs as shown below, use
alignment marks from disassembly to align the components similarly to their previous positions.

Stuffing Box
Gland lubrication port

Back Liner

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29. Apply anti-seize to the back liner studs.

Back Liner Studs Stuffing Box
Back Liner

30. Fit the three adaptor plate studs, using appropriate lifting equipment lift the adaptor plate to gain
access to the lock nuts and tighten them.
Note: Do not place any part of your body under a suspended load, make sure the adaptor plate is secure
before tightening the lock nuts.

Adaptor Plate Pedestal Securing Bolts

Adaptor Plate

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31. Fit the adaptor plate onto the back liner and tighten the four back liner/adaptor plate nuts.
Note: Ensure the gland lubrication port is in the correct orientation before the nuts are tightened.

Back Liner and Adaptor Plate Pedestal

Securing Bolts
Adaptor Plate
Back Liner

Stuffing Box

32. Using appropriate lifting equipment, lift the assembled adaptor plate and fit to the pedestal. Tighten
the pedestal securing nuts.

Stuffing Box

Adaptor Plate

Pedestal

Back Liner

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8.7.3 Fitting the Bearing Assembly into the Pedestal

33. Fit the neck ring into the stuffing box.
Neck Ring

34. Ensure that the adjusting nuts are loosened and are as far apart as possible. Using appropriate lifting
equipment, use the cast lifting lugs to lift the bearing assembly, fit it to the pedestal as shown below
through the stuffing box and lower onto the pedestal.

Cast Lifting Lugs

Adjusting Nut

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35. Grease both the o-ring grooves at each end of the shaft sleeve.

O-Ring Groove
Shaft Sleeve

36. Fit both the o-rings into the greased o-ring grooves at each end of the shaft sleeve and grease over
both of the o-rings to ensure they do not fall out during assembly.

Shaft Sleeve

O-Ring

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37. Fit the shaft sleeve to the impeller end of the drive shaft (the shaft sleeve is directional and will only
fit one way).
38. Check the shaft sleeve where it butts up against the labyrinth has no gap, if there is a gap the o-ring
is not seated. If this is the case, remove the shaft sleeve re-fit the o-ring.

Shaft Sleeve

39. Apply anti-seize on the bearing assembly pedestal securing bolts.

Pedestal Securing Bolts

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40. Fit the bearing assembly pedestal securing bolts hand tight with their respective washers to the
assembly. Fit the bolts from the bottom upwards.
Washer
Pedestal

Pedestal Securing Bolt

41. Using suitable sized tools, tighten the two bearing assembly-pedestal securing bolts on the pedestal
side without the lip as shown below.
42. Tighten the bolts on the opposite side of the pedestal, check the mating surfaces between the
bearing assembly and the pedestal are snug together without any gap.

Pedestal Securing Bolt

43. Once the bearing assembly is secured, back off the pedestal securing bolts slightly, to allow the
horizontal adjustment of the bearing assembly (for impeller clearance adjustment).
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44. Fit the key to the shaft and use a shaft lock to secure the shaft.

Key

45. Using the c-spanner, fully tighten the left hand threaded lock nut.

Labyrinth Lock Nut

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8.7.4 Fitting the Impeller

46. Remove the shaft lock from the shaft.
47. Ensure that the o-ring face on the impeller is clean and free from debris.

Impeller

Impeller thread

O-Ring Face

48. Apply anti-seize to the shaft thread and impeller thread.

Shaft Thread

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49. Ensure that the o-ring on the impeller end of the shaft sleeve is still in place.
50. Using appropriate lifting equipment, lift the impeller with a sling. Ensure that the impeller is parallel to
the back liner.

Back Liner
Adaptor Plate

Impeller

51. Fit the impeller to the shaft by turning the shaft to screw in the impeller thread.
Note: Do not force the thread to engage, if it is tight inspect the issue before proceeding, if the thread galls
it will be difficult to remove.

Impeller

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52. While the impeller is still in the sling, use its resistive force on the impeller to further tighten the
impeller thread.
53. Remove the sling from the impeller.
54. Set the impeller in place by further tightening the impeller thread.

8.7.5 Assembling the Volute

55. Fit the o-ring to the suction cover plate, use grease to lubricate it for assembly.
56. Lay the volute horizontally on the ground, with the suction side end facing upwards as shown below.
Suction Side Volute

Adaptor
Plate End

57. Fit the front door to the volute. Apply anti-seize to the sixteen front door-to-volute bolt threads. Evenly
tighten the sixteen bolts to secure the front door to the volute.

Securing Bolts

Front Door

Volute

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58. Grease the o-ring groove on the corner where the liner intersects the adaptor plate.
Adaptor Plate

Liner

59. Lubricate the o-ring for assembly and fit it to the liner.

O-Ring

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60. Using appropriate lifting equipment and the lugs cast into the volute, lift the volute and front door
assembly. Ensure the discharge is roughly in the orientation required for assembly.

Cast Lifting Lugs

61. Clean the mating surfaces on the volute and the adaptor plate assembly.
62. Grease the mating surfaces on the volute.
63. Fit the volute to the adaptor plate assembly. Apply anti-seize to the sixteen adaptor plate-to-volute
securing bolt threads. Evenly tighten the sixteen bolts to secure the volute to the adaptor plate. Do
not fully tighten at this point as the volute will need to be levelled.

Adaptor Plate

Adaptor
Plate
Fasteners

Volute

Front Door
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64. Before levelling the volute, ensure that the pedestal is levelled front to back and side to side.
65. Once the pedestal is levelled, place a spirit level on top of the discharge flange of the volute. Using
appropriate lifting equipment, adjust the volute until the volute is level.
Note: Ensure the discharge is in the correct orientation for your application.

Discharge Flange

Pedestal

66. Once the volute is levelled, fully tighten the adaptor plate volute bolts.
67. Once the volute is secured, remove the lifting equipment from the pump.

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8.7.6 Setting the Impeller to Front Door Gap

68. Check the bearing assembly bolts are loose enough to allow the assembly to move for adjustment.

Bearing Assembly
Bolts

69. While turning the shaft by hand, adjust the rear adjusting nut so the bearing assembly moves
forward, continuing adjusting the nut until the impeller hits the door. Keep rotating the shaft 1 full turn
after the impeller has first touched to check for high spots.

Forward

Drive Shaft

Rear Adjusting
Nut

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70. Once the impeller reaches the front door, back off the rear pedestal adjusting nut and then move the
front pedestal adjusting nut so it touches the bearing assembly adjusting lug. This position of the
front adjusting nut will be the datum for adjusting the clearance between the impeller and the front
door.

Front Pedestal
Adjusting Nut

Drive Shaft

Bearing Assembly
Adjusting Lug

71. Secure a dial indicator on the pedestal. Adjust the needle of the dial indicator so it has travel in both
directions and touches the rear of the bearing assembly. Zero the dial indicator once it is in position.

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72. Use the front pedestal adjusting nut to bring back the drive shaft 1 mm. Once 1 mm of clearance is
achieved between the impeller and the front door, tighten both the rear and front pedestal adjusting
nuts. Ensure that the clearance is not affected during the tightening process of both the bolts. This
clearance greatly affects the performance of the pump and therefore the adjusting nuts must be
secure enough so during normal operation the clearance does not change.
73. Once the clearance between the impeller and the front door has been set, fully tighten the bearing
assembly to pedestal bolts.

Frame Size Recommended Torque (± 10%) (Nm)

FF 300

Pedestal
Securing Bolt

74. Turn the shaft to ensure there is no interference between the impeller and the front door.
75. Fit the discharge flange clamp.
Discharge
Flange
Clamp

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8.7.7 Fitting Gland Packing

76. Fit the gland packing between the shaft sleeve and the stuffing box. It is permissible to thin out the
glands slightly using a rubber mallet to allow for easier fitting.
77. Fit the first gland (there are five rows of packing in total); ensure that the join on the gland is facing
vertically upwards.
78. Fit the remaining glands, indexing the join 900 for each row.

Gland Packing

79. Once the gland packing has been installed, fit the gland follower, the square head gland securing
bolts and the offset gland nuts. Tighten the gland nuts until the gland follower is touching the packing
but loose in the stuffing box.

Gland Follower

CAUTION
ENSURE GLANDS ARE NOT OVER-TIGHTENED DURING ASSEMBLY
During the assembly process, glands may be over tightened and will need to be adjusted
for normal operation. Over-tightening will cause premature wearing and failure of the gland
packings.
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NOTICE
Refer to the gland packing adjustment section of this manual for further information on
setting the gland follower.

80. Fit the lower gland guard.

Lower Gland Guard

81. Fit the upper gland guard.

Upper Gland Guard

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8.7.8 Finalising Assembly

82. Fit the breather assembly onto the bearing assembly, if the breather is being reused from the old
assembly, ensure the filter material is not oil soaked or excessively dirty.

Breather Assembly

83. Fit the oil drain onto the bearing assembly. Ensure this is done before the bearing assembly is
lubricated.
CAUTION

FIT OIL DRAIN

Fit the oil drain with a suitable plug to avoid oil leaks to the environment.

Oil Drain Plug

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84. Lubricating the bearings using Mobilgrease XHP 222 or equivalent. Apply the oil through the oil
lubrication ports on the bearing caps.

Bearing Oil
Lubrication Port

85. Purge both the front and rear labyrinths with Mobilegrease XHP 222. Purge until grease can be
visibly seen to come out of the labyrinth. Apply the grease through the grease ports on the bearing
caps.

Lubrication Grease Port

86. The assembly should be painted in accordance with the requirements and standards dictated by the
application to prevent corrosion and extend component service life.

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8.8 Assembly of BSP to the Engine

1. Ensure all engine-mounting bolts are correctly tensioned, ensure all bare shaft pump-mounting pads
are clear of debris, and tapped holes are clean.

2. Ensure engine flywheel spigot is clean and mount coupling adaptor using 1/2"x1 3/4" UNC cap screws.

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3. Clean and lightly oil element hub bore and taper lock bush, loosely assemble bush to hub do not lock
up setscrews.

4. Remove all three BSP flywheel adaptor guards, ensure shaft and key are clear of burrs, coat shaft and
key with anti-seize.

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5. Mount coupling element on to BSP shaft, move towards bearing housing. Apply anti-seize to adaptor
spigot.

6. Using an appropriate lifting mechanism, mount the BSP to the motor, ensuring the adaptor spigot is
fully engaged. Align and assemble all flywheel-mounting bolts partially.

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7. Utilising the pedestal jacking bolts, apply approx. 23 Nm. Ensuring that the flywheel mounting bolts
remain free.

8. Tension the flywheel mounting bolts fully.

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9. Determine by using feeler gauges the amount of shimming required under the pedestal mount, insert
shimming and tension pedestal-mounting bolts.

10. Before moving the coupling element into engagement with the coupling adaptor, ensure that the BSP
shaft can be rotated. Centralise the element in the adaptor (the adaptor to be in front of the element
by 5 mm when correctly assembled), tension taper lock bush set screws.

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11. Refit all three flywheel adaptor guards.

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8.9 Routine General Maintenance

Timeline Schedule Maintenance
Inspect the bare shaft pump gland.
Gland packing
Adjust if required.

Maintain the level at the top of the

sight glass. Use Lithium base - not
containing Molybdenum - with RP
Every 10 Operational Hours or Lubrication additives.
Daily NLGI consistency of 2.Multiflo
recommends Mobilgrease XHP-222
or equivalent, or refer to Lube List.

Fill to 10 mm (3/8”) below filler pipe

Gland oil tank (if fitted) opening. Use SAE15W40 or refer to
Lube List.

EVERY 250 Operational Hours Shutdown protection Check pressure switch operation.
Perform in addition to Daily
Schedule Items Check for oil leaks around end caps,
bearing drain and breather. Repair
General
leaks as required and clean
assembly.

Check for oil flow at the bearing

Lubrication circuit
caps.

EVERY 500 Operational Hours Drain oil (sample as required).

Perform in addition to Daily Lubrication oil
Replace filter.
Schedule Items
Check all fasteners, tighten, or
General
replace as required.

Check impeller adjustment, adjust as

Impeller adjustment
required.

Check the breather filter material for

Breather oil and dirt saturation, replace as
required.

EVERY 1000 Operational Hours

Check relief valve operation and
Perform in addition to 500 Hours Lubrication
pressure setting.
of maintenance items

EVERY 2000 Operational Hours

Inspect the bare shaft pump
Perform in addition to 1000 Hours Bearing assembly
bearings for moisture inclusion.
of maintenance items

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Bare Shaft Pump Commissioning

9 Commissioning
This section is a general guide and is applicable to direct drive and belt drive complete pump units. This
section also describes in detail, the:
 Bare Shaft Pump commissioning steps.
 Motor rotation checks procedure.
Refer information on pump auxiliary equipment, as the details can vary with manufacturer or supplier.

9.1 Commissioning Safety

DANGER
PERSONNEL INJURY
Do not stand near an operating pump during commissioning as pump may fail during this
period.

DANGER
EXPLOSION
Excess loading from the discharge pipe on the pump casing may crack the casing.

WARNING
HOT SURFACES
Pump bearing assembly becomes hot during operation. Do not touch bearing assembly
surfaces without taking appropriate precautions to protect against personnel injury.

CAUTION

THERMAL SHOCK
Be aware that thermal shock may damage pump components during priming.

CAUTION

FLANGE DAMAGE
Over torqueing of the flange bolts may cause flange damage.

CAUTION

FIT JOINT RINGS

Failure to fit joint rings, leads to product leakage.

CAUTION

TAPER LOCK
Check taper lock tension after first 3 hours of operation.

CAUTION
VIBRATION
Components may become loose under excessive vibration. Ensure tensioning and locking
procedures are followed.

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Bare Shaft Pump Commissioning

9.2 Commissioning Steps

Check the following before commissioning the pump:
1. Shaft rotation
a. Remove any pump or motor shaft clamps.
b. Check that the mechanical seal (if fitted) setting tabs are removed.
c. Turn the shaft by hand to ensure that components turn freely.
2. Electrical connections and motor rotation check. Alignment and tensioning of v-belts.
a. Remove all v-belts or completely disconnect shaft coupling.
Note: Do not bump test motors with the driver attached to the pump, the impeller will wind off of
the shaft and cause damage to the impeller, shaft, bearings and door.
b. Bump motor and check rotation. Correct if necessary to produce pump shaft rotation as indicated
by the arrow on the pump casing.
c. Reinstall v-belts or coupling.
d. Align and tension v-belts to the recommended settings of the manufacturer.

DANGER
PUMP ROTATION DIRECTION
Rotation in the opposite direction indicated by the arrow on the pump unscrews the impeller
which may lead to suction cover plate, bearing, impeller and shaft damage.

WARNING
REPLACE GUARDS
Replace and secure the guards removed for maintenance and other purposes prior to
operating the pump.

9.2.1 Impeller Adjustment

The impeller is factory set with a minimum running gap between the impeller and the front door. If required
for any reason, check and readjust the impeller as described in the assembly section of this manual.
9.2.2 Pipework
Ensure that the:
a. Pipe work is correctly aligned with the pump and is supported independently of the pump.
b. Weir Minerals Australia joint rings are in the correct position on pump intake and discharge flanges.
The pipe flanges to support joint rings must be flush.
c. Pipework on the suction side of the pump is as short as possible.
d. Air pockets are avoided by correct installation of any reducers in the suction pipe.

9.2.3 Fasteners
Check that all the fasteners are tight, particularly the:
a. Bearing housing to pedestal bolts.
b. Bearing assembly adjusting nuts.
c. Pedestal mounting bolts.

9.2.4 The following are the commissioning steps normally done with clean water:
These steps are generic for an electric driven flood primed pump. For specifics on you application contact
Weir Minerals Australia technical support.
a. Bump test the motor
b. Prime the pump
c. Open all applicable suction and discharge valves.
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Bare Shaft Pump Commissioning

d. Turn the pump ON.

e. Check whether pump starts correctly and runs smoothly.
f. If faults occur, check for possible cause as mentioned in the troubleshooting guide in this manual.
g. Check and adjust gland leakage as required.
WARNING
GLAND ADJUSTMENT
During gland seal adjustment the fixed guard needs to be removed while the pump is
operational. When the guard is removed, the rotating shaft is exposed. Additional safety
management measures must be implemented to manage this specific hazard and only
suitable trained and qualified personnel must work on gland adjustment. The guard must be
replaced when adjustment is complete.

DANGER
OVERPRESSURE IN PUMP
 Pumps that are not fitted with an over pressure relief device are at risk of generating
excessive pressures and temperatures when run with restricted or no discharge flow,
such as against a closed discharge valve.
 The system design should include suitable pressure relief measures and operation
with restricted discharge flow must be limited such that the static pressure limit of the
pump or discharge pipework is not exceeded.
 Running the pump with the discharge valve closed produces heat and pressure build
up in the pump. The time between closing the valve and pump shut down must be
minimized to reduce the risk of exceeding the pumps temperature and pressure limits.

9.2.5 Monitor Performance

a. Check operating parameters are within limits and comply with performance requirements.

9.2.6 Turn the Pump OFF

a. Close the discharge valve.
b. Turn OFF the pump and its associated systems and allow it to stop.

9.2.7 Avoidance of Impeller Loosening – Runback and Reverse Rotation

The loosening of the impeller can be avoided by checking the direction of rotation of pump and impeller
before starting the pump. This section describes this aspect in detail.

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Bare Shaft Pump Commissioning

9.2.7.1 Correct Direction of Rotation and Input Torque via Pump Shaft
MF-200HVCC pump impeller features a right-hand impeller thread on its boss and engages to the pump
shaft, which is threaded to suit the impeller thread. The correct driven direction of rotation of the impeller
when viewed from the intake end of the pump is anticlockwise for all standard Weir Minerals Australia
impellers as shown in the figures below.
Intake End

Figure 9-1: Impeller Tightening

When the impeller is driven in the correct direction by the pump shaft, torque is applied to the impeller. This
torque reinforces the fastening of the impeller to the shaft.
9.2.7.2 Incorrect Direction of Rotation and Input Torque via Pump Shaft
If power is transmitted to the impeller via the pump shaft in the incorrect (clockwise) direction of rotation as
shown in the figure below, the torque unscrews the impeller from the shaft.

Intake End

Figure 9-2: Impeller Loosening

Perform the motor rotation “bump” test referring to motor rotation check in the proceeding section of this
manual. The danger of an impeller loosening is present regardless of whether the pump is started empty or
when containing product.

NOTICE
IMPELLER LOOSENING
If the impeller is tightened to the pump shaft during fit-up and then started at least once
then the chances of impeller loosening are greatly diminished.
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Bare Shaft Pump Commissioning

9.2.7.3 Shut Pump Down on High Static Discharge Heads

When multi-stage pumps are applied on a duty featuring a very high static head the product in the
discharge system can runback through the pump when the pump is stopped. This high flow may be
sufficient to drive the impeller (and electric motor or diesel engine) in the reverse (clockwise) direction. It is
possible for the speed of this reverse rotation to become significantly high. In some cases resulting in motor
speeds which are in excess of the maximum safe speed permitted for structural integrity of the motor
rotors. The motor and pump are protected from dangerously high speed rotation by: limiting the reverse
flow via non-return valves.

9.2.7.4 Effects of Unrestricted Runback and Reverse Rotation

DANGER
PUMP ROTATION DIRECTION
Rotation in the opposite direction indicated by the arrow on the pump unscrews the
impeller, which may lead to suction cover plate, bearing, impeller and shaft damage.

CAUTION
ALWAYS COMPLETE DE-PRESSURISING
Unrestricted runback would not occur if the intake system is completely de-pressurised
during runback operations.

All rotational motion would cease with the impeller partially unfastened from the shaft. This is a dangerous
condition as leakage can occur past the impeller o-ring into the bearing assembly as on the next startup.
The pump shaft would very rapidly draw the impeller back, towards its fastened position. The impact of this
sudden axial movement of the impeller is often sufficient to damage the shaft sleeve, bearing assemblies,
and other components.
This problem is not commonly encountered in practice but is more likely to occur when:
a. The initial fastening of the impeller is not sufficiently tight.
b. The pump has not been operated for a sufficiently long period to allow the impeller fastening to be
further tightened by normal startup and operating torques.

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Bare Shaft Pump Commissioning

9.3 Motor Rotation Check (Bump)

Check drive rotation before v-belts or shaft couplings are connected. The correct pump rotation is indicated
by an arrow on the pump casing.

DANGER
PUMP ROTATION DIRECTION
Rotation in the opposite direction indicated by the arrow on the pump, unscrews the
impeller leading to suction cover plate, bearing, impeller and shaft damage.

WARNING
PERSONNEL INJURY
Do not touch the rotating elements with hands to establish the direction of rotation.

NOTICE
PUMP ROTATION DIRECTION
Always check the direction of the pump shaft and not the gearbox input shaft which may be
in the opposite direction and is the incorrect direction for the pump.

Perform the following test, before operating the pump after any maintenance. This is to ensure that the
direction of rotation of the pump is correct.
1. Isolate the drive unit from the power supply.
2. Remove the v-belt or coupling guarding.
3. Remove the v -belts or coupling element.
4. Replace the v -belt or coupling guarding.
5. De-isolate the drive unit from the power supply.
6. Turn ON the motor and then turn OFF.
7. Check the direction of the pulleys using the inspection hatch.
8. Isolate the drive unit from the power supply.
9. Remove the v-belt or coupling guarding.
10. Replace the v-belts or coupling element and tension them.
11. Replace the v-belt or coupling guarding.
12. De-isolate the drive unit from the power supply.
9.4 Gland Seal
CAUTION
ENSURE GLANDS ARE NOT OVER-TIGHTENED DURING ASSEMBLY
During the assembly process, glands may be over tightened and will need to be adjusted
for normal operation. Over-tightening will cause premature wearing and failure of the
packings.

A slight leak is desirable from the newly packed gland to allow the packing time to bed in. Excessive
tightening at this period will result in burning of the packing and scoring of the shaft.
After the pump has started, the glands must be adjusted to provide reasonable leakage. When water
pressure is at a minimum the gland must leak slightly, therefore when this pressure rises, leakage will be
excessive. If the gland is adjusted to provide optimum leakage at higher pump rpm (high pressure),
insufficient leakage will occur when the rpm falls or is less from the point of adjustment.
As well as lubricating and cooling the gland, the water escaping from the gland also prevents the ingress of
air when the pressure at the shaft falls below atmospheric level.
Always adjust the gland leakage with the pump at the normal operating duty.

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Bare Shaft Pump Commissioning

NOTICE
Refer the troubleshooting guide in this supplement for further information on
troubleshooting problems with gland seal.

9.5 Impeller Adjustment

Weir Minerals Australia pump performance changes with the clearance existing between an impeller and the
front door. With wear, the clearance increases and the pump efficiency drops. For best performance it is
necessary, to stop the pump occasionally and move the impeller forward (this applies to metal and high
efficiency style impellers). This adjustment can be carried out in a few minutes without any disassembling.
The correct setting of the impeller is when the clearance between the impeller and the front door is a
minimum.

CAUTION

DRIVE ALIGNMENT
After completing an impeller adjustment check the drive is aligned correctly.

To adjust the impeller:

1. Rotate shaft clockwise by hand and move bearing assembly forward, towards the front door, by
tightening the rear nut on the adjusting screw until the impeller starts to rub on the front liner.
2. Release the rear nut by one sixth of a turn(1 flat of the nut), and then move bearing assembly back by
means of front nut until housing touches the rear lug.
NOTICE
ADVANTAGES OF IMPELLER ADJUSTMENT
 Impeller adjustment is a key element in extending the wear life.
 Field tests on certain pumps indicate if impellers are adjusted right forward when fitted
and again at regular intervals during the wear life, then an increase of 40% to 50% in
life can be achieved over pumps which were not correctly adjusted forward at the initial
fit-up.
Further, pumps which were regularly adjusted over their life have shown a 20% increase in
life, over pumps which were only adjusted once at the initial fit-up.

Recommended intervals for impeller adjustment:

1. On initial fit-up, adjust the impeller.
2. Re-adjust the impeller after 50 hours to 100 hours.
3. Re-adjust further two to three times at regular intervals during the wear life of the pump (this could
coincide with the regular maintenance intervals, for example, 500 hours).
4. After adjustment of the impeller, it is important to tighten the bearing housing clamp bolt to a given
torque value as given in the table below.
5. The amount of adjustment each service will indicate the wear rate. If the adjustment each time is
minimal the service life of the wetted components will be longer.
Table 9-1: Bearing Housing Clamp Bolt Torque

Frame Size Recommended Torque (± 10%) (Nm)

FF 300

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Bare Shaft Pump Commissioning

9.6 Tightening Nuts and Bolts

Although Weir Minerals Australia pump impellers are balanced in the factory, before they are supplied,
precise balance cannot be achieved in operation because of uneven wear which can take place. Pumps are
therefore subject to some vibration while running and this can result in loosening of some bolts. It is
recommended, therefore, that a routine maintenance program be established whereby a check is made at
regular intervals to ensure that all the fasteners are tight. To avoid any possible movement between the
bearing assembly and the base, the bearing housing clamp bolt must be always fully tightened. This check
must be carried out at the same time as when impeller adjustment is made. If any location is found where
bolts consistently loosen, Nylock nuts, or other suitable locking devices must be fitted.

9.7 Labyrinth Grease Purging

To improve the sealing properties of the labyrinths on the end covers of some types of Weir Minerals
Australia bearing assemblies, grease purging is utilised to purge out grit and moisture. Less contaminants
entering the bearing assembly results in longer bearing assembly life and ultimately cost savings. Therefore,
careful attention paid to labyrinth purging is an essential maintenance requirement. For more information,
refer to the lubrication section of this manual.

9.8 Bearing Assembly Lubrication

A correctly assembled and lubricated bearing assembly has a long trouble free life, provided it is protected
against ingress of water or other foreign matter and that it is adequately maintained.
It must be left to the good judgment of maintenance personnel, to open bearing housings at regular intervals
(not longer than 12 months) to inspect bearing assembly, to determine the effectiveness of the lubrication
program and to make any adjustments to the program for the period up to the next inspection.

NOTICE
LUBRICANT USAGE
 Use only recommended and clean oil.
 For oil lubricated bearing assemblies, it is recommended that a full oil change is
carried out at a maximum of every 6 months or 2,000 hours of operation.
 Do not use multigrade oil in the bearing assembly.

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Bare Shaft Pump Lubrication

10 Lubrication
10.1 Lubrication Safety
DANGER
FIRE HAZARD
Bearing assemblies may catch fire if bearings are not lubricated or if labyrinths are not
purged.

CAUTION
ENSURE CORRECT LUBRICATION
Some equipment such as gear reducers, motors, and oil-lubricated pump bearing
assemblies are shipped without lubricating oil. Ensure that oil of the correct grade is filled
to the correct level in each piece of equipment before startup.
Do not rely on bearing housing end cover or labyrinth greasing to provide adequate grease
to the bearings. The bearings must always be lubricated according to the
recommendations.

NOTICE
LUBRICATION
This section provides the general recommended information only.
Contact your local Weir Minerals representative for any assistance.

10.2 Recommended Intervals for Labyrinth Grease Purging

NOTICE
LABYRINTH GREASE PURGING
Always pump grease into each labyrinth end cover seal until it emerges on the outside
before starting the pump for the first time.
Labyrinth grease purging is normally carried out when the pump is running.

Table 10-1: Grease Quantities for Labyrinth Grease Purging

Labyrinth Type Frames

FF

Wet-end Labyrinth 4 Shots/12 Hours

Drive-end Labyrinth 4 Shot/120 Hours

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Bare Shaft Pump Decommissioning and Disposal

11 Decommissioning and Disposal

This section describes the decommissioning and disposal of the pump.

11.1 Decommissioning Safety

DANGER
LIFTING POINT SAFETY
 Use lifting devices to lift heavy or awkward components.
 The lifting devices must be in good condition, certified and tagged.
 The lifting devices must be of adequate capacity and must be used whenever they are
required.
 Personnel must never work under suspended loads.

DANGER
LIFTING POINT SAFETY
 Refer to Weir Minerals Australia lifting instructions at all times.
 Tapped holes (for eye-bolts) and cast-on lugs (for shackles) on Weir Minerals Australia
parts are for lifting individual parts only.
 Lifting devices of adequate capacity must be used whenever they are required.
 Safe workshop practices must be applied during all assembly and maintenance work.
 Personnel must never work under suspended loads.

WARNING
TIPPING OR FALLING
During decommissioning, ensure that the pump components are secured properly, so that
they do not fall or tip over, or cause injury.

WARNING
SHARP EDGES
Before disassembly, identify working parts that could be hazardous due to sharp edges.
Parts with sharp edges are usually, the impeller, front door, and volute. All metal
components must be considered to have sharp edges.
Worn pump components can have sharp or jagged edges. Handle worn parts carefully, to
prevent damage to slings or personnel injury.

WARNING
HAZARDOUS CHEMICALS
During disassembly, personnel may come in contact with hazardous chemicals. These
chemicals must be identified before disassembly, and the correct MSDS must be made
available and appropriate safety management precautions put in place.

WARNING
GLOVES MUST BE WORN
Cut proof gloves must be worn while handling parts with sharp edges.

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Bare Shaft Pump Decommissioning and Disposal

CAUTION
WORKING AREA SAFETY
Barricade and clearly sign the wok area.

CAUTION
FOLLOW SAFE WORKING PRACTICES
Follow safe working practices during all decommissioning and disposal work.

NOTICE
TOOLING
Only impact type sockets must be used with air or electric impact tools.

NOTICE
PERSONNEL PROTECTIVE EQUIPMENT (PPE)
Wear PPE when disassembling pumps.

11.2 Decommissioning
To decommission the bare shaft pump, Weir Minerals Australia recommends the following steps:
1. Flush the pump with clean water.
a. For large pumps, flush the pump for 15 to 20 minutes.
2. Confirm the hazards associated with the slurry last pumped and adopt necessary safety precautions.
3. Isolate the pump electrically, hydraulically, and mechanically.
4. Disconnect the pump electrically, hydraulically, and mechanically
5. Decontaminate by a static flush and drain.
WARNING
HAZARDOUS CHEMICALS
Personnel may come in contact with hazardous chemicals. Adopt necessary safety
precautions such as wearing appropriate PPE.

Follow the above procedure to make the pump ready for sale or disposal.

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Bare Shaft Pump Decommissioning and Disposal

11.3 Disposal
When a pump is sold, all pump documentation and guarding must be supplied with it. To dispose of a
complete pump unit, Weir Minerals recommends the following steps:
1. Confirm the hazards associated with the slurry last pumped.
2. Ensure that all lifting points are suitable to use.
3. Remove complete pump unit to a decontamination area.
4. Decontaminate by a static flush and drain.
5. Disassemble the main components from the baseplate.
6. Grease, oil, rubber, and urethane must be disposed under applicable waste and environmental
regulations.
7. All metal and alloys can be recycled if they are decontaminated and are not classified as hazardous
material under applicable environmental regulations.
Wet-end alloy components are valuable as scrap. Contact your local Weir Minerals representative to find out
more about recycling these components.

DANGER
MAXIMUM ALLOWABLE PUMP SPEEDS
For recommended maximum allowable pump speeds, refer to the specific pump
performance curve which takes into consideration the impeller and liner materials and the
maximum allowable peripheral velocity.

DANGER
LIFTING POINT GIVING WAY
Lifting points may be corroded and may not be fit to use by the time of disposal.

WARNING
HAZARDOUS CHEMICALS
Personnel may come in contact with hazardous chemicals. Adopt necessary safety
precautions such as wearing appropriate PPE.

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Bare Shaft Pump Troubleshooting

12 Troubleshooting
12.1 Gland Packing Problems
This section describes reasons for gland problems and the methods to troubleshoot them.

Table 12-1: Packed Gland Troubleshooting

Problem Cause Solution

• Slurry wears the packing. Upgrade sleeve to Tungsten Carbide

Short Packing life.
• Slurry wears the shaft sleeve. coated option.

Short Sleeve life. Packing overheating. Loosen the gland to increase the flow.

• Stop, cool down, repack and then start

• Worn packing. again with the correct GSW pressure
Bulk fluid exiting the gland. • Gland too loose. and flow.
• Worn shaft sleeve • Replace packing if required.
• Adjust gland follower.

• Loosen the gland.

• Pressure too high, causing packing
Flow from the gland is too low. extrusion and flow restriction. • Review packing type (Use
In the worst case, steam exits recommended Flurograph 193 or
• Gland too tight.
from the gland. equivalent packing).
• Packing too soft for high pressure.
• Use packing retainer ring.

• Shaft sleeve worn out.

Disassemble and refurbish the gland
Too much flow from the gland • Wrong size packing.
with new parts.
• Worn out packing.

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Bare Shaft Pump Special Tools

13 Special Tools
13.1 C-Spanner
This is a special tool used to tighten or remove the locking nut (left-hand threaded) on the bearing assemblies.

Figure 13-1: C-Spanner

13.2 Shaft Locking Clamp

This is a special tool used to lock the shaft during transportation and maintenance.

CAUTION
SHAFT DAMAGE
Shaft damage occurs if other tools are used to hold the shaft.

Figure 13-2: Shaft Locking Clamp

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Bare Shaft Pump Special Tools

13.3 Shaft Lifting Nut

This is a special tool used to provide a safe method of lifting the bearing shaft assembly.

Figure 13-3: Shaft Lifting Nut

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Bare Shaft Pump Appendix

14 Appendices
14.1 Fault Finding Chart
Overheating or seizure of pump

Vibration and noise from pump

Excessive horsepower required

Reduced discharge delivery

Leakage from Stuffing box

Symptoms
Short Life of bearings

Packing has short life

Insufficient Pressure

Faults
Pump loses prime

Discharge failure

1 1 Pump not primed

1 1 1 1 Pump or suction pipe not completely filled with liquid
1 1 1 1 Suction lift too high

Intake faults
1 1 1 1 Insufficient margin between suction pressure and vapour pressure
1 1 1 Excessive amount of air or gas in liquid
1 1 1 Air pocket in suction line
1 1 Air leaks into suction line
Non Return Valve too small
Non Return Valve partially clogged
1 1 Strainer partially clogged
1 1 1 1 Wet end not fully submerged
1 1 1 Speed too low
1 1 Speed too high

System Faults
1 1 1 1 Wrong direction of rotation
1 1 1 1 Total head of system higher than design
1 Total head of system lower than design
1 Specific gravity of liquid different from design
1 1 1 Viscosity of liquid differs from that for which designed
1 1 Operation at very low capacity
1 1 1 1 Entrained air in pump.
1 1 1 1 Badly installed pipe line or gaskets partly blocking pipe
1 1 1 1 Misalignment of shafts
1 Foundations not rigid
1 1 1 Shaft bent
1 1 1 1 Rotating part rubbing on stationary part
1 1 1 Bearings worn
1 1 1 1 Impeller damaged or worn
1 1 1 Casing gasket defective, permitting internal leakage
1 1 1
Mechanical Faults

Shaft running off-centre because of worn bearings or misalignment

1 1 1 Impeller out of balance, resulting in vibration
1 1 1 1 1 Foreign matter in impeller
1 1 1 Excessive thrust caused by a mechanical failure inside the pump
1 1 1 Excessive amount of lubricant in bearing housing.
1 1 1 Lack of lubrication
1 1 1 Improper installation of bearings
1 1 Dirt getting into bearings
Shaft or shaft sleeves worn or scored at the packing
1 Rusting of bearings due to water getting into housing
Packing improperly installed
Shaft running off-centre because of worn bearings or misalignment
Gland too tight, resulting in no flow of liquid to lubricate packing
Dirt or grit in sealing liquid, leading to scoring shaft sleeve
Excessive clearance at bottom of stuffing box
Incorrect type of packing for operating conditions

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