Weir Minerals Multiflo

WEIR MINERALS MULTIFLO

MULTIFLO MODEL MF-420E
DIESEL POWERED PUMP UNIT

INSTALLATION, OPERATION,
MAINTENANCE AND
SPARE PARTS MANUAL
Copyright (C) 2010, Weir Minerals Australia Ltd trading as Weir Minerals Multiflo. All rights reserved. MULTIFLO, VACTRONIC
and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd. This document contains information which is confi-
dential 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.

Revised July 2010

 Weir Minerals Multiflo

MF-420E Pump Unit

Master Index
Index
List of Figure References
ISO Certifications
Quality Management System (QMS) AS/NZS ISO 9001:2008
Environmental Management System (EMS) AS/NZS ISO 14001:2004
Occupational Health & Safety System (OHS) AS/NZS 4801:2001

Introduction
Contact Details for O.E.M.
O.E.M. Introduction
General Safety
Shaft Lock Removal
Performance Curve
Weir Minerals Australia General Conditions of Sale
Caterpillar Warranty Conditions

Part 1 Installation
Part Page
Section 1.1 Pump Unit Delivery & Storage Procedures I 1
1.1.1 Storage Procedures I 1
1.1.1.1 General Storage I 1
Section 1.2 Safety Warnings I 2
1.2.1 Bare Shaft Pump Safety I 2
1.2.2 Vacuum Pump Safety I 3
Section 1.3 Unit Lifting Points (Total Unit Mass) I 4
Section 1.4 Assembly Instructions I 6
1.4.1 Assembly of Pump and Skid I 6
1.4.2 Assembly of Pontoon I 8

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Weir Minerals Multiflo

MF-420E Pump Unit

Part 1 Installation
Part Page
Section 1.5 Installation of Suction Assembly I 18
Section 1.6 Fitting Pontoon Handrails (where applicable) I 21
Section 1.7 Discharge Pipework Installation I 22
Section 1.8 Installation & Removal Sequences I 22
1.8.1. Moving and Locating the Pump Unit I 22
1.8.1.1 Pump Site Preparation I 23
1.8.1.2 Moving the Pump Unit I 23
1.8.1.3 Preparation for Towing I 24
1.8.1.4 Procedures for Moving, Locating & Launching I 25
1.8.1.5 Procedure for Towing I 25
1.8.1.6 Positioning and Launching I 26
1.8.1.7 Incorrect Pump Unit Positioning I 28
1.8.1.8 Correct Pump Unit Positioning I 29
1.8.1.9 Pumping Operation Observations I 30
1.8.2 Installation Checks I 31
1.8.2.1 Direct Coupled Units I 31

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Weir Minerals Multiflo

MF-420E Pump Unit

Part 2 Operation
Part Page
Section 2.1 Introduction II 1
2.1.1 General Information & Safety II 1
2.1.2 General Safety Recommendations II 2
2.1.3 General Description & Function of Equipment II 3
2.1.3.1 Operation II 3
2.1.4 Orientation of Major Unit Components II 4
Section 2.2 Normal Operating Procedures II 5
2.2.1 Daily Pre-Start Checks II 6
2.2.1.1 Engine Oil II 6
2.2.1.2 Bare Shaft Pump Auto Lubrication System II 6
2.2.1.3 Vacuum Pump Oil II 6
2.2.1.4 Gland Oil Tank II 6
2.2.1.5 Coolant Level II 6
2.2.1.6 Fuel Tank II 6
2.2.1.7 Battery II 6
2.2.1.8 Drive Belts II 6
2.2.1.9 Water Trap II 6
2.2.1.10 Air Cleaner Indicator II 6
2.2.1.11 Suction Strainer II 6
2.2.1.12 Probes II 6
2.2.2 Starting Procedures II 7
2.2.2.1 Post Start Up Procedure II 7
2.2.2.2 Operating Speed II 7
2.2.2.3 Cavitation II 8
2.2.3 Shutdown Procedure II 9
2.2.4 Shutdown Protection II 9
2.2.4.1 Pump Shutdown System II 9

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MF-420E Pump Unit

Part 2 Operation (Continued)
Part Page
Section 2.3 Detailed Description of Components II 10
2.3.1 Model 420 Bare Shaft Pump II 10
2.3.2 Model 57 Piston Type Vacuum Pump II 13
2.3.2.1 Model 57 Parts Assembly II 14
2.3.2.2 Model 57 Specifications II 14
2.3.3 Vacuum Tank II 15
2.3.4 Vacuum Gauge II 16
2.3.5 Non Return “Vooom” Valve II 17
2.3.6 Vactronic Vacuum Prime System II 20
2.3.7 First Out Indication Panel II 22
2.3.8 1000FH Turbine Series Fuel Filter / Water Separator II 24
2.3.8.1 Overview II 24
2.3.8.2 Installation Instructions II 25
2.3.8.3 Priming Instructions II 28
2.3.8.4 Specifications II 29
2.3.9 Engine Monitoring System II 29
Section 2.4 Electrical II 30
2.4.1 Electrical Drawings / Schematics II 30
Unit Schematic Wiring Diagrams
(Please refer to Unit Specifics at rear of the Manual)
2.4.2 Monitoring Instruments II 31
2.4.2.1 Sensor / Modules II 31

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Weir Minerals Multiflo

MF-420E Pump Unit

Part 3 Maintenance
Part Page
Section 3.1 Normal Maintenance Procedures III 1
3.1.1 Safety Procedures III 1
3.1.2 Disassembly & Assembly Procedures III 2
3.1.2.1 Model 420E Bare Shaft Pump Assembly Procedure III 3
3.1.3 Maintenance – Model 420E Bare Shaft Pump III 15
3.1.3.1 Bare Shaft Pump Gland III 15
3.1.3.2 Impeller III 18
3.1.3.3 Lubrication – Bare Shaft Pump Bearings III 18
3.1.3.4 Lubrication – Bare Shaft Pump Bearings III 23
420E Hydraulic Circuit
3.1.3.5 Lubrication – Bare Shaft Pump Labyrinth Seals III 24
3.1.4 Maintenance – Model 57 Piston Vacuum Pump III 27
3.1.4.1 Vacuum Pump Piston & Re-Ringing Instructions III 27
3.1.4.2 Assembly of a 3 Piece Oil Ring Assembly III 28
3.1.5 Maintenance – Drive Components III 32
3.1.5.1 Drive Belt Tensioning III 32
3.1.5.2 Installation & Operation of Wedge & ‘V’ Belt Drives III 34
3.1.5.3 Taperlock Bushes III 37
3.1.5.4 Taperlock Flanges III 41
3.1.5.5 Tyre Couplings III 42
3.1.5.6 1000FH Series Fuel Filter / Water Separator III 45
Service Instructions
Draining Water III 45
Vacuum Application / Installations III 45
Pressure Applications / Installations III 45
Element Replacement III 45
All Applications III 46
Replacement Parts III 47

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Weir Minerals Multiflo

MF-420E Pump Unit

Part 3 Maintenance (Continued)
Part Page
Section 3.1 Normal Maintenance Procedures (continued)
3.1.6 Frequency of Routine General Maintenance III 49
3.1.6.1 Every 10 Engine Hours or Daily III 49
3.1.6.2 Every 250 Engine Hours III 50
3.1.6.3 Every 500 Engine Hours III 51
3.1.6.4 Every 1000 Engine Hours III 51
3.1.6.5 Every 2000 Engine Hours III 52
Section 3.2 Troubleshooting III 53
3.2.1 Finding & Diagnostic Guide (Including Details of III 53
Normal Readings)
3.2.1.1 Pump Unit Troubleshooting III 53
3.2.1.2 Vacuum Pump III 59
3.2.1.3 Vee Belt Troubleshooting III 61
3.2.1.4 Hydrau-Flo Troubleshooting III 61
3.2.1.5 Hydraulic Pump Troubleshooting III 63
3.2.1.6 1000FH Turbine Series Fuel Filter / Water III 64
Separator Troubleshooting (If Fitted)
Section 3.3 Lubrication Schedule III 67
3.3.1 Grades/Recommended Lubricants & Frequency III 67

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 Weir Minerals Multiflo

MF-420E Pump Unit

Part 4 Spare Parts - Standard
Part Page
Major Components IV 1
Bare Shaft Pump IV
420E Bare Shaft Pump IV 3
420E Bearing Assembly IV 4
420E Shaft Sleeve & Gland Packing IV 6
420E Wetted Parts IV 7
420E Gland Guard IV 8
Priming System IV
Priming Assembly IV 9
Probes IV 10
Model 57 Piston Vacuum Pump IV 11
Vacuum Pump “Robatic” Clutch (24 volt) IV 17
Vacuum Pump Pulley IV 18
Vacuum Pressure Gauge IV 19
Vacuum Pump Mounting Plate IV 20
Drive Components IV
Drive Assembly IV 21
Electrical IV
Battery Box IV 22
Control Box IV 23
Emergency Stop IV 29
Isolators IV 30
Lubrication & Service Points IV
Gland Oil Tank Assembly IV 31
Bare Shaft Pump Hydraulic System IV 32
Hydrau-Flo Valve IV 35
High Wall Filler IV 36
Fuel Float Switch Assembly IV 37
Fuel Fillers IV 38
Fuel Filters IV 39

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 Weir Minerals Multiflo

MF-420E Pump Unit

Part 4 Spare Parts

Part Page
Suction Components
Suction Assembly IV 40
Discharge Components
Discharge Assembly 41
Non Return “Vooom” Valve 43
Discharge Inspection Tee Assembly 44
Standard Options
Worklights 45
Fire Extinguisher 46
Washdown Hose 47
Strobe Light 48

Spare Parts Supplement

Technical Bulletin Document TB-2010-06 relating to 8/6 FFY-HX Oil Lubricated
Bearing Assembly Seal Upgrade

Part 5 Unit Specific Information Appendices

Unit Data
Unit Mass & Dimensions
Specific Spare Parts
Wiring Diagram
List of Accompanying Manuals

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 Weir Minerals Multiflo

MF-420E Pump Unit

List of Figures
Figure Description Part Page
Ref No
Part 1 - Installation & Commissioning
1 Unit Lifting Points I 4
2 Skid Chassis Lifting Points I 5
3 Installing Pump Onto Skid Chassis I 7
4 Pontoon Centre Hull Identification I 8
5 Left Hand Pontoon Hull with Locating Pin & Mounting Pedestal I 9
Identification
6 Left Hand Pontoon Hull Bolting Points I 10
7 Right Hand Pontoon Hull with Locating Pin & Mounting Pedestal I 11
Identification
8 Right Hand Pontoon Hull Bolting Points I 12
9 Pump Unit Base Mounting Pad Indication Points I 13
10 Positioning the Pump Set Over the Mounting Pads I 14
11 Alignment of Pump Set Bolt Holes with Mounting Pad Bolt Holes I 15
12 Non Return Valve with Inspection Plate in the ‘Up’ Position I 16
13 Where to Install the Non Return Valve I 16
14 Non Return Valve Installed on the Pump Set I 17
15A Fitting the Suction Boom I 18
15B Fitting the Reducer and the Hose I 18
15C Insertion of Boom Locking Bolts I 18
16 Attaching Winch Rope to Boom Pulley I 19
17 Fitting the Winch Rope I 19
18A Fitting the Boom Chains I 20
18B Fitting the Suction Strainer I 20
19 Fitting the Left Hand Side Handrail I 21
20 Fitting the Right Hand Side Handrail I 21
21 Blade Contact Point on Pump Push Bar I 27
22 Blade Contact Point on Pontoon Push Bar I 27
23 Incorrect Pump Position Examples I 28
24 Correct Pump Position Examples I 29

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Multiflo Model 420E – List of Figures
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 Weir Minerals Multiflo

MF-420E Pump Unit

List of Figures
Figure Description Part Page
Ref No
Part 2 - Operation
25 Pump Unit Orientation Guide II 4
26 Resulting Effects of Continuous Cavitation II 8
27 Bare Shaft Pump Wetted Parts II 11
28 Bare Shaft Pump Bearing Housing II 12
29 Bare Shaft Pump Pedestal Assembly II 12
30 Model 57 Piston Vacuum Pump Major Components II 13
31 Vacuum Tank II 15
32 Vacuum Gauge II 16
33 Non Return “Vooom” Valve – Flap in Closed Position II 18
34 Non Return “Vooom” Valve – Flap in Open Position II 19
35 Vactronic Circuit Diagram II 21
36 First Out Indication Panel II 23
37 1000FH Turbine Series Fuel Filter / Water Separator II 24
38 Fuel Filter / Water Separator Mounting Instructions II 25
39 Fuel Filter / Water Separator Installation Instructions II 27

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 Weir Minerals Multiflo

MF-420E Pump Unit

List of Figures
Figure Description Part Page
Ref No
Part 3 - Maintenance
40 Model 420E Bare Shaft Pump Frame Assembly III 3
41 Bare Shaft Pump Gland Assembly III 5
42 Bare Shaft Pump Impeller & Bowl Assembly III 7
43 Bare Shaft Pump Bearing Assembly III 8
44 Bare Shaft Pump Volute Assembly III 10
45 Bare Shaft Pump Sectional Drawing III 10
46 Bare Shaft Pump Complete Assembly III 11
47 Bare Shaft Pump Complete Sectional Assembly III 12
48 Packing Removal Tool III 16
49 Bare Shaft Pump Bearing Hydraulic Oil Filter and Pressure III 19
Relief Valve
50 Bare Shaft Pump Bearing Hydraulic Oil Tank Main III 21
Components
51 Bare Shaft Pump Bearing Hydraulic Oil Hoses III 22
52 Bare Shaft Pump Hydraulic Circuit III 23
53 Electro-Luber Component Identification III 24
54 Electro-Luber Starting & Programming III 25
55 Electro-Luber Timer Settings for 420E Labyrinth III 26
56 Electro-Luber III 26
57 Vacuum Pump Winding on Piston Oil Ring Expander III 28
58 Vacuum Pump Upper & Lower Rail of Expander III 29
59 Vacuum Pump Upper & Lower Rail Gap III 29
60 Vacuum Pump Correct Fitment of Compression Rings III 30
61 Vacuum Pump Incorrect Fitment of Compression Rings III 30
62 Vacuum Pump Correct Expansion Method for Compression III 31
Rings
63 Vacuum Pump Correct Ring Back Clearance III 31

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 Weir Minerals Multiflo

MF-420E Pump Unit

List of Figures
Figure Description Part Page
Ref No
Part 3 – Maintenance (continued)
64 Belt Tensioning Indicator Operation III 32
65 Belt Tensioning Indicator III 33
66 Belt Alignment III 35
67 Taperlock Bush Removal III 37
68 Taperlock Bush Insertion into Hub III 38
69 Taperlock Bush Insertion onto Shaft III 38
70 & 71 Screw Torque Settings III 39
72 Taperlock Flange Dimension Chart III 41
73 Table 1 – Internal Clamp Ring Torque III 43
74 Table 2 – Internal Clamp Ring Torque III 44
75 Fuel Filter / Water Separator Parts Identification III 47
76 Vacuum Gauge – High Reading III 53
77 Vacuum Gauge – Low Reading III 54
78 Vacuum Gauge – Normal Operating Range III 54
79 Correct Replacement of Vacuum Pump Crank Seal III 60
80 Fuel Filter / Water Separator Troubleshooting Hints III 66

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ISO CERTIFICATIONS
Introduction
 Weir Minerals Multiflo

Original Equipment Manufacturer

Contact Details

For all information regarding your

Weir Minerals Multiflo Pump Unit
please contact:-

In Indonesia:-

PT Weir Minerals Multiflo

Jl Mulawarman No 29A RT
003 Batakan Kecil Kelurahan Manggar
Balikpapan 76117
East Kalimantan
Indonesia

Ph: 62 542 746098

Fax: 62 542 746099

Or

Banjarbaru Branch Office

Jl. Ahmad Yani Km 33,6 Ruko No. 04 RT.
003 RW.001 Kelurahan Loktabat Selatan
Banjarbaru 70712
South Kalimantan
Indonesia

Ph: 62 511 4773027

62 511 4772357
Fax: 62 511 477 3583

O.E.M. Contact Details

(Always Quote Unit Model and Serial Number when Requesting Information and when Ordering Parts)
 Weir Minerals Multiflo

In Australia:-
Queensland (Bowen Basin)
Weir Minerals Multiflo Authorised Dealer
For Service, Repair and
Spare Parts Supply

NQ Water Services
319 Nebo Road Mackay Qld.
Ph: 07 4952 2252
Fax: 07 4952 2126
Email: [email protected]
Or
Rockhampton Authorised Service Provider
Weir Minerals Service Centre
80 McLaughlin Street
North Rockhampton QLD 4701
Ph:
Ph: 07 4924 7700
Fax:
ax: 0 7 4924 7799
[email protected]
Or
Head Office
Weir Minerals Multiflo
15 Dacmar Road
Coolum Beach Qld 4573
Ph: 07 5449 3032
Fax: 07 5446 4304
Email: [email protected]

O.E.M. Contact Details

(Always Quote Unit Model and Serial Number when Requesting Information and when Ordering Parts)
 Weir Minerals Multiflo

Introduction
The purpose of this Manual is to advise and instruct installers, operators and
repairers of the Weir Minerals Multiflo Pump Unit in the recommended installation,
operation and maintenance of this equipment. You have purchased a quality product
which has been manufactured with utmost care and the finest materials, reflecting
many years of engineering knowledge and design.

The following information will aid you in the installation, operation and maintenance
of your new Weir Minerals Multiflo Pump Unit. To ensure long life and trouble-free
operation, you should read and understand these instructions and provide regular,
periodic maintenance.

The Pump Unit is of a 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 operated, the pump unit will give long, trouble
free service with a minimum amount of maintenance. To achieve the consistent high
performance which Multiflo pumps are designed for, it is imperative that the
instructions contained in these manuals are read, understood and carried out by all
users of this product.

1
Introduction
Weir Minerals Multiflo

MULTIFLO PUMPS
EXCELLENCE THROUGH DESIGN
EXCELLENCE THROUGH ENGINEERING
EXCELLENCE THROUGH PERFORMANCE

2
Introduction
 Weir Minerals Multiflo

Safety

The Weir Minerals Multiflo 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 Pump Unit has been designed to provide a safe working

environment for operators, maintenance personnel and others.

Improper operation, installation, maintenance or repair of this

equipment could result in injury or death.

Do not operate or perform any operation, installation, maintenance

or repair on this product, until you have read and understood the
operation, installation, 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.

SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THE

SUPPLIED DOCUMENTATION. FAILURE TO HEED THESE
WARNINGS AND PRECAUTIONS MAY RESULT IN PERSONAL
INJURY AND/OR DEATH TO YOURSELF AND/OR OTHERS.
FAILURE TO HEED THESE WARNINGS MAY ALSO RESULT IN
EQUIPMENT AND ENVIRONMENTAL DAMAGE.

1
Weir Minerals Multiflo – Pump Unit General Safety
 Weir Minerals Multiflo

Safety Symbols

The accompanying documentation supplied with the Weir Minerals

Multiflo Pump Unit utilises the following safety symbols to highlight
potentially harmful situations to personnel and the environment.

SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES

Fatal or crippling
DANGER ! Imminent risk of Persons
injuries likely to
fatal or crippling
result from any
injuries
exposure

WARNING ! Risk of fatal or Persons Fatal or crippling

crippling injuries injuries possible

CAUTION ! Possibility Persons Minor or slight

of a harmful injuries possible
situation

Possibility Property Damage possible

ATTENTION ! of a harmful and or the to the product or
situation Environment the Environment

Application
INFORMATION ! Hints and other Nil Nil
useful
Information

2
Weir Minerals Multiflo – Pump Unit General Safety
Weir Minerals Multiflo

WARNING!

REMOVE SHAFT LOCKS

(IF FITTED)
FROM BARE SHAFT PUMP
AND/OR
ELECTRIC MOTOR BEFORE
START-
START-UP

Shaft Lock Removal

(Always quote Model and Serial Number of Unit when Ordering Parts)
 WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802

GENERAL CONDITIONS OF SALE

1. APPLICATION 6.2 Any times quoted for delivery are to be treated as best estimates
Until such time as Weir Minerals Australia Ltd ABN 69 009 701 802 or a only, not involving any contractual obligation, unless Weir has
related company of Weir Minerals Australia Ltd which applies these General specifically agreed in writing to negate this Clause 6.2 and to give a
Conditions of Sale to its sales (“Weir”) notifies a customer (“Purchaser”) of contractually binding commitment that dispatch or delivery will be
replacement General Conditions of Sale, these General Conditions of Sale within a specified time or on or by a specified date.
shall form part of any contract for the sale of goods (“Goods”) or supply of
6.3 Any contractually binding commitment by Weir to deliver on or by a
services (“Services”) by Weir to Purchaser, except as varied by written
specific date is subject to the provisions of Clause 18.3 below and
agreement between Weir and Purchaser. Conditions or terms of contract
also subject to Weir not being delayed by instructions or lack of
submitted by Purchaser in or with a purchase order or request for quotation
instructions from the Purchaser. The times quoted shall be
or other document or communication do not form part of any contract with
increased by the duration of any event of force majeure and by the
Weir unless and to the extent agreed to by Weir in writing.
period or periods of any such delay and any consequences of the
2. QUOTATIONS delay.
A quotation by Weir may be withdrawn or varied at any time, prior to
6.4 Weir may make delivery of and invoice any order either as a whole
acceptance by Weir of an order, and ceases to have any effect after 30
or progressively and effect delivery at any time within the period
days from the date of the quotation unless extended in writing by Weir.
advised by it for delivery of the order. If the Purchaser requests
Prices quoted are subject to variation in accordance with clause 5.
Weir to delay delivery or fails to give Weir adequate delivery
3. ACCEPTANCE OF ORDERS instructions, Weir may invoice the Purchaser and store the goods at
Weir is not bound by any order from Purchaser until and unless Weir the Purchaser’s expense.
notifies Purchaser in writing of its acceptance of that order.
7. RISK & INSURANCE
4. TERMS OF PAYMENT Insurance cover is the responsibility of the Purchaser and all Goods will be
4.1 Unless other terms of payment are expressly provided for by Weir, at the Purchaser’s risk from the point of delivery as defined in Clause 6.
invoices are payable strictly net within 30 days from the invoice date Weir will not be responsible for any loss or damage occurring after the time
or the date on which Purchaser is notified that the Goods are ready of delivery or deemed delivery and will only arrange insurance upon written
for dispatch, whichever is the earlier. instructions from the Purchaser and at the cost of the Purchaser.
\

4.2 The due date for payment shall not be postponed on account of 8. AMENDMENT AND CANCELLATION
damage, non delivery or additions, alterations, minor omissions or The Purchaser shall not, after acceptance of order, cancel or amend it in
defects to, from or in the Goods which do not substantially affect the any way without the written approval of Weir. Weir may, on consenting to
commercial use of the Goods. Payments must be made without an amendment, revise its price and delivery schedule and amend the terms
setoffs, counter-claim or deduction. and conditions to reflect such change. In the event of an amendment or
cancellation, the Purchaser shall reimburse Weir for all costs and expenses
5. PRICES & TAXES
already incurred by Weir or for which Weir has or will become liable, and for
5.1 GST All prices quoted are exclusive of GST. In addition to the
any additional costs and expenses resulting from the amendment or
payment of the prices quoted, Purchaser must pay to Weir an
cancellation.
amount equal to any GST imposed on Taxable Supplies made by
Weir to the Purchaser. Weir must give the Purchaser a Tax Invoice The specification by Weir of any particular personnel, in any quotation or
in respect of each such Taxable Supply. “Taxable Supply”, “GST” tender, is subject to availability of those personnel and Weir reserves the
and “Tax Invoice” have the same meanings as in the A New Tax right to substitute any nominated personnel at any time.
System (Goods and Services Tax) Act 1999. If the Purchaser
9. DEFAULT
intends to export the Goods, so that Weir will be exempt from GST
If the Purchaser makes default in payment or fails to carry out any part of
in respect of its supply of the Goods, it must provide Weir with
any contract of which these General Conditions of Sale form part or shall
copies of the shipping documents, and such other documentation as
become bankrupt or commit any act of bankruptcy or compound with its
Weir may reasonably require, within 60 days after the date of Weir’s
creditors or have judgment entered against it in any court or, being a
invoice, otherwise an amount equal to the GST will be payable by
company, have a provisional liquidator, receiver or manager appointed or
the Purchaser to Weir.
enter into any other form of insolvency administration, Weir may at its option
5.2 Unless otherwise specified in writing by Weir, all prices quoted are and without prejudice to any of its rights and remedies under the contract,
ex works (the location specified by Weir in its tender or quotation), suspend or terminate the contract or require payment in cash before or on
unpacked, and all costs of freight and delivery from Weir works, and delivery notwithstanding any other terms of payment specified in the
packing, will be to the Purchaser’s account. contract. If Weir terminates the contract pursuant to this clause, all amounts
payable for work performed up to the date of termination, whether or not
5.3 Where Goods or raw materials or components for Goods are to be
otherwise then due for payment, will become immediately due and payable.
imported:
Weir will not be liable to the Purchaser for any loss or damage the
(a) the quoted prices for those Goods are based on the foreign
Purchaser suffers because Weir has exercised its rights under this clause.
currency rate of exchange disclosed in Weir’s quotation and if
no rate of exchange is disclosed, are based on the 10. RETURN OF GOODS
Commonwealth Bank of Australia Foreign Exchange Rates, Weir may, at its absolute discretion, agree to accept the return of any of
published on the date of the quotation. Goods which have not been made or purchased specifically for the
Purchaser and credit the Purchaser with the invoice value of the Goods
(b) unless otherwise specified in writing by Weir, the quoted prices
provided the Goods is returned in “as purchased” condition and the prior
shall be adjusted upwards or downwards as the case may be
written approval of Weir has been obtained by the Purchaser for the return
to reflect the difference between the base rate of exchange
of the Goods. Weir reserves the right to charge a restocking fee for the
referred to in (a) and the actual rate of exchange prevailing on
return of Goods to stock.
the day Weir remits the foreign currency amount for the Goods
or raw materials or components, or if Weir hedges the order for 11. WARRANTIES
the Goods or raw materials or components, the rate hedged by 11.1 New Goods If within a period of 12 months from the date of delivery
Weir and advised to the Purchaser in writing prior to Weir’s (or in the case of diesel-operated pumps, within the first 1,000 hours
remitting the foreign exchange currency amount. of operation, whichever first expires) (“warranty period”) any new
Goods sold by Weir (other than purchased equipment as referred to
5.4 Any increases in the rate of GST, any increases in customs duty on
in Clause 11.4) are found to be defective in materials or
imported Goods or raw materials or components for Goods (whether
workmanship, or do not conform to any applicable drawings and
because of a change in the Customs Tariff Classification and/or
specifications approved in writing by Weir, or (in the case of Goods
rate), and any new carbon trading or emissions trading or other
which are Weir-manufactured pumps) do not perform in accordance
levies, imposts, duties or taxes, applicable to or impacting on the
with the current applicable water performance curves supplied as
cost to Weir of the Goods or Services, between the date of Weir’s
part of the Weir quotation or published by Weir as at the date of the
tender or quotation and the date of invoice, will be to Purchaser’s
quotation (within the tolerances specified in applicable Australian
account, and will be payable by Purchaser within 30 days from the
Standards), then Weir will, at its option, either repair or provide
date of Weir’s invoice.
replacement parts or Goods provided that:
6. DELIVERY & STORAGE (a) the Purchaser has given written notice to Weir of any alleged
6.1 Delivery shall be deemed to occur when the Purchaser is informed defect within the warranty period;
by Weir that the Goods are ready for collection at Weir’s works. (b) the Purchaser has provided Weir a reasonable opportunity to
perform all appropriate tests on the Goods;
April 2009 Page 1 of 3
 WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802

GENERAL CONDITIONS OF SALE

(c) the defective Goods or parts are promptly returned to a and whether or not such loss or damage was foreseeable.
designated Weir service centre. Any defective Goods or parts The term "consequential damages" in these General
replaced will become Weir property and the repaired or new Conditions of Sale shall include, but not be limited to,
Goods or parts will be delivered free to the Purchaser’s site; economic loss including loss of actual or anticipated
and profits, business interruption, loss of use, revenue,
(d) no warranties are given by Weir as to the water performance of reputation and/or data, .increased cost of working, loss or
pumps other than in a test facility designated by Weir. damage to equipment or other property, and liabilities of
the Purchaser to its customers or third persons.
11.2 Repaired Goods For repaired Goods, the warranty period is 6
months from the date of repair and shall only apply to Goods or 12. INDEMNITIES
parts repaired or replaced by Weir. No separate warranty shall Subject to clause 11, the Purchaser indemnifies and holds Weir
apply to repaired Goods as a whole or to parts not repaired or harmless from and against all liabilities, losses, damages, costs or
replaced by Weir. expenses incurred or suffered by Weir and from and against all
actions, proceedings, claims or demands made against Weir, arising in
11.3 Exceptions The warranties given by Weir in 11.1 and 11.2 above
either case as a result of:
do not cover:
(a) the Purchaser’s failure to comply with any laws, rules,
(a) Fair “wear and tear”, or failures or damage not reported to Weir
standards or regulations applicable in relation to the Goods or
within the warranty period.
Services or the use of the Goods or Services;
(b) Failures or damage due to misapplication, abuse, improper
(b) any use of the Goods or Services contrary to any instructions
installation or abnormal conditions of operation.
or warnings given by Weir;
(c) Failures or damage due to operation, either intentional or
(c) any other negligence or any breach of duty by the Purchaser;
otherwise, above or below rated capacities or in an otherwise
(d) any compliance or adherence by Weir with any instructions by
improper manner.
the Purchaser in relation to the Goods or Services or their
(d) Failures or damage resulting from Goods which have been in
manner of preparation or delivery; or
any way tampered with or altered by anyone other than an
(e) any failures resulting from the incorporation of, or failure of,
authorised representative of Weir.
non-Weir manufactured or supplied parts in the Goods.
(e) Goods damaged in shipment or without the fault of Weir.
(f) Failures or damage resulting from the incorporation of, or 13. DRAWINGS AND SPECIFICATIONS
failure of, non-Weir Mineral manufactured or supplied parts in 13.1 All descriptions, specifications, drawings and particulars of weights
the Goods. and dimensions attached to or submitted with any quotation or
tender are approximate only and the descriptions and illustrations
11.4 Purchased Equipment Weir does not warrant any equipment or
contained in Weir’s catalogues, price-lists and other advertisement
other goods of other manufacturers which is designated by the
matter, are intended merely to present a general idea of the Goods
Purchaser or purchased by Weir for resale to the Purchaser either
or the Services described therein, and none of these shall form part
separately or as a part of or operating in conjunction with equipment
of any contract between Weir and the Purchaser.
or other goods manufactured by Weir. For such equipment or other
goods, the Purchaser must rely on the warranty given by the 13.2 Only such descriptions, specifications, drawings and particulars of
manufacturer of the equipment or other goods. weights and dimensions as are specifically agreed by Weir in writing
to form part of the contract shall do so. The designs and
11.5 Supply of Services When Weir supplies Services to the Purchaser
information concerning the Goods or the Services and as contained
including laboratory testing, process development, equipment on any drawings which are supplied must not be disclosed to a third
selection, design (as part of design and manufacture), detail, party without Weir’s prior written consent.
contract supervision and contract management, Weir shall exercise
due care and skill in undertaking such Services. 14. INSPECTION AND TESTING
14.1 Representatives of the Purchaser approved by Weir will be given
11.6 Limitation of Liability
access to Weir’s works or another site designated by Weir during
(a) Subject to 11.6(b), Weir’s total liability under any contract of normal office hours, for the inspection of the Goods and (subject to
which these General Conditions of Sale form part shall in no 14.2 and 14.3) for any testing of the Goods which is specified in the
event exceed the total price of the Goods and/or Services scope of works attached to or referred to in Weir’s quotation, in
supplied. order to ensure compliance with specification. The Purchaser must
(b) If any term, condition or warranty is implied into these General make appointments for those inspections through Weir’s nominated
Conditions of Sale by law, and cannot be excluded or modified, representative, giving at least 5 days’ written notice (or such shorter
then the term, condition or warranty shall be deemed to be period as may be agreed by Weir), and must be accompanied on
included in these General Conditions of Sale and the such inspections by Weir personnel or other persons designated by
exceptions and limitations in 11.1 to 11.5 do not apply to such Weir.
statutory rights and remedies, Provided That Weir’s liability for 14.2 Where practicable, Weir will subject Goods to Weir’s standard tests
a breach of any such term, condition or warranty, including any before delivery. If tests other than Weir’s standard tests are
consequential loss which the Purchaser may sustain, shall be required, these, unless otherwise agreed, shall be conducted at
limited, at the option of Weir, to either replacing or repairing the Weir’s nominated place of works or at some other place nominated
Goods or, in the case of Services, to supplying the Services by Weir in its sole discretion and may at its option be charged for as
again. extras. Any such charges will be payable by Purchaser within 30
(c) Subject to 11.6(b): days from the date of Weir’s invoice.
(i) All conditions, warranties, terms, undertakings, 14.3 If the Purchaser or its representative fails or is unable to attend the
representations and obligations, not expressly set out in
tests after being given notice by Weir of not less than 7 days that it
these General Conditions of Sale or in any written is ready to carry out the tests referred to in 14.1 and/or 14.2, the
contract of which these General Conditions of Sale form tests will proceed in the absence of the Purchaser or its
part, whether arising under statute, common law, equity, representatives.
custom, trade usage or otherwise (including without 14.4 The water performance of Weir-manufactured pumps in accordance
limitation, any implied condition, warranty, term or with 11.1 above can be verified where required by the Purchaser
representation as to the correspondence of the Goods or with water performance tests carried out in a test facility designated
Services with any contract description or as to by Weir. Additional charges and delivery extension apply if this
merchantable quality, fitness for any purpose or safety of verification is required.
the Goods or Services, or operating performance where
such performance is conditional on empirical factors or on 15. INTELLECTUAL PROPERTY RIGHTS
the whole installation or on the individual or overall 15.1 Weir is the owner of certain patents and registered designs as well
operation or on the skills of an operator), whether made as other intellectual property rights, including, but not limited to,
known or not and any liability of Weir to compensate or copyright (together the “Intellectual Property Rights”). Weir has also
indemnify any person or persons in respect of the made certain applications for patents. The Purchaser must not
foregoing, are expressly negatived and excluded; directly or indirectly manufacture or purchase from any third party
(ii) In no event shall Weir be liable for any special, indirect, the subject matter of the Intellectual Property Rights or the patent
consequential, incidental or punitive losses or damages applications, or in any way infringe the Intellectual Property Rights
whether in contract, tort (including without limitation or patent applications. The Intellectual Property Rights remain at all
negligence), equity, under statute or on any other basis, times the exclusive property of Weir.
April 2009 Page 2 of 3
 WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802

GENERAL CONDITIONS OF SALE

paid in full for the Goods and for all other goods supplied by Weir.
15.2 Weir retains ownership of the copyright and all other intellectual
Notwithstanding this paragraph, the Purchaser shall not represent
property rights in all drawings, manuals and other documents and
to any third parties that it is in any way acting for Weir and Weir will
materials provided to the Purchaser in connection with the Goods
not be bound by any contracts with third parties to which the
and/or Services. The Purchaser may only use such documents and
Purchaser is a party.
materials for its own internal business purposes and to the extent
necessary for it to enjoy the benefit of the Goods and/or Services, 17.5 If any payment by the Purchaser to Weir is overdue, in whole or in
and may not disclose any of them to any third party without the prior part, or the Purchaser is otherwise in default under any contract
written consent of Weir, which may be granted or withheld in the with Weir, or the Purchaser shall become bankrupt or commit any
absolute discretion of Weir. act of bankruptcy or compound with its creditors or have judgment
entered against it in any court or, being a company, have a
15.3 The Purchaser must keep confidential all information contained in
provisional liquidator, receiver or manager appointed or enters into
all drawings, manuals and other documents and materials provided
any other form of insolvency administration, all sums then owing by
by Weir to the Purchaser in connection with the Goods and/or
the Purchaser to Weir in respect of the Goods or in respect of other
Services, except to the extent that such information is in or comes
goods supplied by Weir shall become immediately due and payable
into the public domain otherwise than through any act or omission
and Weir may (without prejudice to any of its other rights) recover
of the Purchaser. It must only disclose such information to its
and resell the Goods and any other goods supplied by Weir and
employees, directors and advisers on a need-to-know basis.
may, for that purpose, enter upon the Purchaser’s premises by its
15.4 Where and to the extent that the Goods or the Services ordered servants or agents, and Weir is irrevocably authorised to effect such
have been designed by the Purchaser, the Purchaser is liable for entry, including the use of such reasonable force as is necessary to
and agrees to indemnify Weir against any and all costs, expenses, effect such entry, and to use the name of the Purchaser and to act
liabilities and losses suffered or incurred by Weir arising from any on behalf of the Purchaser, if necessary, to recover possession of
claims of infringement or alleged infringement of any third party’s the Goods and any other goods supplied by Weir and to detach the
intellectual property rights. Goods and any such other goods from any other object to which the
Goods have been attached or of which the Goods form a
15.5 Where the Goods or the Services supplied are designed by Weir
constituent part.
and are found by a Court to have breached a third party’s
intellectual property rights, Weir shall have the right to do such 18. GENERAL
things as are necessary to remedy that breach. 18.1 Non-waiver The fact that Weir fails to do, or delays in doing,
something it is entitled to do under any contract of which these
16. DISPUTE RESOLUTION
General Conditions of Sale form part, does not amount to a waiver
16.1 If any dispute arises between the Purchaser and Weir in relation to
of any right or remedy with respect to any existing or subsequent
or in connection with a sale or supply of Goods or Services by Weir
breach or default.
to the Purchaser, they will use their best endeavours to resolve that
dispute in a spirit of good faith and on a commercially realistic basis 18.2 Severability If any provision of any contract of which these General
by mutual negotiation or by mediation prior to commencing litigation Conditions of Sale form part is void, voidable, illegal or
proceedings. unenforceable it shall be severed from the contract but without in
any way affecting the effectiveness, validity, legality or enforceability
16.2 Any mediator shall be an independent person chosen by the parties
of the remaining provisions of the contract.
or, at their request, nominated by the Australian Commercial
Disputes Centre. Each party shall bear its own costs. Any mediation 18.3 Force Majeure Weir shall not be considered in default or liable if
shall take place in Sydney. The costs of the mediator shall be borne there is any failure to perform or delay in performing any of its
by the parties equally. obligations under any contract of which these General Conditions of
Sale form part, to the extent that such failure or delay is due to an
16.3 If any dispute, controversy or claim has not been resolved within 30
event of force majeure, but Weir shall use all reasonable
days after written notice from one party to the other giving details of
endeavours to cure such event (if curable) and to comply with its
the dispute, controversy or claim, each party will be entitled to seek
obligations under that contract, and as soon as any such event
relief from an appropriate court.
ceases to affect the performance of its obligations under that
16.4 This Clause 16 does not prevent either party from seeking or contract Weir shall use all reasonable endeavours to resume
obtaining from a court any injunctive or other interlocutory relief compliance with such obligations. In these General Conditions of
which it may urgently require. Sale, an “event of force majeure” means any act of God or other
occurrence outside the reasonable control of Weir including, but not
17. RETENTION OF TITLE
limited to, war (whether declared or not), acts of public enemies,
17.1 The Goods shall remain the sole and absolute property of Weir as
industrial disputes, strikes, lock-outs, accidents, hurricanes, fire and
legal and equitable owner, and the property in and title to the Goods
flood.
shall not pass from Weir to the Purchaser until the Purchaser has
paid Weir in full for the Goods and for all other goods supplied by 18.4 Interest The Purchaser must pay Weir interest on all overdue
Weir. payments due to Weir under these General Conditions of Sale at
the Corporate Overdraft Interest rate (monthly Charging Cycle) (or
17.2 Until title and property in the Goods passes, the Purchaser holds
its successor) from time to time charged by the Commonwealth
the Goods as bailee in the capacity of a fiduciary for Weir, and
Bank of Australia, plus 2% per annum, calculated on daily rests
must mark the Goods or store them separately and keep all
from and including the due date to and including the date of
necessary records, so that the Goods can at all times be clearly
payment.
identified and distinguished as the property of Weir.
18.5 Governing Law These General Conditions of Sale and each
17.3 If the Goods in any way become attached to or a part of another
contract of which they form part are governed by and must be
object before the Purchaser has paid Weir in full for the Goods and
construed in accordance with the laws of New South Wales.
for all other goods supplied by Weir, property in so much of the
object as is comprised by the Goods shall remain with Weir and
shall not pass from Weir to the Purchaser until the Goods and all
other goods supplied by Weir have been paid for in full. Until Weir is
paid in full for the Goods and all other goods supplied by Weir the
Purchaser holds any objects to which the Goods are attached or of
which the Goods form a constituent part as bailee in the capacity of
a fiduciary for Weir and shall store such objects separately so as to
be readily identifiable.
17.4 If the Goods (or any objects to which the Goods are attached or of
which the Goods form a constituent part) are on sold by the
Purchaser to a third party prior to payment by the Purchaser in full
for the Goods and all other goods supplied by Weir, the Purchaser
does so as agent for Weir and the Purchaser unconditionally agrees
to keep the proceeds of such on sale in a separate bank account on
trust for Weir and, at Weir’s request, to assign to Weir any debt
owed to the Purchaser in respect of the on sale, until Weir has been
April 2009 Page 3 of 3
 PART 1

Installation
 Weir Minerals Multiflo

PART 1
INSTALLATION
1.1 Pump Unit 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, skid, 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 A CARRIER AS TENDERED BY
THE SHIPPER. In the event of damage or shortage, have the transportation
company note the same on the freight bill.

You will find a packing list attached to one of the items in the shipment. Check each
item against the list. Check by description, specification, quantity, count, etc. Should
there be any discrepancies, notify Multiflo 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. We cannot be responsible for loss of items that are listed and
included on our packing list.

1.1.1 Storage Procedures

1.1.1.1 General

It is the responsibility of the purchaser to store the equipment of supplied

items prior to use. The pump unit and any associated equipment must be
stored in a manner which will not interfere with the integrity of the equipment
whether through exposure to an unsuitable environment, undue rough
handling and on-site transportation or the loss/damage of equipment
components.

THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP

UNIT AND ANY ASSOCIATED EQUIPMENT WHEN STORED, HANDLED
AND TRANSPORTED ON-SITE.

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 Weir Minerals Multiflo

1.2 Warnings
(Regarding Installation &
Pre-Operational Procedures)
Pump unit to be locked and tagged before
DANGER ! any maintenance or service is performed.

1.2.1 Bare Shaft Pump Safety

It must be checked that the intake and
WARNING ! discharge openings are totally isolated from
all potentially pressurized connections and
that they are and can only be exposed to
atmospheric pressure.

The following instructions relate to the

ATTENTION ! operation and maintenance of the bare shaft
pump.

Do not operate the pump at low or zero flow conditions for prolonged periods, or
under any circumstance that could cause the pumping liquid to vaporize. Personnel
injury and equipment damage could result from the pressure created.

Do not apply heat to impeller boss or nose in an effort to loosen the impeller thread
prior to impeller removal. Personnel injury and equipment damage could result from
the impeller shattering or exploding when the heat is applied.

Do not feed very hot or very cold liquid into a pump which is at ambient temperature.
Thermal shock may cause the pump casing to crack.

Tapped holes (for eye bolts) and lugs (for shackles) on Warman Parts are for lifting
individual parts only.

Shaft Locks (If Fitted) must be removed from the bare shaft pump before the unit is
started.

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Weir Minerals Multiflo

1.2.2 Vacuum Pump Safety

Prior to initial operation the vacuum
pump oil level must be checked before
INFORMATION ! operating the vacuum pump. Running
the vacuum pump without oil will cause
damage.

If installing the vacuum pump, the

direction of rotation should be checked.

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 Weir Minerals Multiflo

1.3 Unit Lifting Points

Pump unit to be locked and tagged before
WARNING! any maintenance or service is performed.

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.

FIGURE 1
UNIT LIFTING POINTS

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Weir Minerals Multiflo

FIGURE 2
SKID CHASSIS
LIFTING POINTS

Lifting points on the High Lift Skid Chassis

WARNING! are designed for lifting of the Skid Chassis
only.

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 Weir Minerals Multiflo

1.4 Assembly Instructions

All assembly and installation is to be
INFORMATION ! performed on solid level ground.

1.4.1 Assembly of Pump and Skid

Pump unit to be locked and tagged before
WARNING! any maintenance or service is performed.

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.

Do not stand under suspended load.

WARNING! Do not place any part of body under
suspended load.

1.4.1.1 Using suitable lifting equipment, lift pump base over high lift skid.

1.4.1.2 Make sure the skid is clean of all rocks and debris.

1.4.1.3 When pump base is suspended over skid, gently lower base into
skid. Be sure that base moves into position freely and does
interfere with skid sides.

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Weir Minerals Multiflo

FIGURE 3
INSTALLING PUMP
ONTO SKID CHASSIS

1.4.1.4 Make sure the pump unit is sitting flat in the skid.

1.4.1.5 When base is sitting on skid frame, on one side only, insert
spacers between the skid and the pump unit (approximately
6mm). Fit the bolts and tighten that side. Repeat with the other
side fitting the required shim for the gap left between the skid and
pump unit.

Do not attempt to insert bolts until pump

WARNING! base is sitting on skid frame and is not
suspended by lifting equipment.

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 Weir Minerals Multiflo

1.4.2 Assembly of Pontoon (If Fitted)

The centre hull of the pontoon should be placed on flat ground for easy
installation of the pontoon side hulls. The work area should have enough
space on either side so that a crane may be used to install the side hulls.

PONTOON
CENTRE SECTION
RIGHT HAND SIDE

PONTOON
CENTRE
SECTION LEFT
HAND SIDE
PONTOON
FRONT
(PUSH BAR)
END

FIGURE 4
PONTOON CENTRE
HULL IDENTIFICATION

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Weir Minerals Multiflo

1.4.2.1 Using a crane, lift the left hand side pontoon into position as
shown in the diagram below.

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.

LOCATING PIN

LEFT SIDE BOLT

ON PONTOON

MOUNTING
PEDESTAL

FIGURE 5
LEFT HAND PONTOON HULL
WITH LOCATING PIN &
MOUNTING PEDESTAL
IDENTIFICATION

Each “bolt on hull” locates to a mounting pedestal protruding from the

underside of the central pontoon hull. Each “bolt on hull” has a number
of locating pins welded on the bottom of each hull along the in board
side of the hull. All locating pins must locate into each pedestal
correctly as shown, prior to installing the securing bolts.

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Weir Minerals Multiflo

FIGURE 6
LEFT HAND PONTOON
HULL BOLTING POINTS

1.4.2.2 Align the bolt holes at either end of the pontoon and install the
appropriate bolts as shown.

Be sure to use Anti-seize on all bolt

INFORMATION ! threads before tightening the bolts.

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1.4.2.3 Using a crane, lift the right hand side pontoon into position as
shown in the diagram below.

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.

ACCESS STEPS

FIGURE 7
RIGHT HAND PONTOON
HULL WITH LOCATING
PIN & MOUNTING
PEDESTAL
IDENTIFICATION

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Weir Minerals Multiflo

1.4.2.4 Align the bolt holes at either end of the pontoon and install the
appropriate bolts as shown in the diagram below.

Be sure to use Anti-seize on all bolt

INFORMATION ! threads before tightening the bolts.

FIGURE 8
RIGHT HAND PONTOON
HULL BOLTING POINTS

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1.4.2.5 There are a number of mounting pads welded onto the pontoon
deck to which the pump unit base is bolted. These are marked
on the diagram below.

Prior to installation of the pump base, remove any surface rust or

debris from the threaded holes in each pad. This will ensure that
the bolts do not “cross thread” when they are tightened.

A clearing tap and compressed air may be used in the cleaning

process.

BOLT HOLE

PUMP BASE
MOUNTING PAD

FIGURE 9
PUMP UNIT BASE
MOUNTING PAD
INDICATION POINTS

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Weir Minerals Multiflo

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.

Using a crane equipped with

a “spreader bar”, lift the
pump set into position over
the deck mounting pads on
the pontoon deck.

FIGURE 10
POSITIONING THE PUMP
SET OVER THE
MOUNTING PADS

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Weir Minerals Multiflo

1.4.2.6 Carefully align the bolt holes on the pump set with the mounting
pad holes on the pontoon.

Bolt with Flat and spring washers.

BOLT NOT
REQUIRED IN
THIS
LOCATION

FIGURE 11
ALIGNMENT OF PUMP
SET BOLT HOLES WITH
MOUNTING PAD BOLT
HOLES

Be sure to use Anti-seize on all bolt

threads before tightening. If they need
INFORMATION ! to be removed in the future they will be
easily undone.

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1.4.2.7 Now the discharge pipe work can be fitted to the pump unit. If
not already done, firstly install the Non Return Valve to the pump
discharge elbow.

The Non Return Valve inspection plate

INFORMATION ! must be installed in the UP position.

FIGURE 12 - LEFT
NON RETURN VALVE
WITH INSPECTION
PLATE IN THE ‘UP’
POSITION

FIGURE 13 - ABOVE
WHERE TO INSTALL THE
NON RETURN VALVE

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Weir Minerals Multiflo

1.4.2.8 The Non Return Valve must be fitted as shown in the diagram
below, with the inspection plate in the “UP” position and the
green arrow showing the direction of water flow through the
valve.

FIGURE 14
NON RETURN VALVE
INSTALLED ON THE
PUMP SET

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 Weir Minerals Multiflo

1.5 Installation of Suction Assembly

Pump unit to be locked and tagged before
WARNING! any work is performed.

Installation of the boom assembly

WARNING! components to be undertaken by
experienced personnel only. Refer to site
procedures for lifting, personnel and
equipment requirements.

WARNING! Chains to be connected with Hammerlocks

only.

FIGURE 15A
FITTING THE SUCTION
BOOM

FIGURE 15C
FIGURE 15B INSERTION OF BOOM
FITTING THE REDUCER LOCKING BOLTS
AND THE HOSE

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Weir Minerals Multiflo

1.5.1 With boom lying flat, insert boom locking bolts in boom and
pump base. Tighten bolts. As shown in Figure 15C.

1.5.2 If not already done so, attach winch to pump base winch mount.

1.5.3 With boom lying flat, run winch rope through boom pulley.
Removal of the pulley may be necessary. As shown in Figure 16
on the right.
FIGURE 16
ATTACHING WINCH
ROPE TO BOOM PULLEY

FIGURE 17
FITTING THE WINCH
ROPE

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FIGURE 18A
FITTING THE BOOM
CHAINS

FIGURE 18B
FITTING THE SUCTION
STRAINER

1.5.4 Connect boom chains to boom using Hammerlocks as per Figure

18A.

1.5.5 Using suitable lifting device, pick up boom and lift into a position
that will allow the boom chains to reach the boom chain mounting
points on the pump. Refer Figure 18A.

1.5.6 Fit boom chains to mounting points using Hammerlocks only.

Connect winch rope to spreader bar using an approved shackle.

1.5.7 Fit Suction Strainer to hose as per Figure 18B.

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1.6 Fitting Pontoon Handrails

(where applicable)

FIGURE 19
FIT THE LEFT HAND SIDE
HANDRAIL

FIGURE 20
FIT THE RIGHT HAND SIDE
HANDRAIL

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1.7 Discharge Pipework Installation

Pump unit to be locked and tagged before
WARNING! any work is performed.

Installation of the pipework components to

WARNING! be undertaken by experienced personnel
only. Refer to site procedures for lifting,
personnel and equipment requirements.

1.8 Installation & Removal

Sequences
1.8.1 Moving and Locating the Pump Unit

Pump unit to be moved by experienced

WARNING ! personnel only.

Pump unit to be locked and tagged before

WARNING! any maintenance or service is performed.

Pump unit moving and locating

instructions are intended as a guide only.
INFORMATION ! Site preparation, unit towing and
positioning to be undertaken with regard
to site conditions and procedures.

Multiflo Pumps are mounted on a skid base chassis. A robust push beam assembly
and towing brackets are attached to the skid base to enable the unit to be pushed or
pulled.

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For long term pumping operations in deep water or in high rain fall areas, the pump,
complete with skid base, can be mounted on a floating pontoon. Skids are also
provided at the base of the pontoon.

Before preparing the pump site, consideration must be given to the best pumping
location, with the aim at positioning the pump as near as possible to the deepest part
of the water catchment area.

1.8.1.1 Pump Site Preparation

Proper pump site preparation is important. It should provide a good approach

for the final positioning of the pump and allow access for fuel and service
vehicles. Also, when using a skid mounted pump in areas prone to flash
flooding after heavy rainfall, quick access to the unit may be needed to tow it
to safer ground.

For skid mounted pumps, the site should be prepared as close to the water as
possible and the final resting place of the pump should be reasonably level.
Operating the pump at an incline of over 10° is not recommended.

1.8.1.2 Moving the Pump Unit

Pump unit to be moved by experienced

WARNING ! personnel only.

Moving or relocating a pump unit within the pit is normally done by a wheel
dozer or small track dozer. A small excavator can also be used especially for
launching pontoon units.

Obviously, the proper way to move a pump unit is by towing, using appropriate
tow chains. Pushing the pump unit over long distances or over uneven ground
is to be avoided.

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1.8.1.3 Preparation for Towing

Pump unit to be connected to prime-mover

WARNING ! by suitable towing apparatus. Suitability of
towing apparatus to be determined
according to local site requirements.

1. Ensure the pipes or hoses are disconnected from the wet end pump
discharge.
2. Stow any loose items of pump hardware, such as clamps, connectors,
lengths of pipe etc. that be may be lying around the deck.
3. Raise and secure the suction strainer and suction hose well clear of the
ground. The suction boom can remain in its normal suspended
position.
4. If not already fitted, attach appropriate towing chains to the towing
brackets at the front of the pump unit skid base, or at the towing
brackets at the front end of the pontoon. The front end is the engine
end of the pump unit.
5. Connect towing chains to the draw bar of the towing vehicle.

Towing should be kept at a reasonable safe speed and extra caution should be taken
when towing along haul roads, keeping as close as possible to the left side. Don't
tow or push the pump over rough, uneven ground. Unhitch the dozer and level the
way.

Final positioning will usually involve pushing the pump down a ramp at a maximum
grade of 15°, either with the dozer blade or the excavator bucket. For launching
pontoon pumps, an excavator may be the best tool. Pushing must be done with
extreme caution and only on the push beam assembly provided. Pontoon pumps are
pushed on the pontoon push bar only and not on the base chassis push beam.
Under no circumstances should any pump unit be pushed on the sides or at the
suction end (rear).

Before launching a pontoon pump, consideration should be given to the best method
of connecting up the discharge line. (It is extremely difficult to connect up hoses and
pipes in deep water). If layflat hose is to be connected to the initial discharge pipe,
then this connection can be made before the pump is launched. If polypipe is used,
one or two lengths can be connected to the pump discharge before launching and
the final connection made on land when the pontoon is floating.

To assist in positioning the pontoon when it is in the water, a rope tag line long
enough to reach the bank should be attached to it.

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1.8.1.4 Procedure for the Movement, Locating and Launching of

Dewatering Pumps

Pump unit to be moved by experienced

WARNING ! personnel only.

Final positioning will involve pushing the

WARNING ! pump down a ramp with a maximum 15°
gradient.

Use When
Whenever pumps have to be moved, located and/or launched at a pump site.
Purpose
To minimise the risk of damage to equipment and injury to personnel when
moving and/or locating pumps at a pump site.
Before Starting
Before preparing a pump site, consideration must be given to the best
pumping location, with the aim of positioning the pump as near as possible to
the deepest part of the water catchment area.

1.8.1.5 Procedure for Towing

1. Ensure appropriate towing chains are available for the particular pump
type.

2. Ensure that pipes and hoses are disconnected from the wet end pump
discharge.

3. Secure any loose items of pump hardware such as clamps, connectors,

lengths of pipe etc. that may be lying loose on the pump deck.

4. If not already fitted, attach appropriate towing chains to the towing

brackets at the front (engine) end of the pontoon.

5. Connect towing chains to the draw bar of the towing vehicle.

6. If ground is excessively rough, have it levelled first.

7. When towing, travel at a safe speed and keep as close as possible to the
left hand side of the road.

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1.8.1.6 Positioning and Launching

1. Ensure that a suitable pump location is established which will provide a

good approach for final positioning and safe access for fuel and service
vehicles.

2. Skid mounted pumps should be positioned on level ground.

3. Pumps should be positioned/launched using a wheel dozer, small track

dozer or small excavator.

4. The operator of the dozer or excavator must be able to see the point at
which the blade or bucket is making contact with the pump. The pushing
operation must be directed by a person on the ground. The equipment
operator and person directing must be clear on the hand signals being
used by the person directing. Skid mounted pumps must only be pushed
on the push beam assembly provided.

Pontoon mounted pumps must only be

pushed on the pontoon push bar, and not
ATTENTION ! on the pump push beam. (see diagrams)
Under no circumstance should any pump
unit be pushed on the sides or at the
suction end (rear).

5. Before launching, consideration should be given to connecting layflat or

polypipe discharge lines. Final connections can then be done on land
after the pump is floating.

As well, a rope tag line long enough to reach the bank should be fitted to assist
in final pontoon positioning.

Graphical description intended as a

INFORMATION ! guide only.

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FIGURE 21
BLADE CONTACT POINT ON
PUMP PUSH BAR

FIGURE 22
BLADE CONTACT POINT ON
PONTOON PUSH BAR

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1.8.1.7 Incorrect Pump Sitting Angle

Pump Position – Not on Flat

ground

Discharge Hose is Kinked

Distance from Pump to Water

Surface is more than 10 metres

FIGURE 23 EXAMPLES OF
INCORRECT
PUMP UNIT POSITIONING

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1.8.1.8 Correct Pump Sitting Angle

Pump Position – Flat ground

Suction Lift less than 10 Metres

Discharge Hose Curved where

Possible

FIGURE 24
EXAMPLES OF CORRECT
PUMP UNIT POSITIONING

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1.8.1.9 Pumping Operation Observations

Ensure the hose couplings at the wet end pump, both suction and discharge, are
completely sealed.

Ensure the pump unit is positioned as close as possible to the level of the fluid being
pumped. (If the height of the wet end pump is above 8 metres from the level of fluid,
the pump will not pump).

Ensure that the suction strainer is free from blockages and fully submerged in the
fluid.

Ensure that the largest possible pipe diameter, both at suction and discharge, is
being used.

Ensure that the vacuum tank gauge reading is within the normal range (depending on
suction height).

Ensure that the wet end pump is operating without cavitating.

Ensure that the engine is set at the correct speed (RPM) to give maximum pump
efficiency.

When using "layflat" hose, ensure that it is free from kinks and sharp turns.

Ensure that the vacuum prime indicator light on the “First Out” panel goes out once
the unit is primed. If the light stays illuminated, then a fault has occurred. Refer to
the priming section of the Trouble Shooting guide in the Maintenance Manual.

Ensure that the pump unit is situated in a safe position and not operating at an angle
of more than 10°.

Ensure that there is a good rate of liquid flow coming from the end of the discharge
line.

Pump Unit that is not Pontoon Mounted:

What are weather conditions like?
Is there good access to the pump?
Should it have to be moved to a safer area in case of flooding?

If cavitation is experienced during

INFORMATION ! pumping operations because of low
head, compensation for this can be made
by setting the position of the turn flow
valve.

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1.8.2 Installation Checks

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

On-site pump unit alignment checks to be

ATTENTION ! carried out prior to pump unit operation.

1.8.2.1 Direct Coupled Units

Alignment

All units are assembled, aligned and test run at Weir Minerals Multiflo
Caloundra Factory before they are despatched. This alignment may be affected
during transportation, therefore should be checked before the unit is used on
site.

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 PART 2

Operation
 Weir Minerals Multiflo

PART 2
OPERATION
2.1 Introduction

2.1.1 General Information (& Safety)

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 Multiflo MF-420E pump unit has been designed to
provide a safe working environment for operators, maintenance
personnel and others.

Improper operation, installation, maintenance or repair of this equipment

could result in injury or death.

Do not operate or perform any operation, installation, maintenance or

repair on this product, until you have read and understood the operation,
installation, 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.

SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THE

SUPPLIED DOCUMENTATION. FAILURE TO HEED THESE WARNINGS
AND PRECAUTIONS MAY RESULT IN PERSONAL INJURY AND/OR
DEATH TO YOURSELF AND/OR OTHERS. FAILURE TO HEED THESE
WARNINGS MAY ALSO RESULT IN EQUIPMENT AND ENVIRONMENTAL
DAMAGE.

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2.1.2 General Safety Recommendations

The accompanying documentation supplied with the Weir Minerals
Multiflo MF-420E utilises the following safety symbols to highlight
potentially harmful situations to personnel and the environment.

SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES

DANGER ! Imminent risk Persons Fatal or crippling

of fatal or injuries likely to
crippling result from any
injuries exposure

WARNING ! Risk of fatal or Persons Fatal or crippling

crippling injuries possible
injuries

CAUTION ! Possibility Persons Minor or slight

of a harmful injuries possible
situation

Possibility Property Damage possible to

ATTENTION ! of a harmful and or the the product or the
situation Environment Environment

Application
INFORMATION ! Hints and Nil Nil
other useful
Information

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2.1.3 General Description and Function

of Equipment
The type of Bare Shaft Pump used on Multiflo pumps is of the centrifugal
design. This type of Pump will not operate until initially filled with water
(primed). Multiflo pumps use an automatic prime system to initially prime and
to maintain prime as long as fluid is available.

The automatic prime system consists of the vacuum tank, vacuum pump and
fluid level control.

A vacuum gauge which is mounted in the vacuum tank indicates, while the
pump unit is operating, dynamic head loss in the suction system. As this
reading will vary with different pumping conditions, i.e. varying lengths of
suctions hose, height of pump unit above fluid, quantity of fluid being pumped
etc., it is impractical to predict a general vacuum gauge operating reading.

2.1.3.1 Operation

1. As the unit uses vacuum to prime the Bare Shaft Pump, it is necessary
to ensure that the hose couplings to the Bare Shaft Pump, both suction
and discharge, are completely sealed.

It will be necessary to use a “non-return valve” to prevent the vacuum

pump sucking air back through the discharge side of the pump which
would cause the auto vacuum prime system to malfunction.

2. Although the unit is capable of suction lifts of up to eight metres, it is

advisable to install the pump unit as close as possible to the level of the
fluid being pumped to obtain optimum flow rates.

3. In all pumping operations, ensure that a Multiflo suction strainer is fitted

to the suction hose. NOTE: The suction strainer should be no less
than 1 metre below the surface of the water.

4. Always use a large diameter hose for the suction, and use the correct
size pipe on the discharge to obtain maximum performance from the
unit.

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2.1.4 Orientation of Major Unit

Components
The front end of the pump unit is the
radiator end. The back (or rear) end is
INFORMATION ! the vacuum tank end. Like driving a
vehicle, the engine and radiator are
always in front of the driver, thus the left
and right hand sides then correspond
accordingly.
Refer to diagram below for clarification.

PUMP UNIT REAR END

(VACUUM TANK END)

PUMP UNIT
RIGHT SIDE

PUMP UNIT FRONT

END
(RADIATOR END)

PUMP UNIT LEFT

SIDE

FIGURE 25
PUMP UNIT ORIENTATION
GUIDE

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2.2 Normal Operating Procedures

Engine and bare shaft pump parts and all
DANGER ! fluids may be at extremely high
temperatures when the pump unit is
stopped and may cause serious burns.
Ensure pump unit has cooled down before
any checks or maintenance are carried out.

Pump unit to be locked and tagged before

DANGER ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Operation

Complete pre start checks.

Check emergency stops are out (1 on the Caterpillar engine control box and 1
on the canopy).

Turn the battery isolator to on.

Check all applicable discharge and suction valves are open.

Turn the ignition to the on position and allow the gauges and messenger to
calibrate (5-10 seconds).

Turn the throttle control to idle (clockwise)

Start the engine and allow to idle for 2 minutes.

Bring the revs up to 1000 RPM until the pump is primed. Once the pump is
primed set the revs to suit the duty of the pump.

To find the duty, bring the revs up until the discharge pressure gauge reaches
its highest reading or the pump cavitates, this is the maximum discharge.
Don’t run the pump in cavitation for extended periods.

Check gland leakage and adjust as required.

It is recommended that the unit be monitored for 6 minutes to ensure it doesn’t
shut down on prime or flow.

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2.2.1 Daily Pre-Start Cold Checks

Pump unit to be locked and tagged before
DANGER ! any maintenance or service is performed.

2.2.1.1 Engine Oil

Maintain oil level between ‘add’ and ‘full’ marks on the dipstick.

2.2.1.2 Bare Shaft Pump Lubrication System

Check oil tank sight glass for oil level. Top up if required.

2.2.1.3 Vacuum Pump Oil

Maintain level between ‘high’ and ‘low’ mark on the dipstick.

2.2.1.4 Gland Oil Tank (If Fitted)

Fill to 10mm below the filler pipe opening.

2.2.1.5 Coolant Level

Make sure the engine is stopped and cold. Maintain level in range above
baffle plate and filler neck.

2.2.1.6 Fuel Tank

Fill as required. Check fuel gauge.

2.2.1.7 Battery
Maintain level in range above plates and filler bridge (if applicable).

2.2.1.8 Drive Belts (Fan / Generator / Vacuum Pump)

Check condition and re-tension if required or replace if necessary.

2.2.1.9 Water Trap

Drain and clean the bowl.

2.2.1.10 Air Cleaner Indicator (If Fitted)

If the indicator piston locks in the UP position, service the element.

2.2.1.11 Suction Strainer

Check the suction hose and strainer for blockages or damage. Make sure that
the strainer is properly submerged.

2.2.1.12 Probes
Clean probes.

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2.2.2 Starting Procedures

Pump unit may start at any time by remote
DANGER ! operation.

Pump unit to be operated by experienced

WARNING ! personnel only.

1. Check that personnel are clear of discharge pressure lines.

2. Turn battery isolator switch to ON.
3. Turn engine ignition and allow Cat Messenger panel to initialize.
4. Turn ignition key and start engine and allow to idle for 1 minute
minimum at 750-800 RPM.
5. Increase the RPM to 1000 RPM until the wet end primes (approximately
-20 to -40 on the vacuum gauge). When primed, increase RPM to
achieve the desired duty.
6. Carry out Post Start Up Procedures.

2.2.2.1 Post Start Up Procedure

1. Check all engine gauges.

2. Check for oil or water leaks etc around the engine.
3. The vacuum prime light will go out when the unit is primed.

2.2.2.2 Operating Speed – with Discharge Pressure Device Fitted

(To Set the Operating Speed).

1. Increase the engine RPM while monitoring the discharge pressure

rising on the gauge.
2. Continue to increase RPM until discharge pressure stops rising.

This is the correct engine operating speed for this application.

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2.2.2.3 Cavitation

Cavitation is vaporised water in the form of air pockets around the

rotating impeller which can be identified by a bad vibration and rattling
noise coming from the pump casing. Also poor water discharge from the
pump outlet will be noticed.

This is caused by the impeller forcing water out of the discharge at a

faster rate than the water can be replaced through the suction of the
pump.

Cavitation can be caused by:

1. The pump being too high from the water being pumped
(Excessive suction lift).
2. The engine RPM or pump speed is too high for the required duty.

The resulting effects of cavitation are:

Pitting of material surfaces due to continual hammering action.

Reduction in pump performance.

Damage to pump, if cavitation is severe.

FIGURE 26
RESULTING EFFECTS OF
CONTINUOUS CAVITATION

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2.2.3 To Shutdown
1. When pumping heavy mediums it is advisable to raise the pumps
strainer into clean water prior to shutting down to prevent slurry from
settling in the pumps casing.
2. Decrease engine RPM slowly to idle.
3. Allow the engine to idle for 3 minutes on turbo charged units prior to
shutting down.
4. Turn the ignition key anti clockwise to stop the engine.
5. Turn the battery isolation key to the “off” position.

2.2.4 Shutdown Protection

2.2.4.1 Pump Shutdown System

The bare Shaft Pump protection system consists of probes fitted to the
vacuum tank and a Vactronic System which connects to the engine shutdown.

The Vactronic System has an inbuilt six minute timer which activates when the
water level in the vacuum tank falls below the probe. The orange indicating
light will flash. The unit will remain in this mode for six minutes before
activating the engine shutdown. Once this has occurred, the red indicating
light will stay on.

Should the pump pick up water within the six minutes after being activated, the
unit will automatically reset.

This feature is designed to prevent damage to the pump from dry running.

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2.3 Detailed Description of

Components
2.3.1 Bare Shaft Pump
The ‘HX’ range of Warman pumps are specifically designed for continuous
running in slurry and dirty water duties where ordinary water pumps are not
suitable. Acidic water found in many mine water run off situations can also be
handled.

The pump discharge can be orientated in almost any position through 360°
depending on mounting.

The impellers are specially designed to obtain high efficiencies without

requiring close clearances between impeller and casing, and still maintain the
ability to pass reasonable sized solids.

The wet end parts are cast from Ultrachrome A49/A48 and the impeller is
constructed from H7A stainless steel. These long wearing materials have
been developed for abrasion and corrosion resistance and to give a long life in
slurry pumping applications.

Multiflo Pump Model 420E

Bare Shaft Pump Model 8/6 FFY-HX
Maximum Pumping Speed RPM 1400 rpm
Bare Shaft Pump Operating Speed 1400 rpm
Wet End Material / Impeller Ultrachrome A49/H7A
Bearing Assembly FFY005

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FIGURE 27
BARE SHAFT PUMP
WETTED PARTS

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FIGURE 28
BARE SHAFT PUMP
BEARING HOUSING

FIGURE 29
BARE SHAFT PUMP
PEDESTAL ASSEMBLY

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2.3.2 Model 57 Piston Type Vacuum

Pump
38 C.F.M. air cooled twin reciprocating piston type fully sealed unit - self
contained oil lubrication 2.2 litres capacity. Operating 700 RPM/maximum.
Driven by three "SPZ" section vee belts from the pump input shaft. Vacuum
pump fitted with a 24 volt electromagnetic clutch to disengage the vacuum
pump after priming which eliminates its continuous running. Auto start as
controlled by the vactronic control system.

Prior to initial operation the vacuum pump oil level must be

checked before operating. Running the vacuum pump without
oil will cause damage.
If installing the vacuum pump, the direction of rotation should
be checked.

FIGURE 30
PISTON TYPE
VACUUM PUMP
MAJOR COMPONENTS

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2.3.2.1 Model 57 Parts Assembly

Illustration No: Description

1 Elbow
2 Non Return Valve
3 Nut
4 Keeper Plate (Arm)
Keeper Plate (Top)
5 Vacuum Pump Pulley
6 Bolt
7 Washer
8 Complete Clutch Assembly

2.3.2.2 Model 57 Specifications

Type – 2 cylinder splash feed 90mm bore 108mm stroke

Cylinder Bore Standard 90mm + 0.05
0.00
Oversize 1mm
Piston Standard 89.95mm + 0.03
0.02
Oversize 1mm
Piston Ring Engine Gap Min 0.1mm
Max 1.0mm
Piston to Bore Clearance Max 0.2mm
Crankshaft Journal Standard 44.5mm
Wear Limit 44.459 - 44.475mm
Under Size 44.460 Nil
Journals to Conrod Clearance Standard 0.025mm
Max 0.07mm
Main Bearings Deep Groove Ball Bearings

Torque Settings
Cylinder Head 35 NM + 3 25FT LB + 2
Cylinder to Crankcase 30 NM + 3 20FT LB + 2
Bearing Cap 35 NM + 3 25FT LB + 2
Conrod Big Cap 35 NM + 3 25FT LB + 2
Valve Retainer Cap 35 NM + 3 25FT LB + 2

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2.3.3 Vacuum Tank

Krundimendt Safety
Check Valve

Vacuum Water Trap

FIGURE 31
VACUUM TANK

The high lift vacuum tank is manufactured from 6mm material incorporating a
vacuum and air separator chamber designed to give maximum air separation
and allowing an uninterrupted capacity flow to the bare shaft pump. The
vacuum tank is also complete with a vacuum water trap and back up
Krundimendt Safety Check Valve to give maximum protection to the vacuum
pump under all operating conditions.

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2.3.4 Vacuum Gauge

A vacuum gauge indicates when the pump unit is operating, dynamic head
loss in the suction system. The normal operating range depicted by the gauge
should be within -20kPA to -80kPA.

FIGURE 32
VACUUM GAUGE

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2.3.5 Non Return ‘Vooom’ Valve

Incorporated on the discharge side of the pump is a discharge line non-return
valve. This valve, open during pumping, will automatically close when
pumping stops.

The Non-Return Valve has two (2) purposes:

1. It prevents the fluid already in the discharge line from draining back and
flooding the vacuum tank. It has been known that if the non-return valve
is not working properly the head of water in the discharge pipe will flow
back through the pump and may turn the impeller off the thread of the
pump shaft.
2. It seals the discharge line when the pump is priming so a vacuum can be
created in the vacuum tank allowing the pump to prime or re-prime.

Therefore the non-return valve is an extremely important part in the pump’s

system.
The valve’s flap is manufactured from rubber with an inbuilt steel
counterweight (Multiflo “VOOOM” Valve). The flap should be inspected on a
regular basis.
If the pump is not priming and the gland packing is not leaking then maybe the
valve flap is damaged or stuck open.

1. As the unit uses vacuum to prime the Bare Shaft Pump, it is necessary
to ensure that the hose couplings to the Bare Shaft Pump, both suction
and discharge, are completely sealed.

It will be necessary to use a “non-return valve” to prevent the vacuum

pump sucking air back through the discharge side of the pump which
would cause the auto vacuum prime system to malfunction.

2. Although the unit is capable of suction lifts of up to eight meters, it is

advisable to install the pump unit as close as possible to the level of the
fluid being pumped to obtain optimum flow rates.

3. In all pumping operations, ensure that a Multiflo suction strainer is fitted

to the suction hose.

The suction strainer should be no less

INFORMATION ! than 1 metre below the surface of the
water.

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4. Always use a large diameter hose for the suction, and use the correct
size pipe on the discharge to obtain maximum performance from the
unit.

Multiflo ‘Vooom’ Hinged Flap Valve

FIGURE 33
NON RETURN “VOOOM” VALVE,
FLAP IN CLOSED POSITION

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Multiflo ‘Vooom’ Hinged Flap Valve

FIGURE 34
NON RETURN “VOOOM” VALVE,
FLAP IN OPEN POSITION

In the event of this non-return valve sticking and failing to close when pumping
stops, fluid would then drain back and flood the vacuum tank. If such a case
occurred, fluid will be prevented from entering the vacuum pump by closing of
the vacuum valve by the action of the float rising to close off the vacuum pump
intake port.

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2.3.6 Vactronic Vacuum Prime System

The Vactronic Vacuum Prime System consists of probes fitted into the vacuum
tank, an electric clutch fitted to the vacuum pump and the Multiflo Vactronic
Control system.

Upon start up of the pump unit, the electric clutch engages drive and the
vacuum pump pulls a vacuum which lifts the water into the vacuum tank and
bare shaft pump.

When the water reaches the bare shaft pump, the pump primes and the water
level rises in the vacuum tank and covers the probe. Once this occurs, the
electric clutch disengages and the vacuum pump will not run. The vacuum
pump will remain in this mode under normal pumping conditions.

Should the water level drop below the probe, the vacuum pump will
automatically restart and run until the level in the vacuum tank is restored.

The krundimendt valve, fitted to the top of the vacuum tank, acts as a check
valve. In the event of a shutdown, when the discharge line non-return valve
fails and floods the vacuum tank, the ball will rise in the krundimendt valve and
stop water from entering the vacuum pump. The one way check valve fitted in
the vacuum line stops air being pulled back into the vacuum tank from the
vacuum pump.

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FIGURE 35
VACTRONIC CIRCUIT
DIAGRAM

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2.3.7 First Out Indication Panel

The “First Out” Indication panel is a tool to monitor the operating parameters of
the Multiflo side of the electrical system. When running, the engine running
light will be lit for the entire time the engine is running. The orange prime light
will be on when the water level in the vacuum tank is below the top probe, this
indicates that the clutch on the vacuum pump is engaged. The red pump
water loss light will flash as the pump is priming, when the water level in the
vacuum tank is above the lower probe the light will go out, when the light is
flashing the unit is in a 6 minute cycle to shut down. If the prime is regained in
this time the shutdown will not continue. If the unit has shut down by other
means than by the operator tuning the key the cause will be displayed on the
first out panel and will remain there until the ignition has been turned off. If the
fault is shown as engine shut down it is the Caterpillar system that has shut
the unit down, consult the Cat messenger for fault codes. Pump water loss
could also indicate a loss of flow as well as a loss of prime if the unit is fitted
with a flow switch.

General

Keep the unit as clean as possible.

Replace the gland packing at regular intervals or as required, replace
all of the packing when doing so. A gradual loss of performance or
difficulty priming is an indicator of worn packing, although these
symptoms may have other causes.

Set up the unit as close to level as practicable.

Periodically check the discharge for adequate flow.

Don’t run the pump for extended periods when it is cavitating.

Maximum rpm must not be exceeded; vibration from impeller imbalance
will lessen bearing life.

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FIGURE 36
“FIRST OUT”
INDICATION PANEL

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2.3.8 1000FH Turbine Series Fuel

Filter/Water Separators (If Fitted)
2.3.8.1 Overview

The 1000FH Turbine Series Filter

assemblies protect precision
engine components from dirt,
rust, algae, asphaltines,
varnishes and especially water,
which is prevalent in engine fuels.
They remove contaminants from
fuel using the following legendary
three stage process:

Stage One – Separation

As fuel enters the assembly, it
moves through the centrifuge and
spins off large solids and water
droplets, which are heavier than
fuel, and fall to the bottom of the
bowl.

Stage Two – Coalescing

Small water droplets bead-up on
the surface of the conical baffle
and cartridge element. When
heavy enough, they too fall to the
bottom of the collection bowl.

Stage Three – Filtration

Proprietary Aquabloc II cartridge
elements repel water and remove
contaminants from fuel down to 2
micron. Aquabloc II cartridge
elements are waterproof and
effective longer than water
absorbing elements.

FIGURE 37
FUEL FILTER / WATER
SEPARATOR

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Turbine Series filter assemblies are designed to be installed on the vacuum

side of the fuel transfer pump for best efficiency (see installation diagram
further on). Adjustable one-piece clamp-type mounting brackets, with grade 5
fasteners, are included for ensured durability. The 1000FH uses two mounting
brackets. The see-thru contamination collection bowl allows the operator to
check for water and solid contamination at a glance.

2.3.8.2 Installation Instructions

The following customers supplied materials should be on hand before

beginning installation.

Shop Towels

Diesel Fuel (about 1 gallon)

Thread Sealant (no thread tapes)

Parker Super –O Lube (or equivalent)

Fuel Hose (see Fuel Hose Chart)

Mounting Hardware (3/8” or M10 Fasteners)

Inlet/Outlet Fittings (see Fitting Chart)

V
10° 10°

90°

FIGURE 38
FUEL FILTER / WATER
SEPARATOR
MOUNTING
INSTRUCTIONS

Mount the filter assembly as close to

vertical (V) as possible. Do not exceed
INFORMATION ! 10°° from vertical or the assembly may not
function properly.

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When positioning the Filter Assembly:

FH filter assemblies should be installed on the vacuum side of the fuel transfer
pump for optimum water separating efficiency. (See ‘Installation Diagram’ on
the next page.)
Keep fuel line restrictions to a minimum. Locate the FH filter assembly
between the horizontal planes of the bottom of the fuel tank and the inlet of the
fuel pump, if possible. If the FH filter assembly is installed in an application
where the fuel tank is higher than the filter, a shut-off valve must be installed
between the tank and the FH filter assembly INLET. This will be used when
servicing the replacement element.

Before Installing the Filter Assembly:

Obtain good ventilation and lighting.

CAUTION ! Maintain a safe working environment.
The engine must be off for installation.
DO NOT smoke or allow open flames near
the installation.

Installing the Filter Assembly:

Completely remove any vacuum side filters in the fuel line between the fuel
tank and the fuel pump. This is where the FH filter assembly will mount.
Leaving these filters in place will add to the fuel line restriction. Filter heads
cast into the engine or that are non-removable or hard piped should be
serviced with a new element and left in place.

Keep fuel flow restriction valves to a minimum. Always use the maximum size
fuel hose possible. Do not make sharp bends with flexible fuel hose as kinks
may occur. Avoid the use of two 45° elbow fittings where one 90° elbow will
work.

When routing hose, avoid surfaces that will move, sharp edges, or will get hot
(such as exhaust piping).

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FIGURE 39
FUEL FILTER / WATER
SEPARATOR
INSTALLATION
INSTRUCTIONS

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2.3.8.3 Priming Instructions

1. Remove the ‘T’ handle and lid from top of filter assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and ‘T’ handle O’ring with clean fuel or motor oil.
4. Replace the lid and ‘T’ handle and tighten snugly by hand only –
do not use tools.
5. If applicable, refer to the equipment operator’s service manual to
complete the fuel priming procedure.
6. Start engine and check for fuel system leaks.
7. Correct as necessary with engine off and pressure relieved from filter
assembly.

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2.3.8.4 Specifications - Model 1000FH

Maximum Flow Rate 180 GPH 9681 LPH)

Port Size (SAE J1926) 7/8” – 14 UNF
Replacement Elements
2 micron 2020SM – OR
10 micron 2020TM – OR
30 micron 2020PM - OR
Minimum Service Clearance
Above Assembly 10 inches (254mm)
Below Assembly 2 inches (51mm)
Height 22.0 inches (559mm)
Depth 6.0 inches (152mm)
Width 7.0 inches (178mm)
Weight (dry) 10.0lb (4.5kg)
Clean Element Pressure Drop 0.43 PSI (2.97 kPa)
Maximum Allowable Pressure ¹ 15 PSI (103 kPa)
Water in Bowl Capacity 305ml
Available Options ²
Water Sensor Yes
Heater Yes
Operating Temperature -40° to +255°F / -40° to 121°C

1. Pressure installations are applicable

up to a maximum PSI shown.
INFORMATION ! Vacuum installations are
recommended.

2. Not for use on gasoline applications.

2.3.9 Engine Monitoring System (EMS)

Caterpillar Engine Monitoring System – Please refer to the attached data in the
Accompanying Manuals Section (Information as supplied by Caterpillar).

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2.4 Electrical
2.4.1 Electrical Drawings/Schematics
Pump unit to be locked and tagged before
WARNING ! any maintenance or service is performed.

Pump unit power supply to be isolated

WARNING ! before any work is performed on the pump
unit electrical system.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Refer to the attached Schematic Wiring

INFORMATION ! Diagrams for unit specific information.

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2.4.2 Monitoring Instruments

2.4.2.1 Sensor/Modules

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 PART 3

Maintenance
 Weir Minerals Multiflo

PART 3
MAINTENANCE
3.1 Normal Maintenance Procedures
3.1.1 Safety Procedures
Engine and bare shaft pump parts and all
DANGER ! fluids may be at extremely high
temperatures when the pump unit is
stopped and may cause serious burns.
Ensure pump unit has cooled down before
any checks or maintenance are carried out.

Pump unit to be locked and tagged before

WARNING! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Observe for gauge leaks and general

condition of the unit. If condition exists,
INFORMATION ! determine the cause and have necessary
repairs made.

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3.1.2 Disassembly & Assembly

Procedures
The assembled bare shaft pump and the
WARNING! bare shaft pump individual components are
heavy. Attention must be paid to the weight
of the assembled bare shaft pump or
individual component prior to lifting. Lifting
apparatus must be used to lift assembled
bare shaft pump or individual pump
components.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Names and basic part numbers are used

INFORMATION ! in assembly instructions in this manual.
Full part numbers are given in the
drawings in the spare parts section of
this manual. Full part numbers should be
used upon ordering spare parts.

When pumps have been dismantled for

INFORMATION ! complete overhaul, all parts should be
closely inspected and new parts checked
for correct identification.

Used parts being replaced should be

INFORMATION ! thoroughly cleaned and repainted where
required.

Mating faces and spigots should be free

INFORMATION ! of rust, dirt and burrs and given a coat of
grease before they are fitted together to
assist future overhaul.

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It is preferable to renew small bolts and

set screws during overhaul and all
INFORMATION ! threads should be coated with graphite
grease before assembly. It is also
recommended that all rubber seals
should be replaced during major
overhauls as rubber tends to harden and
seals lose their effectiveness.

3.1.2.1 Model 420E Bare Shaft Pump Assembly Procedure

FIGURE 40
BARE SHAFT PUMP
FRAME ASSEMBLY

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Fitting Bearing Assembly to Base

1. Insert ADJUSTING SCREW (001) in BASE (003) from outside. Screw

on the nut, and fully tighten. Screw on two additional nuts with two flat
washers in between. These nuts are to be left loose and maximum
distance apart.

2. Apply grease to machined surface (bearing housing support cradle) in

BASE.

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

3. Lower BEARING ASSEMBLY (005) into BASE. Approximately match

machined surfaces of housing with surfaces in base. Check that
BEARING HOUSING LUG has fitted over adjusting screw in base and
is also between nuts and washers.

4. Fit CLAMP BOLTS (012) through BASE from underneath. Drop

CLAMP WASHER (011) over each bolt (domed side up) and screw on
nuts.

5. Grease shaft protruding from labyrinth at impeller end. This application

of grease will assist fitting and removal of shaft components and
prevent damage by moisture to shaft.

Heavy Components – pump must be

WARNING! secured to prevent pump from falling
forward.

6. Fit two pieces of timber to underside of base or appropriate assembly

cradle to prevent pump from tipping forward during assembly of wet
end.

Gland Assembly - Fitting Stuffing Box, Neck and Lantern Rings, Packing, Gland,
Shaft Sleeve, Shaft Spacer and Shaft Sleeve ‘O’ Ring.

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

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Fitting Adaptor Plate

1. Insert ADAPTOR PLATE (032) for BASE (003), making certain that the
adaptor spigot has engaged with the corresponding base recess.

2. Insert ADAPTOR PLATE STUDS (039). Fit nuts and tension.

FIGURE 41
BARE SHAFT PUMP
GLAND ASSEMBLY

3. Place STUFFING BOX (MK121333) flat on bench (Gland side up).

4. Drop NECK RING (067) in gland recess to rest on retaining lip.

5. Stand SHAFT SLEEVE (075) on end and slide through neck ring.

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6. Fit the following items in turn:

a) First PACKING RING (PAK-DWF193) of correct length to fill
annulus. Flatten packing ring then fit two more packing rings with
the joints staggered. Flatten each one separately.
b) Fit LANTERN RING (063). If the gland assembly is grease
lubricated, fill LANTERN RING (063) prior to assembly.
c) Fit final packing ring with the join 180° away f rom the lubrication
hole.

7. Assemble GLAND (044) halves, insert GLAND CLAMP BOLTS (126)

and fully tighten. Place gland in stuffing box and push down to
compress packing rings. Insert GLAND BOLTS (045) and just nip up
nuts sufficiently to hold shaft sleeve.

8. Fit shaft ‘O’ RING (109) to shaft, followed by SHAFT SLEEVE SPACER
(179) and second SHAFT ‘O’ RING (109).

9. Insert assembled stuffing box in adaptor plate and tap into position with
a soft faced mallet. Locate stuffing box with threaded connection at
top. The shaft sleeve will probably remain forward. It should be
pushed back to the shaft sleeve spacer on the shaft. Check that ‘O’
Rings are correctly positioned in grooves.

10. Fit the SHAFT SPACER (117) and the final SHAFT ‘O’ RINGS (109).

a) To assist in holding the last ‘O’ Ring in

INFORMATION ! position which seals against the
impeller, apply heavy grease to the ‘O’
Ring groove.

b) All the ‘O’ Rings in their respective

grooves will be compressed and fully
covered by these metallic parts when
the impeller is screwed onto the shaft.

11. Liberally grease shaft thread.

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Fitting Back Liner, Impeller, Bowl, Door, Clamp Rings, Stuffing Box, Bowl Seals,
Intake and Discharge Flanges

1. Fitting SEAL RING (122). The seal is an ‘O’ Ring. Fit into the groove on
the rim of the stuffing box.

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

2. Fitting BACK LINER (041) and impeller. In the back liners, provision is
made to accommodate studs for mounting back liners on adaptor plates.
Proceed as follows;

FIGURE 42
BARE SHAFT PUMP
IMPELLER & BOWL
ASSEMBLY

a) Screw and tension STUD (026) into tapped holes provided in back
liner.

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

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b) Suspend LIFTING TUBE (FH4302E02) from a hoist stand back liner on

edge and insert lifting tube into back liner hole. Lift back liner into
position and slide over shaft thread. Line up studs with holes and push
back liner against adaptor plate. Locate back liner spigot into adaptor
plate recess. Check that the various seals have not moved. Screw on
nuts and tighten. Remove lifting tube.

c) Fit SHAFT KEY (070) in key way and bolt SHAFT WRENCH (306) over
key. Check that CLAMP BOLTS (012) on side B of base are nipped up
just enough to hold the bearing assembly horizontal but not to lock it.

d) Check that ‘O’ RING (109) is correctly seated in groove in shaft spacer.

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

e) Obtain correct type of impeller. Apply grease to thread, lift impeller with
hoist using a chain or wire sling and screw it onto shaft. Use a bar
between vanes and hold shaft with wrench to tighten impeller. Ensure
that the various ‘O’ Rings on the shaft are not damaged during
assembly and that they are fully covered by the various parts.

3. Fit BOWL SEAL (124) over rim of BACK LINER (041).

FIGURE 43
BARE SHAFT PUMP
BEARING ASSEMBLY

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4. Fitting BOWL (131) and CLAMP RING (135):

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

(a) Pump bowls are provided with three lifting lugs around the periphery.
Lift BOWL (131) with hoist using one or two lugs to obtain discharge
position required. Pass it over the impeller and fit it over the tapered
rim on the back liner. Check that the bowl seal has not moved.
(Bowl discharge can be orientated in any position through 360°).

(b) Fit CLAMP RING (135).

These rings are made up of four segments and are joined together
by means of CLAMP RING BOLTS (129) during pump assembly.
Whilst the bowl is still held in position by means of the hoist, fit upper
clamp ring segment over bowl and adaptor plate rim, attach to each
end of upper segment the two side segments, then complete ring
circle by attaching lower segment to side segments using clamp ring
bolts.

5. Fitting DOOR (013), CLAMP RING (135) and FLANGES (130):

a) Fit INTAKE FLANGE (130) halves around intake neck of DOOR

(013), clamp halves with BOLTS (270) and fully tighten.
b) Fit ‘O ring type SEAL (124) over rim of door.
c) Attach door LIFTING PLATE (309) to intake flange (ensure that
bowl seal is in position against door rim) lift into place and fit inside
the bowl tapered bore.
d) Fit CLAMP RING (125) exactly the same as described in 4 (b)
above.
e) Fit DISCHARGE FLANGE (130) halves around discharge neck of
BOWL (131), clamp halves with BOLTS (270) provided and fully
tighten.

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FIGURE 44
BARE SHAFT PUMP
VOLUTE ASSEMBLY

FIGURE 45
BARE SHAFT PUMP
SECTIONAL DRAWING

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Fit the INTAKE JOINT RING (132) and the DISCHARGE JOINT RING (132)
as shown in Figure 51.

FIGURE 46
BARE SHAFT PUMP
COMPLETE ASSEMBLY

Impeller end clearance has yet to be adjusted.

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Impeller Clearance Adjustment

In these pumps, the impeller should just clear the door.

1. Loosen clamp bolts on recessed side of base, side B to allow movement

of bearing assembly during adjustment.
2. Rotate shaft clockwise by hand and move bearing assembly forward
(towards door) by tightening the rear nut on the ADJUSTIING SCREW
(001) until the impeller starts to rub on the door.
3. Release the rear nut by one sixth of a turn, then move bearing assembly
back by means of front nut until housing lug touches the rear nut.

FIGURE 47
BARE SHAFT PUMP
COMPLETE SECTIONAL
ASSEMBLY

4. Rotate shaft, impeller should not touch door.

5. Loosen nuts on either side of ADJUSTING LUG (001), tighten clamp
bolts on side B to 185Nm and tighten both nuts on either side of
adjusting lug.
6. Rotate shaft and check clearance. If impeller rubs start again from ‘1’.

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Impeller adjustment is a key element in

extending the wear life. Field tests on
INFORMATION ! certain pumps indicate if impellers are
adjusted right forward when fitted and
again at regular intervals during the wear
life, then an increase of 40-50% in life can
be achieved over pumps which were not
correctly adjusted forwards at the initial
fit up. Further, pumps which were
regularly adjusted over their life have
shown a 20% increase over pumps which
were only adjusted once at the initial fit
up.

Recommended Procedure:

a) On initial fit up, adjust the impeller so it “just touches” the door.
b) Re-adjust the impeller to “just touch” the door after 50-100 hours.
c) Re-adjust a further two or three times at regular intervals during the
wear life of the pump.
d) After adjustment of the impeller, it is important to tighten the
bearing housing clamp to 185Nm.

Before applying power, verify that the

available power source matches the
ATTENTION ! configuration settings of the product as
described in the manual.

Packing will require adjustment

INFORMATION ! during initial start-up.

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Impeller Removal

Heavy Components – appropriate lifting

CAUTION! techniques to be used.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

All Warman ‘HX’ pumps utilize a threaded

INFORMATION ! shaft and impeller, of right hand thread
form.

To gain access to the impeller generally the BOWL (131) and the DOOR
(013) can be withdrawn from the pump by removing the CLAMP RING (135)
securing the bowl to the ADAPTOR PLATE (032).

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3.1.3 Maintenance Model 420E

Bare Shaft Pump
These pump units are of robust construction and when correctly installed and
operated, will give long trouble free service with a minimum amount of
maintenance. There are only three areas of maintenance for the bare shaft
pump and these are:

Gland.

Impeller.

Lubrication.

3.1.3.1 Gland

The Multiflo Pumps' oil feed system provides lubrication and sealing of the
gland packing under snore and high vacuum conditions.

This system requires the use of "Flurograph 193" or equivalent packing, which
has been found, through experience, capable of providing excellent service
under the harsh conditions under which it may be called upon to operate.

The gland should be adjusted regularly to prevent excess leakage. The gland
must not be over tightened as this will lead to over heating of the gland area
and short life of the sealing components.
The pumps will require repacking when the gland follower is tight against the
stuffing box. It is imperative that all packing rings are replaced when
repacking. Replacement of only the first few sets of packing will lead to
premature wear of the shaft and priming difficulties.

Each ring of packing should be inserted separately and pushed in place into
the stuffing box. The split opening of the successive packing rings are to be
positioned at 180° intervals. A slight leak is des irable 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.

All these pumps utilise five rows of ¾ gland packing. The part number for the
set of packing is PAK-DWF193.

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Gland Packing Removal:

The gland packing must be replaced when packing has deteriorated to the
point that no further tightening of the gland will provide a seal or when the
gland follower has reached the end of its travel. All packing rings must be
replaced, adding one or two new rings on top of the old rings is not sufficient
to provide a proper seal.

Remove the two gland adjustment nuts and withdraw the gland follower from
the stuffing box. Remove the two gland follower securing bolts then remove
both halves of the follower from the shaft.

Using the appropriate packing removal tool, (PAK 2) remove all packing rings
from stuffing box and clean out any remaining residue.

FIGURE 48
PACKING REMOVAL TOOL

Gland Packing Installation:

New packing rings must be installed one at a time by placing rings on the shaft
and pressing each ring all the way into the stuffing box, ensuring the ends are
fitted neatly together. Successive ring joints must be staggered around
stuffing box. Pump models with Lantern rings should have the lantern ring re-
installed. Check with the pump manual for correct positioning between the
gland packing rings.

Fit gland follower to shaft and nip gland nuts up to pack gland packing.
Ensure front face of gland follower has entered the stuffing box housing. If
after tightening the gland nuts the packing has compressed enough to allow
space for another ring, remove gland follower, fit extra packing ring, re-
assemble follower and nip gland nuts up again. Back nuts off and leave finger
tight until pump is started.

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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.

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 apply, air may be induced into the pump
through the gland. This may prevent the pump “picking up” its prime or cause
it to loose 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.

Gland Oil Tank:

The tank oil level should be checked on a regular basis. If the oil level drops
at a higher than normal rate, check the gland packing for adjustment or
replacement. The Tap on the oil feed line should be opened only on initial
start up. Once primed, the tap should be closed.

As stated before the glands are designed for water lubrication and some
leakage is necessary during operation to lubricate and cool the packing and
shaft sleeve, however the oil feed system is used to assist with lubricating the
gland and shaft when the presence of water is limited.

Gland leakage at all times must be clean and free from as much abrasive
material as possible. If there is any sign of excess slurry leaking from a gland
then one of the following must be occurring:

Gland packing requires replacement.

Shaft sleeve requires replacement.

Incorrect gland adjustment.

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3.1.3.2 Impeller

The performance of the pump can change with excessive clearance between
the impeller and the front wear plate/door. For best performance it may be
necessary to occasionally stop the pump and move the impeller forward. The
procedure is:-

1. Loosen drive on pump shaft.

2. Loosen bearing housing clamp bolts.
3. Adjust impeller forward so it “just touches” the door.
4. Re-align coupling.
5. Lock adjusting bolts.
6. Re-tighten bearing housing clamp bolts to 185Nm.
7. Tighten pump drive components.

3.1.3.3 Lubrication - (Bare Shaft Pump Bearings)

A correctly assembled and pre-greased bearing assembly will have a long

trouble free life, provided it is protected against ingress of water or other
foreign matter and that it is adequately maintained.

The wet end bearings are pressure fed via a hydraulic pump and reservoir.
The reservoir level must be checked daily, keep the level of oil in the top sight
glass.

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HYDRAULIC OIL HYDRAULIC OIL

PRESSURE FILTER
RELIEF VALVE

FIGURE 49
BARE SHAFT PUMP
BEARING HYDRAULIC
OIL FILTER AND
PRESSURE RELIEF
VALVE

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Hydraulic Oil and Filter Change

1. Drain the hydraulic oil tank by removing the hydraulic oil tank drain
plug. Once empty re-fit the plug to the tank. Remove and clean the
strainer located under the hydraulic oil cap. Refit the clean strainer to
the oil cap assembly.

Remove Adaptor plate T00420Z0002 by removing 4 bolts. Remove

Assembly and clean Hydraulic Suction Strainer P/No 1910000648.
Then fit Adaptor plate assembly to tank.

2. Remove the old oil filter from the tank and replace with a new oil filter.
Check that the new oil filter seal is in place on top of the filter and lightly
coat the seal with clean hydraulic oil before fitting to the filter housing.

3. Refill the hydraulic oil tank with clean new hydraulic oil. Fill to bottom of
the strainer ensuring that oil is evident in tank. Sight glass.

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DIVIDER BARE SHAFT PUMP BARE SHAFT PUMP

BLOCK BEARING SUPPLY LUBE OIL HYDRAULIC
HOSES (2 OF) PUMP, RETURN HOSE

HYDRAULIC PUMP DIPSTICK IN HYDRAULIC

SUCTION HOSE FILLER CAP OIL TANK

FIGURE 50
BARE SHAFT PUMP
BEARING HYDRAULIC
OIL TANK
MAIN COMPONENTS

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BARE SHAFT PUMP

LUBRICATION OIL
HYDRAULIC PUMP

SUCTION

FEED

BARE SHAFT PUMP BEARINGS

LUBRICATION SYSTEM
HYDRAULIC OIL HOSES

FIGURE 51
BARE SHAFT PUMP
BEARING HYDRAULIC
OIL HOSES

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3.1.3.4 Lubrication (Bare Shaft Pump Bearings)

420E Hydraulic Circuit

HYDRAULIC PUMP HP FILTER

NON-RETURN VALVE

ORIFICE SIZE .055" (1.45mm)

RELIEF VALVE
SETTING 100PSI ORIFICE SIZE .045" (1.40mm)

FRONT BEARING REAR BEARING

SUCTION FILTER

PUMPSET 1

FIGURE 52
BARE SHAFT PUMP
HYDRAULIC CIRCUIT

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3.1.3.5 Lubrication (Bare Shaft Pump Labyrinth Seals)

Electro-Luber - Working Principle

When one or a combination of selector switches are turned on, an electro-
chemical reactor cell is activated. This begins an electro-chemical reaction
whereby electrical energy is converted into nitrogen gas. The gas is trapped
in a hermetically sealed bellows type gas chamber. As the gas is produced,
an internal pressure builds up, which is applied against a piston. The piston
then forces the lubricant out of the cylinder and into the lube point. The
strength of the electrical current determines the amount of gas produced,
which in turn, controls the rate of lubricant flow and the length of time the
ELECTRO-LUBERTM will operate.

FIGURE 53
ELECTRO-LUBER
COMPONENT
IDENTIFICATION

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Starting Procedures
Select the dispensing time and
amount of lubricant required,
then click the appropriate
switch or switches. This
action closes a circuit and the
gas generation begins.

Also click on the "BLIP" light

switch. The blip light will soon
appear and will repeat every
15 to 20 seconds for as long
as the circuit is closed. The
presence of the blip light
assures that the system is in
working order.

FIGURE 54
ELECTRO-LUBER
STARTING &
PROGRAMMING

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Electro-Luber Settings for 420E Pump Unit

FIGURE 55
ELECTRO-LUBER TIMER
SETTINGS FOR 420E
LABYRINTH

FIGURE 56
ELECTRO-LUBER

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3.1.4 Maintenance
Model 57 Piston Vacuum Pump
Pump unit to be locked and tagged before
WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Heavy Components – appropriate lifting

WARNING ! techniques to be used.

Oil level must be checked before

INFORMATION ! operating the vacuum pump. Running
the vacuum pump without oil will cause
damage.

3.1.4.1 Vacuum Pump Piston & Re-Ringing Instructions

It is advisable that the ridge be removed from the top of worn cylinders prior to
removing the piston. Failure to do so may result in cracked or broken piston
ring lands.

The ring sets are designed to bed in on both new bores and worn bores.
Honing is not essential but it is recommended to give the optimum result.
However, it is essential if one of the following conditions are present:-

Excessive wear;

Bore distortion;

Polishing or Glazing;

Scuffing;

Scratching.

When boring to oversize, allow sufficient honing allowance to completely

remove boring marks (0.06mm is usually needed).
Aim for a high cross hatch angle (30° - 60° included) and an even cut in both
directions.
Machine hone if possible as hand honing is harder to achieve the desired
result.

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Poor cleaning after honing accounts for most of today’s wear out / oil
consumption problems. Petrol and kerosene are not suitable. Soap and hot
water with a nylon scrubbing brush are best. Check with a clean white cloth
which should not come out grey. Finally, swab with a light engine oil to
prevent corrosion.

Always replace scuffed, cracked, worn or otherwise damaged pistons.

Always check the gap clearance of new rings in the lower unworn portion.
The gap should not be less that 0.003mm per mm of cylinder diameter.

Maximum gap condition is not especially

INFORMATION ! critical but should not exceed 0.01mm
per mm for compression rings while gap
on oil ring rails may be up to 1.75mm
regardless of bore size.

Ensure piston rings and pin are thoroughly clean and then lubricate rings,
skirt, pin bores and bearings with engine oil. Use a good quality ring
compressor held firm against the engine block at the time of entry of the rings
into the cylinder.

3.1.4.2 Assembly of a 3 Piece Oil Ring Assembly

• Wind on expander.

FIGURE 57
WINDING ON PISTON OIL
RING EXPANDER

• Hold the expander end in place with thumb. Wind on lower rail then wind
on upper rail.

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FIGURE 58
UPPER & LOWER RAIL
OF EXPANDER

• Both ends of the expander should be visible and not over lapped.

FIGURE 59
UPPER
&
LOWER
RAIL GAP

• Align all gaps as per the diagram above (gaps must not be lined up).
Check the assembly can rotate in the groove.
• When fitting the compression rings, make sure they are fitted the correct
way up as per the diagram on the following page.

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FIGURE 60
CORRECT FITMENT OF
COMPRESSION RINGS

• To avoid breakage, do not wind on the compression rings.

X FIGURE 61
INCORRECT FITMENT OF
COMPRESSION RINGS

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• Use a ring expander or expand with the thumbs before placing in piston
grooves.

FIGURE 62
CORRECT EXPANSION
METHOD FOR
COMPRESSION RINGS

• All rings must have clearance between the back of the ring and the back
of the groove. To check this, push the rings against the bottom of the
groove on the thrust side of the piston, then place a straight edge against
the skirt of the piston. The minimum clearance between rings and edge
should be 0.3mm for compression rings and 0.15mm fir oil rings.

FIGURE 63
CORRECT RING
BACK CLEARANCE

Correct running in of rings is essential, especially on un-honed bores. Firstly,

avoid prolonged idling and vary the engine speed and load. The load provides
the build-up of pressure behind the compression rings and helps them to bed
in.
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3.1.5 Maintenance - Drive Components

3.1.5.1 Drive Belt Tensioning

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Put the belts around the pulleys, set them to the appropriate tension value
stated in the "Tensioning Forces" Table (using the Belt Tension Indicator as
shown), run the drive under load for 30 minutes, stop the drive, check the
tension, re-setting to catalogue value if necessary. On a properly designed
drive for the application there will be no need for any further attention during
the life of the drive.

Belt Tension Indicator applied to mid span

FIGURE 64
BELT TENSIONING
INDICATOR OPERATION

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1. Calculate the deflection distance in mm on a basis of 16mm (5/8”) per

metre (yard) of span. Centre Distance (m) x 16 = Deflection (mm).

2. Set the lower marker ring at the deflection distance required in mm on the
lower scale.

3. Set the upper marker ring against the bottom edge of the top tube.

4. Place the belt tension indicator on top of the belt at the centre of span, and
apply a force at right angles to the belt deflecting it to the point where the
lower marker ring is level with the top of the adjacent belt.
For single belt drives a straight edge
INFORMATION ! should be placed across the two pulleys
to act as a datum for measuring the
amount of deflection. If the measured
force falls within the values given, the
drive should be satisfactory. A measured
force below the lower value indicates
under-tensioning. A new drive should be
tensioned to the higher value to allow for
the normal drop in tension during the
running-in period. After the drive has
been running for 30 minutes, the tension
should be checked and re-adjusted to the
higher value, if necessary.

5. Read off the force value indicated by the top edge of the upper marker ring.

6. Compare this force to the kgf value shown in the attached table.

7. If a Fenner Belt Tension Indicator is not available, a spring balance and

rule will suffice.

FIGURE 65
BELT TENSIONING
INDICATOR

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Belt Tensioning Forces

Pump unit to be locked and tagged before
WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Force required to deflect belt 16mm per metre of span

BELT SECTION
Small Pulley Newton (N) Kilogram Force
Diameter (mm) (kgf)
SPZ 95 10 to 15 1.0 to 1.5

3.1.5.2 Installation & Operation of Wedge & V-Belt Drives

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Pulley Installation

Before assembling the drive, check the pulley grooves are free from scores or
sharp edges and all dimensions conform to the relevant standard. The
Taperlock Bush is the starting point when it comes to assembly and
installation. Drive installation is a straight forward job with Taperlock, but the
stages set out on the installation leaflet provided with every Taperlock bush
should be followed closely.

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Alignment

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Good alignment of pulleys prior to belt installation is important to avoid belt

flank wear. The diagram below shows some of the common alignment faults.
You should only be satisfied if the conditions in sketch 4 prevail.

A. B. C. D.

Figure A. Figure B. Figure C. Figure D.

Shafts are not Shafts are not Shafts are Correct
parallel to one in correct parallel and in installation -
another. alignment alignment but both shafts
although they pulleys are not and pulleys
appear in alignment. are parallel
parallel when and in
seen from alignment.
above.

FIGURE 66
BELT ALIGNMENT

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Belts

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

When the pulleys have been correctly positioned on the shafts, the belts can
be installed to complete the drive. The drive centre distance should be
reduced prior to the installation of the belts so that they may be fitted without
the use of force. Under no circumstances must belts be forced into the
grooves. Belts and pulley grooves can be easily damaged by using sharp
tools to stretch the belts over the pulley rim.

The installation allowance given in the table on the following page is the
minimum recommended reduction in centre distance for the various belt
section and lengths to allow for correct fitting. The take-up allowance given in
the same table should be added on to the calculated centre distance to allow
for belt stretch.

Installation And Take-Up Allowance

Installation Take-Up
Belt Allowances (mm)
Pitch Length
SPZ
(mm)

2030 20 30

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3.1.5.3 Taperlock Bushes

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Removing a Taper Lock Bush

Removing a Taper Lock Bush

FIGURE 67
TAPERLOCK BUSH
REMOVAL

1. Slacken all screws by several turns, remove one or two according to

number of jacking holes shown thus • in diagram. Insert screws in
jacking holes after oiling thread and point of grub screws or thread and
under head of cap screws.
2. Tighten screws alternately until bush is loosened in hub and assembly
is free on the shaft.
3. Remove assembly from shaft.

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Installing a Taper Lock Bush

1. Insert Bush
Remove the protective coating from the bore and outside of bush, and
bore of hub. After ensuring that the mating tapered surfaces are
completely clean and free from oil or dirt, insert bush in hub so that
holes line up.

FIGURE 68 LEFT
INSERTING
TAPERLOCK BUSH
TO HUB

FIGURE 69 BELOW
LOCATING
TAPERLOCK ONTO
THE SHAFT
2. Insert Screws & Locate on Shaft
Sparingly oil thread and point of grub screws, or thread and under head
of cap screws. Place screws loosely in holes threaded in hub, shown in
diagram below.

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3. Torque Screws to “Finger Tight”

Clean shaft and fit hub and bush to shaft as one unit and locate in
position desired, remembering that bush will nip the shaft first and then
hub will be slightly drawn on to the bush.

FIGURE 70 ABOVE &

FIGURE 71 BELOW
TORQUING SCREWS

4. Torque Screws Alternately

Using a hexagon wrench tighten screws gradually and alternately to
torque settings shown in the torque settings table.

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5. Hammer against large end of bush using block or sleeve to prevent

damage. (This will ensure that the bush is seated squarely in the bore).
Screws will now turn a little more. Repeat this alternative hammering
and screw tightening once or twice to achieve maximum grip on the
shaft.
6. If a key is to be fitted place is in the shaft keyway before fitting the bush.
It is essential that it is a parallel key and side fitting only and has TOP
CLEARANCE.
7. After drive has been running under load for a short time, stop and
check tightness of screws.
8. Fill empty holes with grease to exclude dirt.

Taper Lock Screw Torque Settings

Bush Size 4535

Screw Tightening Torque 190 Nm

Screw Qty 3

Screw Size (BSW) 1/8”

Screw Hex Socket Size (mm) 14

Large End Diameter (mm) 162.0

Approximate Mass (kg) 7.5

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3.1.5.4 Taperlock Flanges

FIGURE 72
TAPERLOCK FLANGE
Dimensions of Fenaflex Flanges Types F & H DIMENSION CHART

F180 F H
Bush No. 4535 4535 Notes
Max Bore mm 125 125
§: G is the amount by which
L 112 112 clamping screws need to be
E 89 89 withdrawn to release tyre
J† 89 89
A 470 470 †: J is the spanner clearance
to allow for tightening the
C 398 398 bush on the shaft and the
D 205 205 clamp ring screws
F 94 94 ¶: M is half the distance
between flanges. Shaft ends
G§ 19 19 (normally Mx2) can project
M¶ 23 23 beyond the flanges. In this
Mass Kg 42.2 42.2 event allow sufficient space
between shaft ends for end
Inertia kgm² 0.847 0.847 float misalignment.

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3.1.5.5 Tyre Couplings

Installation Instructions

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Satisfactory performance depends on

INFORMATION ! correct installation and maintenance.
Under no circumstances should any
machine be started unless the coupling
and associated machine is completely
assembled. All instructions following
must be adhered to carefully.

1. Thoroughly clean all components, paying particular attention to the

removal of the protective coating in the bore of flanges.

2. Fit flanges to the shafts after placing the external clamp rings on the
shafts. (Where Taper Lock Flanges are used, see separate fitting
instructions supplied with the Taper Lock Bushes.) Locate flanges to that
dimension ‘M’ is obtained (see para 3). Flanges with internal clamping
rings should then have the clamping rings fitted, engaging only two or
three of the threads of the screws at this time.

3. Bring shafts into line until dimension ‘M’ is obtained (Refer Figure 73 &
Table 1, Page 43). If shaft end float is to occur, locate the shafts at mid-
position of end float when checking dimension ‘M’. Note that shaft ends
may project beyond the faces of the flanges if required. In this event,
allow sufficient space between shaft ends for end float and mis-
alignment. Flanges should be fitted flush with the end of the shaft when
used with Mill-Motor flanges.

4. Check parallel alignment by laying a straight edge across the flanges at

several positions around the circumference. Check angular alignment by
measuring gap between flanges at several positions around the
circumference. It is desirable to align the coupling as accurately as
possible, particularly on high speed applications.

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5. Open out tyre and fit over coupling flanges ensuring that the tyre beads
seat properly on the flanges and/or clamping rings. To ensure proper
seating, it may be necessary to strike the outside diameter of the tyre with
a small mallet. When seated, there should be a gap between the ends of
the tyre as shown in Figure 74 & Table 2, Page 44.

6. Tighten clamping ring screws alternately and evenly (half turn at a time)
working round each flange until the required screw torque is achieved
(Table 1).

FIGURE 73 TABLE 1
INTERNAL CLAMP RING TORQUE
Table 1

Coupling M mm Screw Clamping Screw

Size Size Torque Nm
F180 46 M16 105

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FIGURE 74 TABLE 2
INTERNAL CLAMP RING TORQUE

Table 2

Coupling Size F180

Tyre Gap mm 6

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3.1.5.6 1000FH Series Fuel Filter / Water Separator

Service Instructions

Draining Water:
Frequency of water draining is determined by the contamination level of the
fuel. Inspect or drain the collection bowl of water daily or as necessary. The
collection bowl must be drained before contaminants reach the top of the
turbine or when the Water Detection Module (optional) indicates it’s time to
‘drain water’.

Vacuum Application/Installations:
1. Close the inlet valve (or valve#1) and open the self-venting drain on
the bottom of the bowl.
2. Close the drain after all the water and contaminants have been
evacuated – DO NOT leave the drain open too long as it will eventually
completely drain the entire filter assembly of water AND fuel.
3. Follow ‘Priming Instructions’.

Pressure Applications/Installations:
1. Open the self-venting drain on the bottom of the bowl to evacuate water
and contaminants with a suitable collection container in place. Head
pressure will push any water and contaminants out of the drain while
keeping the filter primed.
2. Close the drain after all the water and contaminants have been
evacuated – DO NOT leave the drain open too long as it will eventually
completely drain the entire filter assembly of water AND fuel, and
possibly drain the entire tank.

Element Replacement:
Frequency of element replacement is determined by the contamination level of
fuel. Replace the elements every 10,000 miles, every 500 hours, every other
oil change, when the vacuum gauge (optional) reads between 6 to 10 inches
of mercury (inHg), if power loss is noticed, or annually, whichever comes first.

Always carry extra replacement elements

INFORMATION ! as one tank full of excessively dirty fuel
can plug a filter.

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Weir Minerals Multiflo

All Applications:
1. Bypass filter assembly with bypass valves, if applicable.
2. Remove the ‘T’ handle and lid.
3. Remove the element by holding the bail handles and slowly pulling
upward with a twisting motion. Dispose of properly.

4. Replace old lid gasket and ‘T’ handle O’ring with new seals (supplied
with new element). Lubricate both seals with motor oil or diesel fuel
before installation.

5. Refer to ‘Priming Instructions”, otherwise, fill the unit with clean fuel,
then replace the lid and ‘T’ handle and tighten snugly – by hand only –
do not use tools.

Above ground tanks or transfer pump

INFORMATION ! applications may use head pressure to
prime the filter assembly.

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 Weir Minerals Multiflo

Replacement Parts

Item Part Number Description

1. RK 11-1945 T - handle & O’ring kit
11350 T - handle & O’ring

2. RK 11-1927-01 Lid & Lid Gasket

11007 Square Cut Gasket (Lid &
Bowl)

3. RK 11021-03 1000FH – Outer Cylinder

4. RK 11-1930 1000FH – Return Tube

5. RK 11815-103 Body Clamp Bracket

6. 2020SM-OR 2 Micron Element w/seals

7. RK 11-1953 Valve, Spring & O’Ring

Kit
8. RK 11-1800-01 12 vdc Heater w/Body
Feed Thru
RK 11-1800-02 24 vdc Heater w/Body
Feed Thru
9. RK 21067 Body Feed Thru Ass’y
(for heater)
RK 11-1679 Body Feed Thru Plug
(not shown)
10. 11007 Square Cut Gasket (Lid &
Bowl)

11. RK 11028B Check Ball and Seal

12. RK 11-1939 Turbine

Centrifuge/Conical Baffle

13. RK 11-1938 See-thru Bowl w/Drain &

Plug

14. RK 32204 Water Sensor

RK 22838 Water Sensor Plug

15. RK 11-1776 Body 7/8” – ¼

16. RK 11037A Bowl Ring 5” Diameter

FIGURE 75
17. RK 11542 Capscrew Kit (4) FUEL FILTER / WATER
SEPARATOR PARTS
18. RK 30476 Self-venting Drain IDENTIFICATION
Additional Parts
RK 11-1952 FH Assembly Seal Kit
RK 31605 Parker Super O’Lube
(Various) Racor Additives (see chart on next page)

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 Weir Minerals Multiflo

Racor Additives

Additive Part Size Treatment Benefits

Number
ADT 2116 16 oz Bottle 1,280 Gallons • Concentrated formula.

Diesel • Kills bacteria & fungi.

Biocide ADT 2201 1 Gallon Bottle 10,240 Gallons • Prevents corrosion.
• Enhances engine
Diesel ADT 1116 16 oz Bottle 320 Gallons performance.
Conditioner
Plus + • Stabilizes the fuel.

ADT 1201 1 Gallon Bottle 2,560 Gallons • Quieter engine

operation.
• Inhibits waxing, icing &
Diesel gelling.
ADT 4116 16 oz Bottle 128 Gallons
Winter Plus
+ • Protects down to -
30°F (-34°C).
ADT 4201 1 Gallon Bottle 1,024 Gallons • Enhances engine
performance.

Weir Minerals Multiflo Model 420E Pump Unit – Maintenance Manual 48

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 Weir Minerals Multiflo

3.1.6 Frequency of Routine General

Maintenance
Engine and bare shaft pump parts and all
DANGER ! Engine and
fluids maybarebeshaft
at pump parts and
extremely all
high
DANGER ! fluids may when
temperatures be atthe extremely
pump unithigh is
temperatures
stopped when cause
and may the pump
serious unit is
burns.
stoppedpump
Ensure and unit
mayhas
cause serious
cooled burns.
down before
Ensure pump
any checks unit has cooled
or maintenance are down
carriedbefore
out.
any checks or maintenance are carried out.
Pump unit to be locked and tagged before
WARNING! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

3.1.6.1 Every 10 Engine Hours or Daily

EVERY 10 ENGINE HOURS OR DAILY

SCHEDULE MAINTENANCE
Bare Shaft Pump Visually inspect the level in hydraulic oil tank.
Lubrication System Fill with fresh oil if required, to the bottom of the strainer.
Engine Oil Maintain oil level between “add” and “full” marks on the
dipstick. Use SAE15W40 or refer to Lube List.
(Refer also to the Engine Manual)
Vacuum Pump Oil Maintain level between “high” and “low” marks on the
dipstick. Use SAE15W40 or refer to Lube List.
Gland Oil Tank Fill to 10mm (3/8”) below filler pipe opening.
(If fitted) Use SAE15W40 or refer to Lube List.
Gland Check gland leakage and adjust if required.

Coolant Level Maintain level in range above baffle plate and filler neck.
(Engine Stopped and Cold)
Fuel Tank Fill as required.

Battery Maintain level range above plates and filler bridge.

Drive Belts Check condition and tension if required.

Water Trap Empty water trap on vacuum tank.

Discharge Check discharge pipe work for leaks.

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 Weir Minerals Multiflo

Observe for unusual gauge leaks and

INFORMATION ! general condition of the unit. If condition
exists, determine the cause and have
necessary repairs made.

3.1.6.2 Every 250 Engine Hours

EVERY 250 ENGINE HOURS

Perform in addition to Daily Schedule Items
SCHEDULE MAINTENANCE
Engine Engine service as prescribed by Caterpillar.

Engine Oil & Filters Change the oil and filters.

(Refer to Engine Manual)

Engine Fuel Filters Change Filters.

(Refer to Engine Manual)

Bare Shaft Pump Change the oil and filters.

Lubrication System

Gland Check gland packing condition.

Non Return Valve Inspect condition. Repair if necessary.

Drive Coupling Inspect condition.

Re-tension bolts and grub screws if required.

Engine Air Cleaner Inspect condition. Replace if necessary.

Element Pre-Cleaner to be removed from deck of unit, NOT roof.

Vacuum Pump Change the Oil.

Use SAE15W40 or refer to Lube List.

Vacuum Pump Check vacuum pump belt tension and condition.

Vacuum Tank Probes Inspect and remove and clean the probes.
(Vactronic & Waterloss)

Mounting Bolts Check all bolts on Engine, Bare Shaft Pump and Vacuum
Pump. Tighten if necessary.

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 Weir Minerals Multiflo

3.1.6.3 Every 500 Engine Hours

EVERY 500 ENGINE HOURS

Perform in addition to 250 Hours Service Items
SCHEDULE MAINTENANCE
Engine Engine service as prescribed by Caterpillar.

Bare Shaft Pump Change filter on pump bearing lubrication circuit.

Lubrication System

3.1.6.4 Every 1000 Engine Hours

EVERY 1000 ENGINE HOURS

Perform in addition to 500 Hours Service Items
SCHEDULE MAINTENANCE
Engine Engine service as prescribed by Caterpillar.

Bare Shaft Pump Change oil on pump bearing lubrication circuit.

Lubrication System

Bare Shaft Pump Condition/Adjustment.

Inspection of impeller, wear plate(s), volute, and packing.

Vactronic Control Check condition of wires and probes etc.

Radiator 1. Clean core finning.

2. Inspect condition of radiator hoses.

Auto Shutdown System 1. Test shutdown operation.

2. Inspect condition of wiring, hoses etc.

Non Return Valve Replace Flap if Required.

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 Weir Minerals Multiflo

3.1.6.5 Every 2000 Engine Hours

EVERY 2000 ENGINE HOURS

Perform in addition to 1000 Hours Service Items
SCHEDULE MAINTENANCE
Bare Shaft Pump Check condition of Bare Shaft Pump Bearings for moisture
inclusion.

Engine Check operation and performance.

Non Return Valve Replace Valve Seat if required.

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 Weir Minerals Multiflo

3.2 Troubleshooting
3.2.1 Finding and Diagnostic Guide
(Including Details of Normal
Readings)
3.2.1.1 Pump Unit

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

The engine must not be run when

ATTENTION ! disconnected from the battery!!
Doing so may damage the Vactronic Module

Failure to Prime
Check Vacuum Gauge Reading.

FIGURE 76
VACUUM GAUGE –
HIGH READING

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Weir Minerals Multiflo

FIGURE 77
VACUUM GAUGE –
LOW READING

Normal Operating Range

FIGURE 78
VACUUM GAUGE
NORMAL OPERATING
RANGE

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Weir Minerals Multiflo

VACUUM GAUGE READINGS – BASIC FAULTS

SYMPTOM CAUSE REMEDY
High Vacuum
Static suction lift too high.
Lower suction lift.
Gauge Reading
(-80 and above)
Obstruction in suction
Remove obstruction
hose or strainer. from hose and/or
strainer.

Suction hose kinked or
Unkink suction hose.

collapsed.

Suction hose collapsed
Replace suction hose.

internally.

Suction hose stuck low
Remove suction hose

into the mud. from mud.

Low or No
Air leak in the suction line.
Repair suction line.

Reading
(-20 and below)
Discharge reflux valve not
Replace seal.
sealing.
If Vacuum Pump is
Operating with Air
Air leak in vacuum line
Repair vacuum line.
Being Exhausted from tank.

Leaking gland packing.
Adjust gland packing.

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 Weir Minerals Multiflo

VACUUM PUMP - BASIC FAULTS

SYMPTOM CAUSE REMEDY
Pump wont prime.
Check gland packing
Change gland packing if
condition. worn or hard.

Check the gland follower
Tighten if required to show
isn’t loose. small visual leak.

Check suction side of the
Repair if required.
pump for vacuum leaks.

NRV seat or flap may be
Replace seat and/or flap if
damaged (if the discharge damaged.
is still primed the flap and
seat are ok).
Pump keeps
Check the probe condition.
Replace if damaged.
shutting down on
water loss.
Check the suction strainer
isn’t in the mud.
Remove from mud if
required.

Check the operation of the
flow switch.
Ensure continuity between
common and normally
closed terminals.

Check the water loss
Adjust if required.
module (M2) in the control
box has the LED on.
Prime light won’t
Check the suction line for
Clear blockage if required.
go out. blockage.

Check the float in the
Replace valve if required.
krundimendt valve isn’t
shut.
Pump oil pressure
Check the hydraulic oil tank
Fill hydraulic oil tank if
light is on with the level. required.
engine shut down.

Check and replace the
Replace hydraulic filter if
filter. required.

Check the switch for
Check switch.
operation.
Low fuel light is on
Check the plug at the
Check plug is correctly
with the engine switch under the vacuum inserted in switch.
shut down tank.
(presuming there
is enough fuel).
Remove the float from the
Replace float if damaged.
tank and see if the float
floats.

Check the switch for
Check switch.
operation.
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 Weir Minerals Multiflo

VACUUM PUMP - BASIC FAULTS (continued)

SYMPTOM CAUSE REMEDY
Pump bearings
Check the flow at the
Ensure no blockages are
overheating bearings from the present and clear if
(over 100ºC). distribution block. required.

If there is sufficient flow,
Ensure no blockages are
check the pressure at the present and clear if
distribution block. required.

If there is no flow check for
Repair suction strainer and
flow through the bypass foot valve if required.
valve and from the pump,
still no flow, remove the
suction strainer and foot
valve and check their
condition.
If Vacuum Pump is
Krundimendt valve float
Clean or replace valve
Operating with no sticking. ball.
Air Being
Exhausted.
Non-return valve sticking.
Check and seal.

Vacuum pump faulty.
Repair vacuum pump.

If Vacuum Pump
Dirty probes – fault in probe
Clean probes & check
Electromagnetic wiring. probe wiring.
clutch fails to
engage.
Faulty vactronic module.
Repair or replace
vactronic module.

Faulty clutch.
Repair or replace clutch

Faulty clutch relay.
Repair or replace clutch
relay.

If the pump fails to prime after all the above conditions have been checked,
remove the suction hose from the vacuum tank inlet and the delivery hose
from the pump discharge. Seal the vacuum tank inlet and the pump
discharge. Start the engine and check the vacuum gauge reading. The
reading should be within 80 KPA to 100 KPA.

A low reading indicates:

1. An air leak in the vacuum tank.
2. An air leak in the bare shaft pump.
3. Leaking gland packing or mechanical seal.
4. Faulty vacuum pump.

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Weir Minerals Multiflo

ENGINE – BASIC FAULTS

SYMPTOM CAUSE REMEDY
Engine won’t
Emergency stop may be
Ensure emergency stop
crank. pushed. is in out position.
Engine shuts
Remove the R5 relay and
down with no run the engine:-
diagnostic lights
on. - If the fault is now gone, - Test the Pico for the
the Multiflo side of the correct outputs.
electrics has the fault.
- If the fault is still there, - Refer to the Cat manual
the problem is in the Cat or a Cat Representative.
side of the electrics.

Faulty Vacuum Pump

1. Sticking inlet or exhaust valves.
2. Worn rings.
3. Broken crankshaft.
4. Blown head gasket.
5. Blocked exhaust pipe.
6. Broken belts.

Pump Primes but Fails to Deliver Water or Delivers at a Reduced Rate

1. Foreign materials lodged in the impeller.
2. Low bare shaft pump RPM (1400 RPM maximum).
3. Obstruction in discharge hose.
4. Partial obstruction in suction hose, strainer or vacuum tank.
5. Obstruction in non-return valve.
6. Air leak in suction system.
7. Worn pump components.
8. Collapsed suction hose.
9. Pump located too high above water being pumped.

Pump Overloads Engine

1. Speed too high.
2. Specific gravity and viscosity of pump fluid different from pump
rating.
3. Mechanical defects.
4. Total dynamic head lower than pump rating – pumping too much
water.

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Weir Minerals Multiflo

3.2.1.2 Vacuum Pump

Sticking valves, inlet and exhaust, or both are visually evident by a popping
noise emitted from the vacuum pump exhaust, or uneven exhaust pulses or
no emission from exhaust pipe.

Remove inlet and exhaust caps from top of cylinder head. Remove valves.

Clean valves in solvent and check for broken springs, worn valve plates and
faces. Replace faulty components where necessary.

Replace copper washer between valve and valve seat in the cylinder head.
Retention mounting bolts as per specifications.

To test valves, place upside down and fill

INFORMATION ! with kerosene (diesel) for one (1) minute.
Okay if fluid does not disappear.

Leak in Balance Tube

The balance tube maintains a balance of vacuum between the crankcase and
cylinder head to reduce oil consumption. A leaking balance tube will cause
excessive oil consumption.

Check tube and fittings for damage and/or tightness.

Vacuum Leaks in Crankcase

(a) Damaged crankcase seal.
(b) Damaged seal on dipstick.

Vacuum leaks in the crankcase will be indicated by loss of vacuum and

excessive oil consumption.

Inspect and repair as necessary.

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 Weir Minerals Multiflo

When replacing a crankcase seal, it is to be inserted as per the diagram here.

FIGURE 79
CORRECT REPLACEMENT OF
VACUUM PUMP CRANK SEAL

Worn Rings
For conventional rings, the gap should be 0.1mm when assembled. Where
one groove of segmental is being used with one groove of a conventional oil
ring, the latter is in the lowest groove. The segments in the centre groove,
and the compression in the upper. Segmental rings, when fitted should be
paired.

Gaps should be fitted initially over the end of the gudgeon pin alternating
sides, but they will tend to move around during operation.

The piston ring groove should have a minimum of 0.25mm clearance behind
the rings.

Always rough hone a serviceable bore when fitting new rings.

Broken or Slipping Belts

Inspect and replace as necessary.

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Weir Minerals Multiflo

3.2.1.3 ‘V’ Belt Troubleshooting

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Symptom Remedy
Small cracks on ‘V’ Belt
Generally caused by shortage of belt tension but
side and base. excessive heat and/or chemical fumes can also
give same failure.

‘V’ Belt swelling or
Caused by excessive contamination by oil,

softening. certain cutting fluids or rubber solvent.

Whipping during
Usually caused by incorrect tensioning,

running. principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires re-design
or a Banded belt.

3.2.1.4 Hydrau-Flo Valve Troubleshooting

Pump unit fuel system may contain diesel

DANGER ! fuel.
Pump unit fuel system should be isolated
and drained prior to any work on the fuel
system being undertaken.

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

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Weir Minerals Multiflo

Symptom Cause Remedy

Fuel nozzle shutting Nozzle or receiver spring Check condition and rating
off prematurely. setting too low. of spring, replace if
necessary.
Back pressure in filler pipe Ensure there is no
too high. excessive restriction in the
flow of fuel from the
Hydrau-Flo to the tank.
Breather blocked. Check and clean or
replace if necessary.

Float valve set too low in Adjust to desired fill height.

tank.

Restriction in capillary line. Check line for damage,

kinks, or crushing.
Replace if necessary.

Fuel nozzle not Float valve not closing Check operation of float
shutting off. capillary line. ensuring it does not hit
internal walls of fuel tank.
Check valve seat for
damage or obstruction.
Piston stuck open. Check piston operation is
smooth and unrestricted.
Leakage in capillary line. Check line and fittings for
leaks or damage.

Float lever set above Lower float lever below

breather height. height of breather.

Fuel weeping from Float level set too high, not Lower float level setting.
breather after tank has allowing enough air space
been filled. for fuel expansion due to
rise in temperature.

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Weir Minerals Multiflo

3.2.1.5 Hydraulic Pump Troubleshooting

Engine and bare shaft pump parts and all

DANGER ! fluids may be at extremely high
temperatures when the pump unit is
stopped and may cause serious burns.
Ensure pump unit has cooled down before
any checks or maintenance are carried out.

Pump unit to be locked and tagged before

WARNING ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Symptom Cause Remedy

Low pressure/flow at Blocked filter. Change filter.
bearings. Check pressure relief
settings.

Blocked orifice. Remove fittings from

distribution block and check
for debris.

Worn hydraulic pump. Dead head the pump and

check the pressure.

Engine shuts down on Faulty switch. Remove switch and check

low pump oil pressure. for open circuit. Replace if
it is faulty.

Blocked suction filter. Remove filter from the tank

and inspect. Fill reservoir
with Delvac 1330 Oil.

Low oil. Remove pump from the

engine remove the back
plate and inspect pump
components for wear.

Pump failure. Check drive rotation in the

engine.

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Weir Minerals Multiflo

3.2.1.6 1000FH Turbine Series Fuel Filter / Water Separator

Troubleshooting (If Fitted)

Correct external fuel leaks immediately!

ATTENTION ! These conditions will result in reduced
engine performance such as: hard starting,
stalling, reduced power and other
associated problems.

New filter installations must be filled with fuel and the fuel system must be
adequately primed following the engine manufacturer’s recommendations, if
applicable. Existing installation difficulties are usually associated with
improper priming procedures or damage to the unit or fuel system. The result
is either internal air suction or external fuel leakage. Diagnosis should be in
the following steps:

1. Check the fuel level and make sure any fuel delivery valves are in the
open position as applicable.
2. Ensure the T-handle, bowl fasteners and fuel fittings are tight. Also
verify that the bowl drain is closed.
3. If the Racor element is new, check potential restrictions at the fuel tank
draw tube. An in-tank strainer may be plugged.
4. Review some of the workings of the units below to possibly uncover the
solutions.

Correct Application
It is very important that the RH filter assembly is not ‘under specified’ for the
application. The maximum fuel flow rating of the FH filter assembly must not
be exceeded. Doing so will reduce efficiency and de-gas (pull air from) the
fuel.

Filter Elements
Replacement elements are available in 2, 10 and 30 micron ratings. Filtration
needs are based on application, fuel quality, maintenance schedules and
operating climates. A simple rule to remember is – the finer the filtration, the
more frequent the filter change. Always carry extra replacement elements with
your equipment as one tank full of excessively contaminated fuel can plug an
element. When clogged to the maximum capacity, elements will have a brown
to black colour or tar like contaminants may be present – this is normal. An
appearance of a multi-coloured slime (which may have a foul odour) is an
indication of microbiological contamination. This condition must be treated
immediately. Severe conditions must be corrected by a repair facility.

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 Weir Minerals Multiflo

Never operate the filter assembly without

ATTENTION ! the element in place. The element safety
valve will not expose the outlet hole on the
return fuel tube if the element is removed.
Instead, punch the emergency tab on the top
of the element and leave in place.
Puncturing the emergency tab will bypass
all filtration and send unfiltered fuel to the
engine. Service the element as soon as
possible to avoid harmful contaminants
flowing down stream to the engine.
Correct external fuel leaks immediately. In
the event difficulties are experienced with
the filter assembly or a problem appears to
prevent the engine from running smoothly,
follow the quick-help instructions below or
refer to the procedures on the previous
page.

All Racor FH filter assemblies are 100% tested to ensure a leak-proof, quality
product.

Apply Parker Super O-Lube (part number

INFORMATION ! RF31605) or equivalent to all seals at
major attachment points to maintain
integrity, seal elasticity, to fill small voids
and to provide protection from
degradation.

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Weir Minerals Multiflo

FIGURE 80
FUEL FILTER / WATER
SEPARATOR
TROUBLESHOOTING
HINTS

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 Weir Minerals Multiflo

3.3 Lubrication Schedule

3.3.1 Grades & Frequency of Lubrication
Engine, bare shaft pump and transmission
DANGER ! parts and all fluids may be at extremely high
temperatures when the pump unit is
stopped and may cause serious burns.
Ensure pump unit has cooled down before
any checks or maintenance are carried out.

Pump unit to be locked and tagged before

DANGER ! any maintenance or service is performed.

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

Grades and Frequency of Lubrication

Recommended Maximum
Item Lubricant Frequency Capacity

C27 Engine Oil Mobil Delvac MX 15W40 Checked Daily 72 litres

Shell Rimula 15W40

Model 57 Piston Mobil Delvac MX15W40 Checked Daily 2.2 litres

Vacuum Pump Oil SAE15W40

Bare Shaft Pump

Bearing Assembly Mobil Delvac 1330 Oil Checked Daily 26 litres

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Weir Minerals Multiflo

WEIR MINERALS MULTIFLO

MULTIFLO MODEL MF-420E
DIESEL POWERED PUMP UNIT

SPARE PARTS MANUAL

Copyright (C) 2010, Weir Minerals Australia Ltd trading as Weir Minerals Multiflo. All rights reserved. MULTIFLO, VACTRONIC
and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd. This document contains information which is confi-
dential 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.

Revised June 2010

 Weir Minerals Multiflo

MF-420E Pump Unit

Parts Manual Index
Part 4 Spare Parts
Part Page
Major Components IV 1
Bare Shaft Pump IV
420E Bare Shaft Pump IV 3
420E Bearing Assembly IV 4
420E Shaft Sleeve & Gland Packing IV 6
420E Wetted Parts IV 7
420E Gland Guard IV 8
Priming System IV
Priming Assembly IV 9
Probes IV 10
Model 57 Piston Vacuum Pump IV 11
Vacuum Pump “Robatic” Clutch (24 volt) IV 17
Vacuum Pump Pulley IV 18
Vacuum Pressure Gauge IV 19
Vacuum Pump Mounting Plate IV 20
Drive Components IV
Drive Assembly IV 21
Electrical IV
Battery Box IV 22
Control Box IV 23
Emergency Stop IV 29
Isolators IV 30
Lubrication & Service Points IV
Gland Oil Tank Assembly IV 31
Bare Shaft Pump Hydraulic System IV 32
Hydrau-Flo Valve IV 35
High Wall Filler IV 36
Fuel Float Switch Assembly IV 37
Fuel Fillers IV 38

1
Multiflo Model MF-420E – Parts Index
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 Weir Minerals Multiflo

MF-420E Pump Unit

Part 4 Spare Parts

Part Page
Fuel Filters IV 39
Suction Components
Suction Assembly IV 40
Discharge Components
Discharge Assembly 41
Non Return “Vooom” Valve 43
Discharge Inspection Tee Assembly 44
Standard Options
Worklights 45
Fire Extinguisher 46
Washdown Hose 47
Part 4A – Unit Specifics
If Fitted

Spare Parts Supplement

Technical Bulletin Document TB-2010-06 relating to 8/6 FFY-HX Oil Lubricated
Bearing Assembly Seal Upgrade

2
Multiflo Model MF-420E – Parts Index
Rev 04.10
(Always quote Model and Serial Number of Unit when Ordering Parts)
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9
6
5
6
7
6 3
7
6 3

THERMO BLANKETS KIT PN: 102750 ( RH & LH )

MAJOR COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 CANOPY CA0420Z0001 1
2 CABLE COVER BA0000Z0001 1
3 STEP TREADS WA0420Z0017 2
4 LADDER MCT420A035 1
5 WALKWAY PLATFORM (RIGHT SIDE) WA0420Z0003 1
6 WALKWAY PLATFORM MOUNTS (RIGHT SIDE) MCLAPB420A 4
7 HANDRAIL (SET OF 2) WA0420Z0007 1
8 PRECLEANER PBHOO-2224 2
9 MESH PANEL WA0420Z0015 1
10 THERMO BLANKETS - MUFFLER (NOT SHOWN) EX0027Z0001 2
11 THERMO BLANKETS - TURBO (NOT SHOWN) EX0027Z0002 2
12 THERMO BLANKETS - PIPE (NOT SHOWN) EX0027Z0003 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 1
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4
3

2
1

5
8
7

UNIT ASSY PN: 204140

MAJOR COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 CATERPILLAR C27 POWER PACK CAC27 1
2 EXHAUST REFER CAT MANUAL 2
3 RAINCAP REFER CAT MANUAL 2
4 STROBE LIGHT - AMBER LENS (STANDARD) PRE3414SL A/R
STROBE LIGHT - BLUE LENS (OPTIONAL) BR95QBS A/R
5 WALKWAY PLATFORM (LEFT SIDE) WA0420Z0004 1
6 WALKWAY PLATFORM MOUNTS (LEFT SIDE) MSS000N001 5
7 HANDRAIL (SET OF 2) WA0420Z0008 1
8 MESH PANEL WA0420Z0015 1
9 THERMO BLANKET KIT RH & LH (NOT SHOWN) 102750 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 2
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1
3 5

420E BARE SHAFT PUMP

ITEM DESCRIPTION PART NUMBER QTY
1 WARMAN 8/6 FFY-HX (OIL) BARE SHAFT PUMP BS0420Z0004 1
2 FLANGE INTAKE (2 PIECE) F8130E02 1
3 FLANGE DISCHARGE (2 PIECE) E6130E02 1
4 INTAKE JOINT F8132S01 1
5 DISCHARGE JOINT F6132S01 1

Revised 08.09
420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 3
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BEARING ASSEMBLY P/N : 203192 1

2
6 4

8
10
12
3
5
7
9
11
13

6 9
5
6

8
7
4

420E BEARING ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY
1 LOCKNUT FFY061C23 1
2 O RING 53T126N353 1
3 LABYRINTH (DRIVE END) 203191 1
4 V SEAL SKF V150 203194 2
5 BOLT D027ME62 16
6 GREASE LUBRICATING NIPPLE 5AA-07 2
7 BEARING CAP 203193 2
8 O RING BS269 203196 2
9 RADIAL OIL SEAL 203095 2
10 FLINGER DRIVE END FFY184DE02 1
11 BEARING DRIVE END S009D 1
12 BEARING SPACER OUTER S276-AE02 1
13 BEARING SPACER INNER S276-BE02 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 4
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16 14
15

17
21
22

18

19
14 20
23

24

420E BEARING ASSEMBLY (CONTINUED)

ITEM DESCRIPTION PART NUMBER QTY
14 GASKET 203199 2
15 SHAFT 420E - 02 1
16 BREATHER UCSAB7101 1
17 ADAPTOR HF1014Z0001 1
18 BEARING HOUSING BH0420Z0001 1
19 OIL DRAIN LU1000Z0001 1
20 LOCK NUT LU1000Z0002 1
21 BEARING IMPELLER END S009 1
22 SPACER FFY008E62 1
23 FLINGER IMPELLER END SYGSM184E62 1
24 LABYRINTH WET END 203195 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 5
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6
7

3 5

420E SHAFT SLEEVE & GLAND PACKING

ITEM DESCRIPTION PART NUMBER QTY
1 NECK RING F067C23 1
2 PACKING KIT (5 RINGS) PAK-DWF193 1
3 GLAND (2 PIECE) F044C23 1
4 GLAND BOLT F045MC23 2
5 NUT (OFF SET) 390-34N 2
6 O RING F109S10 2
7 SHAFT SLEEVE (J31) SH0420Z0001 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 6
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11
10
9
8

6
1

4
7
3
12

1
2

420E WETTED PARTS

ITEM DESCRIPTION PART NUMBER QTY
1 BOWL SEAL FX6124S00 2
2 FRONT DOOR FX6013HET1A48 1
3 CLAMP RING (4 PIECE - NO BOLTS) F10135E02 2
4 VOLUTE FX66131A48 1
5 IMPELLER 420E-69 1
6 BACKLINER FX66041A48 1
7 CLAMP BOLT (C/W 1 NUT) F129ME62 8
8 O RING FH122S01 1
9 STUFFING BOX MK121333AA55 1
10 ADAPTOR PLATE FX66032D21 1
11 ADAPTOR PLATE STUD & 2 NUTS FH039ME63 3
12 BACK LINER STUD & NYLOC NUT FX026ME62 4

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 7
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420E GLAND GUARD

ITEM DESCRIPTION PART NUMBER QTY
1 GLAND GUARD BOTTOM MSA420N001 1
2 GLAND GUARD TOP MSA420N002 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 8
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6 5

3
2

PRIMING ASSEMBLY
ITEM DESCRIPTION PART NUMBER QTY
1 VACUUM TANK (BARE) VT0420Z0001 1
2 VACUUM TANK MOUNT VT0420Z0002 1
3 BOLTS & NUTS BLTM16050G8SA 8
4 WASHERS BLTSQ50506-16 16
5 KRUNDIMENDT VALVE (C/W BOLTS & O'RING) VT2002-02 1
6 WATER TRAP 200-0345 1
7 GASKET VRA150-20 1
8 BOLTS BLTM10040SS6 8

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 9
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1 1

PROBES
ITEM DESCRIPTION PART NUMBER QTY
1 PROBE VT2002-01 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 10
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MODEL 57 VACUUM PUMP

ITEM DESCRIPTION PART NUMBER QTY
1 COMPLETE VACUUM PUMP MVP150-200 1
2 EXHAUST PIPE MVP150-254 1
3 OIL DRAIN PLUG c/w O' RING MVP150-223 1
4 REDUCING BUSH MVP150-278 1
5 HOSE MVP250-279 1
6 GUARD MVP150-282 1
7 GASKET MVP150-215 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 11
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CRANK CASE GROUP

ITEM DESCRIPTION PART NUMBER QTY
1 REAR BEARING CAP MVP150-242 1
2 GASKET MVP150-234 2
3 BEARING SUPPORTER MVP150-245 2
4 BOLT BLTM06020 12
5 DIPSTICK COVER PLATE MVP150-254DA 1
6 CRANK CASE MVP150-220 1
7 STUD MVP150-265 6
8 GASKET MVP150-218 2
9 INSPECTION PLATE MVP150-219 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 12
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CRANK CASE GROUP (CONTINUED)

ITEM DESCRIPTION PART NUMBER QTY
1 DIPSTICK c/w O'RING MVP150-252 1
2 GASKET MVP150-222 1
3 CRANKSHAFT MVP150-247 1
4 BEARING MVP150-239 2
5 SHAFT KEY MVP150-235 1
6 BOLT BLTM10025 4
7 FRONT BEARING CAP MVP150-240 1
8 OIL SEAL MVP150-238 2
9 BOLT BLTM10025 16
10 O'RING MVP150-253 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 13
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CYLINDER BLOCK GROUP

ITEM DESCRIPTION PART NUMBER QTY
1 GASKET MVP150-216 1
2 STUD MVP150-265 2
3 CYLINDER BLOCK MVP150-217 1
4 CIRCLIP MVP150-228 4
5 RING SET (BOTH PISTONS) MVP150-261 1
6 NUT BLTMCN10 6
7 PISTON MVP150-231A 2
8 PIN MVP150-229 2
9 CONNECTING ROD MVP150-232 2
10 SLIPPER SET (PAIR) MVP150-233 2
11 BIG END BOLT MVP150-275 4
12 NUT MVP150-276 4
13 SPLASHER MVP150-248 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 14
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CYLINDER HEAD GROUP

ITEM DESCRIPTION PART NUMBER QTY
1 DISCHARGE VALVE MVP150-213 2
2 DISCHARGE CAGE MVP150-212 2
3 DISCHARGE TRIANGLE MVP150-210 2
4 GASKET MVP150-209 2
5 PUSH BOLT MVP150-208 2
6 CAP NUT MVP150-207 2
7 BLIND NUT MVP150-277 2
8 GASKET MVP150-206 4
9 HEAD MVP150-214 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 15
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CYLINDER HEAD GROUP (CONTINUED)

ITEM DESCRIPTION PART NUMBER QTY
1 BOLT BLTM10030 12
2 BOLT BLTM08035 4
3 PLUG BSPP 1-8GM 2
4 DIAMOND MVP150-201 2
5 GASKET MVP150-202 2
6 INLET TRIANGLE MVP150-204 2
6 O'RING (NOT SHOWN) MVP150-203 2
7 INLET VALVE MVP150-205 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 16
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VACUUM PUMP CLUTCH

ITEM DESCRIPTION PART NUMBER QTY
1 CIRCLIP 540-140-717 1
2 CIRCLIP 540-140-716 1
3 SHIM KIT 540-140-719 1
4 BEARING 540-140-713 1
5 MOUNTING FLANGE 540-140-708 1
6 ROTOR 540-140-711 1
7 TRANSMISSION FLANGE 540-140-709 1
8 WAVE WASHER 540-140-722 1
9 BEARING 540-140-705 2
10 COIL CARRIER 540-140-712-24 1
11 CIRCLIP 540-140-702 1
12 CIRCLIP 540-140-701 1
COMPLETE CLUTCH 540-140-700-24

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 17
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VACUUM PRESSURE GAUGE

ITEM DESCRIPTION PART NUMBER QTY
1 VACUUM PRESSURE GAUGE 200-0365PM 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 19
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1 3

VACUUM PUMP MOUNTING PLATE

ITEM DESCRIPTION PART NUMBER QTY
1 MOUNTING PLATE MVP150-288 1
2 ADJUSTING BOLT MVP150-283 1
3 NUT MVP150-284 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 20
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12
11
1
10
10

7
4
5 6 8
3 9
2
13

DRIVE ASSEMBLY
ITEM DESCRIPTION PART NUMBER QTY
1 COUPLING GUARD (3 PIECE) GU0420Z0001 1
2 FENAFLEX COUPLING TYPE H (2 PIECE) F180H 1
3 FENAFLEX ELEMENT F180ST 1
4 FENAFLEX COUPLING TYPE F (2 PIECE) F180F 1
5 TAPERLOCKS TL4535-120 2
6 STUBSHAFT MPT420A017 1
7 KEY MPT420A235 1
8 DRIVE PLATE MPT420A018 1
9 BOLTS BLTMF24080B 8
10 WASHER BLTW24G 16
11 SPRING WASHERS BLTSW24G 8
12 NUTS BLTMFNN24 8
13 BELTS VB2030SPZ 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 21
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10
4

9 2

7
3
2

BATTERY BOX
ITEM DESCRIPTION PART NUMBER QTY
1 BATTERY BOX EL0420Z0003 1
2 BATTERY BATCENTN200 2
3 BATTERY MAT BM1 2
4 BATTERY BOX GAS STRUT BB24V6B-07 1
5 HOLD DOWN BRACKET EL0420Z0004 1
6 HOLD DOWN TIE FA0000Z0001 2
7 HOLD DOWN ROD FA0000Z0002 2
8 BATTERY CABLE (BRIDGE) BC2101Z0380 1
9 BATTERY CABLE (BATTERY-ISOLATOR +) BC1102Z2300 1
10 BATTERY CABLE (BATTERY-ISOLATOR -) BC2102Z2450 1
11 BATTERY CABLE (ISOLATOR-STARTER +) (NOT SHOWN) BC1105Z2180 1
12 BATTERY CABLE (ISOLATOR-STARTER -) (NOT SHOWN) BC2105Z2150 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 22
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1 2

5,6,7,8,9 & 10
5,6,7,8,9 & 10

CONTROL BOX (OUTSIDE)

ITEM DESCRIPTION PART NUMBER QTY
1 CONTROL BOX (BARE) EL0000Z0002 1
2 'FIRST OUT PANEL' EL0000Z0005 1
3 KEYED CHROME T HANDLE 2535000 1
4 SWITCH 8D-2676 2
5 CONTROL BOX MOUNTING BOLT BLTM08050G4.6 4
6 MOUNT PART A CBM-01-01 4
7 MOUNT PART B CBM-01-02 4
8 WASHER CBM-01-04 8
9 NUT BLTMNN08G 4
10 SLEEVE CBM-01-03-30 4
11 LOCKING KIT (NOT SHOWN) 10009989 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 23
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2 1

4
3

CONTROL BOX (INSIDE)

ITEM DESCRIPTION PART NUMBER QTY
1 MICROLOGIX 101202
2 CAPACITOR 101119
3 70 AMP RELAY 100995
4 TERMINAL BLOCK 4mm 101521
5 TERMINAL BLOCK 6 mm 101498
6 TERMINAL BLOCK 10 mm 101499
7 REDARC FUNCTION TIMER RTIM06
8 MODULE FUNCTION TIMER RCT7320

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 24
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ELECTRICAL COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 FUSE HOLDER 5442BL A/R
2 FUSE (1AMP) 302-9219-01AMP A/R
3 FUSE (2AMP) 302-9219-02AMP A/R
4 FUSE (4AMP) 302-9219-04AMP A/R
5 FUSE (5AMP) 302-9219-05AMP A/R
6 FUSE (10AMP) 302-9219-10AMP A/R
7 FUSE (15AMP) 302-9219-15AMP A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 25
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ELECTRICAL COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 CIRCUIT BREAKER (2AMP) CB-02K A/R
2 CIRCUIT BREAKER (3AMP) CB-03K A/R
3 CIRCUIT BREAKER (4AMP) CB-04K A/R
4 CIRCUIT BREAKER (5AMP) CB-05K A/R
5 CIRCUIT BREAKER (10AMP) CB-10K A/R
6 CIRCUIT BREAKER (15AMP) CB-15K A/R
7 CIRCUIT BREAKER (20AMP) CB-20K A/R
8 CIRCUIT BREAKER (30AMP) CB-30K A/R
9 CIRCUIT BREAKER (40AMP) CB-40K A/R
10 CIRCUIT BREAKER (50AMP) CB-50K A/R
11 CIRCUIT BREAKER (60AMP) CB-60K A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 26
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ELECTRICAL COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 RELAY CHANGEOVER R24VCOAS-01 A/R
2 RELAY BLOCK H4973 A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 27
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ELECTRICAL COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY
1 C.B. BOX RS282-1152M 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 28
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EMERGENCY STOP
ITEM DESCRIPTION PART NUMBER QTY
1 EMERGENCY STOP ES-03-01 1
NC CONTACT (IF REQUIRED) ES-03-02 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 29
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2
1

ISOLATORS
ITEM DESCRIPTION PART NUMBER QTY
1 BATTERY LOCKOUT LS11003-01 1
2 STARTER LOCKOUT (IF FITTED) LS11003-02 1
3 ISOLATOR 341003004 A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 30
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9 3
4
10 8
2

6 1
11 7
9

GLAND OIL TANK ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY
1 TANK TO0000Z0001 1
2 SIGHT GLASS SGA-16 1
3 OIL CAP 200-0356 1
4 NEEDLE VALVE 200-0354-38 1
5 CHECK VALVE VT2004-03 1
6 ELBOW HFS49-0606 1
7 NIPPLE HFS27-0606 2
8 HOSE HHP16-0200 1
9 PLUG HFS64-06 2
10 HOSE TAIL HF802-0606 2
11 NIPPLE REDUCING SS7303 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 31
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1 14

12

13
3
2
5 13
4

6
9
11
7
10 8

PUMP HYDRAULIC SYSTEM

ITEM DESCRIPTION PART NUMBER QTY
1 HYDRAULIC PUMP MSH000N013 1
2 HOSE A (INCLUDES CRIMP ON FITTINGS) HO0420Z0001 1
3 HOSE B (INCLUDES CRIMP ON FITTINGS) HO0420Z0002 1
4 HOSE C (INCLUDES CRIMP ON FITTINGS) HO0420Z0003 1
5 HOSE D (INCLUDES CRIMP ON FITTINGS) HO0420Z0004 1
6 HOSE E (INCLUDES CRIMP ON FITTINGS) HO0420Z0005 1
7 OIL TANK RESERVOIR TO0420Z0001 1
8 MOUNTING PLATES TO0420Z0003 2
9 MOUNTING BOLTS BLTM10040G4.6 4
10 WASHERS BLTW10G 8
11 NUTS BLTMN10G 4
12 ELBOW HFS89-0814 1
13 ELBOW HFS8-0209 2
14 ELBOW HFS89-0812 1
420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 32
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10 6

4
4(New Pn:101495)
3
7 2

PUMP HYDRAULIC SYSTEM

ITEM DESCRIPTION PART NUMBER QTY
1 FILTER SFC-3525E 1
2 FILTER HEAD 1010001820 1
3 TEE LU0420Z0001 1
4 OIL PRESSURE SWITCH New Pn: 101495 76583-4NO 1
5 NIPPLE HFS27-1208 1
6 HOSE F (INCLUDES CRIMP-ON FITTINGS) HO0420Z0006 1
7 ELBOW HFS8-1209 1
8 HOSE G (INCLUDES CRIMP-ON FITTINGS) HO0420Z0007 1
9 NIPPLE HFS90-0909 1
10 PRESSURE RELEASE VA3800B0001 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 33
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7
10
6
11

5
4 9

3
12

PUMP HYDRAULIC SYSTEM

ITEM DESCRIPTION PART NUMBER QTY
1 STRAINER 1910000648 1
2 ELBOW HFS49-1212 1
3 ADAPTOR FBS-19 1
4 VALVE VT84-015 1
5 NIPPLE HFS27-1212 1
6 ADAPTOR TO0420Z0002 1
7 REDUCING ELBOW HFS49-1208 1
8 PLUG HFS64-12 1
9 FILLER / BREATHER VT99-002 1
10 FOUR OUTLET MANIFOLD 226216 1
11 ELBOW HFS49-1616 1
12 SIGHT GLASS SGA-16 1

420E (04.10)+B46 PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 34
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HYDRAU-FLO
ITEM DESCRIPTION PART NUMBER QTY
1 WIGGINS RECEIVER + CAP AUS23L + AUS23C 1
2 VALVE ASSEMBLY FBS-03A 1
3 ELBOW HF807-0609 2
4 HOSE HH1J061062J06-6020 1
5 HOSE HH1J061062J06-0610 1
6 MOUNTING PLATE FBS-08A 2
7 ELBOW HFS8-0409 2
8 FLOAT ASSEMBLY FBS-66-110 2

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 35
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1 3 2

8
5
6

HIGH WALL FUEL FILLER

ITEM DESCRIPTION PART NUMBER QTY
1 ELBOW HFS49-0804 1
2 NIPPLE HFS27-1208 1
3 HOSE (INCLUDE CRIMP-ON FITTINGS) HH1108Z0230 1
4 MOUNTING PALTE FBS-08A 1
5 O'RING (UNDER) FBS-22 1
6 FLOAT LOCK NUT (UNDER) FBS-29 1
7 FLOAT HWFV2002-01 1
8 PLUG HFS64-12 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 36
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FUEL FLOAT SWITCH ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY
1 LOW FUEL FLOAT SWITCH ASSEMBLY EL0420Z0003 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 37
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2 5

6
3 4
1

FUEL FILLERS
ITEM DESCRIPTION PART NUMBER QTY
1 VALVE ASSEMBLY BLACK FBS-03A 1
2 RECEIVER FUEL BANLAW AUS23L 1
3 ALUMINIUM CAP AUS23C 1
4 FUEL GAUGE 62200-A-250 1
5 MANUAL FILL CAP KL50-DC 1
6 MANUAL FILL FITTING KL50-A 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 38
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1 1

FUEL FILTERS
ITEM DESCRIPTION PART NUMBER QTY
1 RACOR 1000 FUEL FILTER 1000FH2 2
REPLACEMENT ELEMENTS 2020SM-OR A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 39
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10

2 12 7
5

11

1
3 6

10 9
6

SUCTION ASSEMBLY
ITEM DESCRIPTION PART NUMBER QTY
1 SUCTION REDUCER MFL300X200ERSS 1
2 BOOM MFB8 1
3 BOOM CHAINS CH80ZP13-06600 2
4 WINCH (INCLUDES GUARD) F11650C 1
5 SPREADER BAR H250JSB-3000 1
6 SUCTION HOSE H25002204JL 2
7 STRAINER MFS300-40SS 1
8 WIRE ROPE WR10-25SASA 1
9 INTERMEDIATE CLAMP UN31-273LE 1
10 HAMMERLOK HL13 4
11 INTERMEDIATE CHAIN CH80ZP10-02200 1
12 D SHACKLE DS-S-13 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 40
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2 1

4 8
3
8
8 6

DISCHARGE ASSEMBLY
ITEM DESCRIPTION PART NUMBER QTY
1 DISCHARGE PIPEWORK 1 PW0420Z0019 1
2 DISCHARGE PIPEWORK 2 PW0420Z0020 1
3 DISCHARGE PIPEWORK 3 PW0420Z0021 1
4 DISCHARGE PIPEWORK 4 PW0420Z0022 1
5 DISCHARGE PIPEWORK 5 PW0420Z0023 1
6 DISCHARGE PIPEWORK 6 MFL300X200ER 1
7 RUBBER HOSE H20002200.90JL 1
8 DISCHARGE SUPPORT MCJ000N006 5
9 RUBBER HOSE 1.5M LONG (NOT SHOWN) H30002201.5JL 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 41
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2
1

5 4

6
5

DISCHARGE ASSEMBLY (CONTINUED)

ITEM DESCRIPTION PART NUMBER QTY
1 AIR VALVE BLANKING PLATE SS316FL080TEB A/R
AIR VALVE (OPTIONAL) MPS-080-116 A/R
2 VOOOM NON-RETURN VALVE NRV150-01SS 1
3 ONYX RING SPACER MSF200-08 A/R
ONYX RING KIT (OPTIONAL) MSF200-K02 A/R
4 ONYX RING GUARD (OPTIONAL) GA0420Z0001 A/R
5 ISOLATION VALVE MF200BFV-KGO 2
6 PLUG BSPP 1-0SS A/R
FLOW SWITCH (OPTIONAL) TWS26SS-140 A/R

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 42
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14

6
13

3
5
11
4

9
12
10 2
1

NON-RETURN VALVE
(STAINLESS STEEL)
ITEM DESCRIPTION PART NUMBER QTY
COMPLETE VALVE NRV150-01SS 1
1 BODY NRV150-02SS 1
2 O'RING NRV150-03 1
3 DOWEL PIN NRV150-24 1
4 STUD NRV150-17 8
5 GASKET NRV150-20 1
6 INSPECTION LID NRV150-13 1
7 BAR, FIXING NRV150-07 1
8 STUD NRV150-19 3
9 STUD NRV150-18 16
10 FLAP NRV150-06 1
11 SEAT NRV150-04SS 1
12 NYLOC NUT NRV150-08 3
13 WASHER NRV150-14 8
14 NUT NRV150-15 8

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 43
Weir Minerals Multiflo

13
12

11
5 10

1
11

4
7
7

3
6
3
2
8
9

INSPECTION TEE ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY
1 TEE PW0420Z0007 1
2 INSPECTION LID PW0400Z0009 1
3 CLAMP (2 PIECE INC BOLTS, INC SEAL) MFF200BC 1
4 GASKET GTE200 2
5 PLUG BSPP 1-0SS A/R
FLOW SWITCH (OPTIONAL) TWS26SS-140 A/R
6 BARE SHAFT PUMP MOUNTING BOLTS BLTM100G8SA 8
7 WASHERS BLTW16G 16
8 SPRING WAHERS BLTSW16G 8
9 NUT BLTMN16G 8
10 VACUUM TANK MOUNTING BOLTS BLTM20075G8SA 8
11 WASHERS BLTW20G 16
12 SPRING WAHERS BLTSW20G 8
13 NUTS BLTMN20G 8
420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 44
Weir Minerals Multiflo

WORKLIGHTS
ITEM DESCRIPTION PART NUMBER QTY
1 LIGHT BODY 9150901 6
2 LIGHT BEAM (24 VOLTS) 1096 6

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 45
Weir Minerals Multiflo

FIRE EXTINGUISHER
ITEM DESCRIPTION PART NUMBER QTY
1 MOUNTING PLATE FEP-1 1
2 FIRE EXTINGUISHER FEQ9KGC-70 1
3 MOUNTING BRACKET FEHDVMBC9KG 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 46
Weir Minerals Multiflo

WASHDOWN HOSE
ITEM DESCRIPTION PART NUMBER QTY
1 ELBOW BSPEMF-1SS6 1
2 REDUCING BUSH BSPRB-50X25SS6 1
3 NIPPLE BSPN 1-0SS6 1
4 BALL VALVE BVF 1-0SS6 1
5 HOSE CLAMP RSC-3437 1
6 HOSE TAIL S21-025 1
7 BRACKET MSLWH42001 1
8 SAFETY HOSE MSLWH42001-01 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 47
Weir Minerals Multiflo

STROBE LIGHT
ITEM DESCRIPTION PART NUMBER QTY
1 AMBER STROBE LIGHT 101078 1

420E (04.10) PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 48
 Weir Minerals Multiflo Document Page
TB-2010-06 1 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

1. Applies To
All 8/6 FFY-HX Bare Shaft pumps delivered prior to March 2010.

Figure 1.1 8/6 FFY-HX Bare Shaft Pump

2. Purpose
Improve the end cap seals to eliminate oil leakage from the bearing assembly.

Figure 2.1 - 8/6 FFY-HX Bearing Assembly Cross-Section

Weir Minerals Multiflo Document Page
TB-2010-06 2 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

Figure 2.2 - Previous Design Details

Figure 2.3 - Improved Design Details

 Weir Minerals Multiflo Document Page
TB-2010-06 3 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

3. Parts Required
Qty Part Number Description
2 203095 RADIAL OIL SEAL
1 203191 LABYRINTH DRIVE END
2 203193 BEARING CAP END
2 203194 V SEAL
1 203195 LABYRINTH WET END
2 203196 ORING
2 203199 GASKET
2 203214 GREASE LUBRICATING NIPPLE (SAP#5AA-07)
Weir Minerals Multiflo Document Page
TB-2010-06 4 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

Figure 3.1 Assembly Drawing - Improved Seal Design

 Weir Minerals Multiflo Document Page
TB-2010-06 5 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

4. Procedure
The following procedure describes the process to upgrade a typical 8/6 FFY-HX Bare Shaft Pump. Please
contact Weir Minerals Multiflo if you have questions regarding your specific unit.
i. Remove the bare shaft pump from the pump unit.
ii. Remove the bearing assembly from the bare shaft pump.
iii. Remove the components as illustrated from the bearing assembly.

Figure 4.iii.1 - Existing Design Disassembly.

Weir Minerals Multiflo Document Page
TB-2010-06 6 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

Figure 4.iii.2 - Existing Design Disassembly - Wet End Detail

Figure 4.iii.3 - Existing Design Disassembly - Drive End Detail

 Weir Minerals Multiflo Document Page
TB-2010-06 7 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

iv. Install the new components as illustrated.

Figure 4.iv.1 - Improved Design Reassembly

Figure 4.iv.2 - Improved Design Reassembly - Wet End Detail

 Weir Minerals Multiflo Document Page
TB-2010-06 8 of 8
Technical Bulletin
8/6 FFY-HX BEARING ASSEMBLY SEAL UPGRADE Rev. Date Rev.
Feb 2010 0

Figure 4.iv.3 - Improved Design Reassembly - Drive End Detail

v. Reinstall the bearing assembly on the bare shaft pump.

vi. Reinstall bare shaft pump on pump unit.
 PART 5

Accompanying
Manuals