Complete 420 Manual SIS Unit 89
July 17, 2022 | Author: Anonymous | Category: N/A
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Download Complete 420 Manual SIS Unit 89...
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Weir Minerals Multiflo
PT SAPTAINDRA SEJATI (DIANLIA SETYAMUKTI) MULTIFLO MODEL MFVC-420 PUMP UNIT SERIAL No: MFVC-420-89-05.19 MFVC-420-89-05.19
INSTALLATION, OPERATIONS, MAINTENANCE AND PARTS MANUAL
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420
Master Index Index List of Figure References Introduction Introduction Contact Details for O.E.M. O.E.M. Introduction General Safety Shaft Lock Removal Weir Minerals Australia General Conditions of Sale Caterpillar Warranty Conditions Twin Disc Warranty Conditions Part 1 1 Installation and Commissioning
Pump Unit Data Sheet
Part I
Page
Mass Dimensions and Fuel Capacity
I
Lubrication Table
I
Model 420 Performance Curve
I
List of Accompanying Manuals
I
Section 1.1 Pump Unit Delivery Delivery & Storage Procedures
I
1.1.1 Storage Procedures
I
1
1.1.1.1 General Storage
I
1
1.1.1.2 Transmission Storage
I
2
1.1.1.3 Belt Storage
I
3
Section 1.2 Safety Warnings
I
1.2.1 Bare Shaft Pump Safety
I
4
1.2.2 Vacuum Pump Safety
I
5
1.2.3 Transmission Safety
I
5
1 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 1 1 Installation and Commissioning Part I
Page 7
Section 1.4 Installation & Removal Sequences Sequences
I
8
1.4.1 Moving & Locating the Pump Unit
I
8
1.4.1.1 Pump Site Preparation
I
9
1.4.1.2 Moving the Pump Unit
I
9
1.4.1.3 Preparation for Towing
I
9
1.4.1.4 Procedures for Moving, Locating & Launching
I
10
1.4.1.5 Procedure for Towing
I
11
1.4.1.6 Positioning and Launching
I
11
1.4.1.7 Incorrect Pump Unit Positioning
I
14
1.4.1.8 Correct Pump Unit Positioning
I
15
1.4.1.9 Pumping Operation Observations
I
16
I
17
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
II
3
II
4
II
5
2.2.1.1 Transmission
II
5
2.2.1.2 Engine Oil
II
6
2.2.1.3 Bare Shaft Pump Auto Lubrication System
II
6
2.2.1.4 Vacuum Pump Oil
II
6
2.2.1.5 Gland Oil Tank
II
6
Section 1.3 Unit Lifting Points (Total Unit Mass) Mass)
1.4.2 Installation Checks
Part 2 2 Operation Section 2.1 Introduction
2.1.3.1 Operation 2.1.4 Orientation of Major Unit Components Section 2.2 Normal Operating Operating Procedures 2.2.1 Daily Pre-Start Checks
2 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 2 2 Operation Part
Page
2.2.1.6 Coolant Level
II
6
2.2.1.7 Fuel Tank
II
6
2.2.1.8 Battery
II
6
2.2.1.9 Drive Belts
II
7
2.2.1.10 Water Trap
II
7
2.2.1.11 Air Cleaner Indicator
II
7
2.2.1.12 Suction Strainer
II
7
II
7
2.2.2.1 Start Up Procedure
II
7
2.2.2.2 Operating Speed
II
8
2.2.2.3 Cavitation
II
8
2.2.3 Shutdown Procedure
II
9
2.2.4 Shutdown Protection
II
10
2.2.4.1 Pump Shutdown System
II
10
2.2.4.2 Waterloss Shutdown System
II
10
Section 2.3 Detailed Description Description of Components
II
11
2.3.1 Model 420 Bare Shaft Pump
II
11
2.3.2 Model MG5202SC Transmission
II
14
2.3.2.1 Oil Pump Drive
II
14
2.3.2.2 Lubrication Features
II
14
2.3.2.3 Suction Screen
II
14
2.3.2.4 Heat Exchanger
II
15
2.3.2.5 Identification Plate
II
15
II
16
2.3.3.1 Parts Identification
II
17
2.3.3.2 Specifications & Torque Settings
II
17
Section 2.2 Normal Operating Operating Procedures (Continued)
2.2.2 Starting Procedures
2.3.3 Model 57 Vacuum Pump
3 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 2 2 Operation Part II
Page 11
2.3.4 Vactronic Vacuum Tank
II
18
2.3.5 Vacuum Gauge
II
19
2.3.6 Non Return “Vooom” Valve
II
20
2.3.7 Vactronic Vacuum Prime System
II
23
2.3.8 Hydrau-Flo Fuel Pressure Control Valve
II
25
2.3.9 Racor Fuel Filter / Water Separator
II
29
2.3.9.1 Overview
II
29
2.3.9.2 Installation Instructions 2.3.9.3 Racor Fuel Hose Specs & Pressure Ratings
II II
30 33
2.3.9.4 Priming Instructions
II
34
2.3.9.5 Specifications
II
35
Section 2.4 Test & Performance Data
II
36
2.4.1 Vactronic Module Tester
II
36
2.4.2 Test of of Operation of Vactronic Vactronic & Waterloss Control Module Using Test Light
II
37
2.4.3 Design & Operating Limits
II
39
Section 2.5 Electrical
II
40
2.5.1 Electrical Drawings & Schematics
II
40
Section 2.3 Detailed Description Description of Components (Continued)
Unit Schematic Wiring Diagram 2.5.2 Monitoring Instruments
Attached II
41
2.5.2.1 Transmission Temperature Shutdown Gauge
II
41
2.5.2.2 Coolant Level Detector
II
43
4 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 3 3 Maintenance Part
Page
3.1.1 Safety Procedures
III
1
3.1.2 Disassembly & Assembly Procedures
III
2
III
3
III
15
3.1.3.1 Bare Shaft Pump Gland
III
15
3.1.3.2 Impeller
III
18
3.1.3.3 Lubrication
III
18
III III
19 20
III
21
3.1.4.1 Vacuum Pump Piston & Re-Ringing Instruction
III
21
3.4.4.2 Assembly of a 3 Piece Oil Ring Assembly
III
22
III
26
3.1.5.1 Drive Belt Tensioning
III
26
3.1.5.2 Installation & Operation Operation of Wedge & ‘V’ Belt Drives
III
29
3.1.5.3 Taperlock Bushes
III
32
3.1.5.4 Taperlock Flanges 3.1.5.5 Tyre Couplings
III III
36 37
III
40
General Maintenance
III
41
Oil Level Setting Procedure
III
41
Lubrication Points
III
42
Filter and Oil Change
III
43
Heat Exchanger
III
44
Suction Strainer
III
44
Flexible Input Coupling
III
44
Section 3.1 Normal Maintenance Procedures
3.1.2.1 Model 420 Bare Shaft Pump Assembly Procedure 3.1.3 Maintenance – Bare Shaft Pump
Manual Grease Guide Auto Grease Guide 3.1.4 Maintenance – Model 57 Piston Vacuum Pump
3.1.5 Maintenance – Drive Components
3.1.5.6
Maintenance
-
Model
MG5202SC
Transmission
5 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 3 3 Maintenance Part
Page
III
45
Water Draining
III
45
Element Replacement
III
45
Parts Identification
III
47
III
49
3.1.6.1 Every 10 Engine Hours or Daily
III
50
3.1.6.2 After First 100 Engine Hours
III
51
3.1.6.3 Every 250 Engine Hours
III
51
3.1.6.4 Every 1000 Engine Hours
III
52
3.1.6.5 Every 2000 Engine Hours
III
52
Section 3.1 Normal Maintenance Procedures (Continued) 3.1.5.7 Maintenance – 1000FH Fuel/ Water Separator
3.1.6 Frequency of Routine General Maintenance
Section 3.2 Troubleshooting 3.2.1 Finding & Diagnostic Diagnostic Guide (Including Details of Normal Readings)
53 III
53
3.2.1.1 Pump Unit Troubleshooting
III
53
3.2.1.2 Vacuum Pump
III
58
3.2.1.3 Vee Belt Troubleshooting
III
60
3.2.1.4 Hydrau-Flo Troubleshooting
III
60
3.2.1.5 1000FH Fuel/Water Separator Troubleshooting
III
62
Section 3.3 Lubrication Schedule
III
65
3.3.1 Grades/Recommended Lubricants & Frequency
III
65
6 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 4 4 Spare Parts (Rev Dec 07) Part
Page
Bare Shaft Pump – Model 420
IV
1
Bearing Housing
IV
2
Shaft Sleeve & Gland Packing
IV
3
(Optional) Tungsten Carbide Shaft Sleeve (Optional)
IV
4
Wetted Parts
IV
5
Gland Splash Guard
IV
6
Vacuum Pump
IV
7
Crank Case Group
IV
8/9
Cylinder Block Group
IV
10
Cylinder Head Group
IV
11/12
Vacuum Pump Electromagnetic Clutch 24 Volt
IV
13
Vacuum Tank
IV
14
Transmission
IV
15
Transmission Oil Cooler
IV
16-18
Transmission Oil Drain
IV
19/20
Engine Breather
IV
21
Engine Oil Drain
IV
22
Fuel / Water Separator Filter
IV
24
Exhaust & Turbo Guard
IV
25
Throttle Cable
IV
26
Drive Coupling
IV
27
Drive Guard
IV
28
Bare Shaft Pump
Priming System Vacuum Pump – Model 57 Piston Type
Engine & Transmission
7 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit Unit MFVC-420 Part 4 4 Spare Parts Part
Page
Battery Box
IV
29
Battery Isolator & Isolator Box
IV
30
Emergency Stop Button
IV
31
Coolant Loss Sender & Detector
IV
32
Monitoring Instruments
IV
33
Control Box
IV
34
Electrical Components
IV
35/36
Hydrau-Flo
IV
37
Highwall Fuel Filler
IV
38
Gland Oil Tank
IV
39
Manual Fuel Filler
IV
40
Auto Greasing Unit (Bare Shaft Pump)
IV
41/42
Suction Strainer, Hose & Boom
IV
43/44
Discharge Pipe Work
IV
45/46
Fire Extinguisher
IV
47
Washdown Hose
IV
48
Worklights
IV
49
Strobe Lights
IV
50
Nordic Worklight
IV
51
Crane
IV
52
Discharge Pressure Gauge
IV
53
Chassis (New Style)
IV
54
Access Platforms
IV
55
Chassis (Old Style)
IV
56
Pontoon
IV
57
High Lift Skid Chassis
IV
58
Electrical
Accessories
Part 5 5 List of Accompany Accompanying ing Manuals 8 Rev Dec 07 Multiflo Model 420 – Master Index Rev (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit MFVC-420
List of Figures Figure Ref No
Description
Part
Page
Part 1 - Installation & Commissioning 1
Unit Lifting Points
I
7
2
Blade Contact Point on Pump Pushbar
I
12
3
Blade Contact Point on Pontoon Pushbar
I
13
4
Incorrect Pump Position Examples
I
14
5
Correct Pump Position Examples
I
15
Part 2 - Operation 6
Pump Unit Orientation Guide
II
4
7
Resulting Effects of Continuous Cavitation
II
9
8
Vactronic Module Waterloss Shutdown
II
10
9
Bare Shaft Pump Wetted Parts
II
12
10
Bare Shaft Pump Bearing Housing
II
12
11
Bare Shaft Pump Pedestal Assembly
II
13
12
Transmission Identification Plate
II
15
13
Model 57 Piston Vacuum Pump Major Components
II
16
14
Vacuum Tank
II
18
15
Vacuum Gauge
II
19
16
Non Return “Vooom” Valve – Flap in Closed Position
II
21
17
Non Return “Vooom” Valve – Flap in Open Position
II
22
18
Vactronic Circuit Diagram
II
24
19
Hydrau-Flo Fuel Valve Components
II
25
20
Hydrau-Flo System - Refuelling in Progress
II
26
21
Hydrau-Flo System - Component Operation
II
27
22
Hydrau-Flo System – Re-Fuelling Completed
II
28
23
1000FH Turbine Series Fuel Filter /Water Separator
II
29
1 Multiflo Model 420 –List of Figures Rev Rev 10.07 (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit MFVC-420
List of Figures Figure Ref No
Description
Part
Page
24
Fuel Filter/Water Separator Mounting Instructions
II
30
25
Fuel Filter/Water Separator Installation Instructions
II
32
26
Fuel Hose
II
33
27
Vactronic Module Tester
II
36
Part 3 - Maintenance 28
Model 420G Bare Shaft Pump Frame Assembly
III
3
29
Bare Shaft Pump Gland Assembly
III
5
30
Bare Shaft Pump Impeller & Bowl Assembly
III
7
31
Bare Shaft Pump Bearing Assembly
III
8
32
Bare Shaft Pump Volute Assembly
III
10
33
Bare Shaft Pump Sectional Drawing
III
11
34
Bare Shaft Pump Complete Assembly
III
12
35
Bare Shaft Pump Complete Sectional Assembly
III
13
36
Packing Removal Tool
III
16
37
Bare Shaft Pump Manual Lubrication Points
III
19
38
Auto Greasing Guide – Outlet Connections & Timer
III
20
Settings 39
Vacuum Pump Winding on Piston Oil Ring Expander
III
22
40
Vacuum Pump Upper & Lower Rail of Expander
III
23
41
Vacuum Pump Upper & Lower Rail Gap
III
23
42
Vacuum Pump Correct Fitment of Compression Rings
III
24
43
Vacuum Pump Incorrect Fitment of Compression Rings
III
24
44
Vacuum Pump Correct Expansion Method for
III
25
III
25
Compression Rings 45
Vacuum Pump Correct Ring Back Clearance
2 Multiflo Model 420 –List of Figures Rev Rev 10.07 (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
MFVC-420 Pump Unit MFVC-420
List of Figures Figure Ref No
Description
Part
Page
46
Belt Tensioning Indicator Operation
III
26
47
Belt Tensioning Indicator
III
28
48
Belt Alignment
III
30
49
Taperlock Bush Removal
III
32
50
Taperlock Bush Insertion into Hub
III
33
51
Taperlock Bush Insertion onto Shaft
III
33
52
Screw Torque Settings
III
34
53
Screw Torque Settings
III
34
54
Taperlock Flange Dimension Chart
III
36
55
Table 1 – Internal Clamp Ring Torque
III
38
56
Table 2 – Internal Clamp Ring Torque
III
39
57
Twin Disc Transmission Lubrication Points
III
42
58
Fuel Filter/Water Separator Parts Identification
III
47
59
Vacuum Gauge – High Reading
III
53
60
Vacuum Gauge – Low Reading
III
54
61
Vacuum Gauge – Normal Operating Range
III
56
62
Correct Replacement of Vacuum Pump Crank Seal
III
59
63
Fuel Filter/Water Separator Troubleshooting
III
64
3 Multiflo Model 420 –List of Figures Rev Rev 10.07 (Always quote Model and Serial Number of Unit when Ordering Parts)
Introduction
Weir Minerals Multiflo
Original Equipment Manufacturer Contact Details For all information regarding your Weir Minerals Multiflo MFVC-420 Pump Unit please contact:-
PT Multiflo Indonesia Jl Mulawarman No 47 RT 053 Manggar Km 20 Balikpapan 76117 Kalimantan Timur Indonesia Ph: 62 542 743252 Fax: 62 542 743253 Or Weir Minerals Multiflo 4 Daniel Street Caloundra Qld 4551 Ph: 07 5491 2877 Fax: 07 5491 2805 Email: multiflo@weir minerals.com ALWAYS QUOTE UNIT MODEL AND SERIAL NUMBER WHEN REQUESTING INFORMATION AND WHEN ORDERING PARTS
O.E.M. Contact Details (Always quote Model and Serial Number of Unit 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 MFVC-420 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 Multiflo MFVC-420 Pump Unit. To ensure long life and trouble-free operation, you should read and understand these instructions and provide regular, periodic maintenance.
The Weir Minerals Multiflo 420 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 cont contained ained iin n this manual.
When ccorrectly orrectly installed and
operated, it 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 Model 420 pump unit is designed to be used as a mine dewatering pump in accordance with the pump performance data contained in this manual. It is the user’s responsibility to be aware of and comply with all federal and state occupational health and safety requirements. The Weir Minerals Multiflo MFVC-420 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.
Weir Minerals Multiflo – Pump Unit General Safety
1
Weir Minerals Multiflo
Safety Symbols The accompanying documentation supplied with the Weir Minerals Multiflo MFVC-420 utilises the following safety symbols to highlight potentially harmful situations to personnel and the environment. SYMBOL
WORDING
DEFINITION
DANGER !
Imminent risk of fatal or crippling injuries
HARMFUL TO Persons
CONSEQUENCES CONSEQUENCES Fatal or crippling injuries likely to result from any exposure
WARNING !
Risk of fatal or crippling injuries
Persons
Fatal or crippling injuries possible
CAUTION !
Possibility of a harmful situation
Persons
Minor or slight injuries possible
Possibility of a harmful situation
Property and or the Environment
ATTENTION !
INFORMATION !
Application Hints and other useful Information
Nil
Weir Minerals Multiflo – Pump Unit General Safety
Damage possible to the product or the Environment
Nil
2
Weir Minerals Multiflo
WARNING!
REMOVE SHAFT LOCKS
(IF FITTED) FROM BARE SHAFT PUMP AND/OR ELECTRIC MOTOR BEFORE START-UP 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 Until such time as Weir Minerals Australia Ltd ABN 69 009 701 802 (“Weir Minerals”) notifies a customer of replacement General General Conditions of Sale, these General General Conditions of Sale shall apply to all sales of products (“Products”) by Weir Minerals and shall form part of any contract resulting from acceptance of a purchase order placed with Weir Minerals by any customer (“Purchaser”) or from Purchaser’s acceptance of a quotation from Weir Minerals, except as varied by a written quotation or by written notice from Weir Minerals before the placement of the order or acceptance of the quotation, or by written agreement between Weir Minerals and Purchaser. In the event of any inconsistency between any order form or other documentation of the Purchaser and these General Conditions of Sale, these General Conditions of Sale shall prevail. 2. QUOTATIONS A quotation is not an offer by Weir Minerals to sell and may be withdrawn or varied at any time,
any loss or damage occurring after the point of delivery and will only arrange insurance upon written instructions from the Purchaser and at the cost of th e Purchaser. 12. AMENDMENT AND CANCELLATION The Purchaser shall not, after acceptance of order, cancel or amend it in any way without the written approval of Weir Minerals. Weir Minerals may, on consenting to an amendment, revise its price and delivery schedule and amend the terms and conditions to reflect such change. change. In the event of an amendment or cancellation, the Purchaser shall reimburse Weir Minerals for all costs and expenses already incurred by Weir Minerals and any additional costs and expenses resulting from the amendment or cancellation. 13. RETURN OF PRODUCTS Weir Minerals may, at its absolute discretion, agree to accept the return of any of its standard Products and credit the Purchaser with the invoice value of the Product provided the Product is returned in “as purchased” condition and the written approval of Weir Minerals has been
prior to acceptance by Weir Minerals of an order, and is void after 30 days unless extended in writing by Weir Minerals. In addition, prices quoted are subject to variation in accordance wit withh clause 5. Weir Minerals reserves the right to correct typographical and clerical errors. ACCEPTANCE OF ORDERS Unless the Purchaser is notified by Weir Minerals in writing within 14 days of the Purchaser placing a purchase order that Weir Minerals does not accept the Purchaser’s order, all purchase orders received by Weir Minerals are deemed to be accepted by Weir Minerals without acknowledgment and the issue by Weir Minerals of an order acknowledgement shall not be or imply acceptance of any terms or conditions in any order form or other documentation of the Purchaser. TERMS OF PAYMENT The terms of payment shall be nett cash before despatch unless the Purchaser possesses a current credit account with Weir Minerals. The terms of payment for a Purchaser with with a current credit account are nett cash, free of exchange, thirty (30) days from the end of the month in which the goods are invoiced or are ready for delivery. Weir Minerals reserves the right to invoice for partial deliveries and deliveries delayed at the request of the Purchaser. PRICE VARIATION Any change in the cost of labour, materials, transport, essential services, tariffs, duties, exchange, and other costs and statutory obligations, between the date of quotation and the date of invoice will be to the Purchaser’s account. The purchase price shall be varied on the following basis: 5.1 Products manufactured by Weir Minerals will be varied to reflect the Weir Minerals standard price list in effect at the time of order. 5.2 Products manufactured by other Vendors will be varied to reflect the Vendor’s price in effect at the time of delivery to Weir Minerals. TAXES AND DUTIES 6.1 Prices do not include Taxes and Duties Duties Prices quoted do not include the taxes, imposts and duties described in clause 6.3. 6.2 Exemptions The acceptance by Weir Minerals of the Purchaser's sales tax certificate or other documents claiming exemption from any of the taxes, imposts or duties described in clause 6.3 will not exonerate the Purchaser from liability to pay any such taxes, duties or imposts (including any interest and penalties) subsequently imposed. 6.3 Payment of Taxes and Duties Duties Weir Minerals may recover from the Purchaser, and the Purchaser must pay, the amount of any sales tax, customs duty, use tax, consumption tax, goods and services tax, valueadded tax or any similar tax, impost or duty levied on any supplies made by Weir Minerals to the Purchaser under or in connection with these General Conditions of Sale (excluding any income tax imposed on Weir Minerals), whether that tax, impost or duty is currently in force or comes into force after the date from when the General Conditions of Sale shall apply. Any such tax, impost or duty must be be paid by the Purchaser at the same time as when payment for the supplies in respect to which the tax, impost or duty is
obtained by the Purchaser for the return of the Product. Weir Minerals reserves the right to charge an administrative fee for the return of Products to stock. 14. WARRANTIES 14.1 New Products Products If within a period of eighteen (18) months from the date of delivery or twelve (12) months from the date of commissioning whichever is sooner (“warranty period”) any new Product sold by Weir Minerals is found to be defective in materials or workmanship, or does not conform to any applicable drawings and specifications approved by Weir Minerals, then Weir Minerals will, at its option, either repair or provide a replacement part or Product provided that: 14.1.1 the Purchaser has given written notice to Weir Minerals of any alleged defect within the warranty period; 14.1.2 the Purchaser has provided Weir Minerals a reasonable opportunity to perform all appropriate tests on the Product; and 14.1.3 the defective part or Product is promptly returned to a designated Weir Minerals service centre. Any defective part or Product replaced will become Weir Minerals property and the repaired or new part or Product will be delivered free to the Purchaser’s site. 14.2 Repaired Products For repaired Products, the warranty period is six (6) months from the date of repair and shall only apply to parts or Products repaired or replaced by Weir Minerals. No separate warranty shall apply to repaired Products as a whole or to parts not repaired or replaced by Weir Minerals. 14.3 Exceptions The warranties given by Weir Minerals in 14.1 and 14.2 above do not cover: 14.3.1 Fair “wear and tear” and failures or damage not reported to Weir Minerals within the warranty period. 14.3.2 Failures or damage due to misapplication, abuse, improper installation or abnormal conditions of operation. 14.3.3 Failures or damage due to operation, either intentional or otherwise, above or below rated capacities or in an otherwise improper manner. 14.3.4 Failures or damage resulting from Products which have been in any way tampered with or altered by anyone other than an authorised representative of Weir Minerals. 14.3.5 Products damaged in shipment or without the fault of Weir Minerals. 14.3.6 Failures or damage resulting from the incorporation of, or failure of, non-Weir Mineral manufactured or supplied parts in the Products. 14.4 Performance Guarantee The performance of a Weir Minerals pump is guaranteed only to the extent of the current water performance curve published published by Weir Minerals for the pump. This performance can be verified where required by the Purchaser with water performance tests carried out in Weir Minerals test facility prior to despatch. Additional charges and delivery extension apply if this verification is required.
levied, is due." 7. PACKING Weir Minerals does not charge for its normal packing and no credit or deduction will be allowed if packing is not required. The cost of providing export or special special packing requested by the Purchaser will be quoted to and paid for by the Purchaser. 8. POINT OF DELIVERY/DELIVERY COSTS Prices quoted or accepted are “ex works” and all costs of freight and delivery from Weir Minerals works will be to the Purchaser’s account. Delivery shall be deemed to occur when the Purchaser is informed by Weir Minerals that the Products are ready for collection at Weir Minerals works. 9. DELIVERY PERIOD The times within which Weir Minerals may advise the Purchaser that it will make delivery of its order shall be regarded as the best estimates, but will not be guaranteed and may be subject to extension to cover delays caused by Government priorities, strikes, lockouts, breakdowns, delays in transport, fire, late delivery of raw material or components, or other causes beyond the control of Weir Minerals and no responsibility will be accepted for the consequences of any delays. Weir Minerals may make delivery of and invoice any order either as a whole or progressively and effect delivery at any time within the period advised by it for delivery of the order. If the Purchaser requests Weir Minerals to delay delivery or fails to give Weir Minerals adequate delivery instructions, Weir Minerals may invoice the Purchaser and store the goods at the Purchaser’s expense.
As the performance of Weir Minerals pumpswill onbe siteaccepted include by many beyond Minerals control no performance guarantees Weirfactors Minerals basedWeir on site measurements. 14.5 Purchased Equipment Weir Minerals does not warrant any equipment of other manufacturers which is designated by the Purchaser or purchased by Weir Minerals for resale to the Purchaser either separately or as a part of equipment equipment manufactured by Weir Minerals. For such equipment, the warranty established by the manufacturer of the equipment shall apply. 14.6 Supply of Services When Weir Minerals supplies services to the Purchaser including laboratory testing, process development, equipment selection, design, detail, contract supervision and contract management, Weir Minerals shall exercise its best skill, competence and experience to undertake such services. 14.7 Limit of Liability Weir Minerals liability under 14.1, 14.2 and/or 14.6 shall in no event exceed the cost of replacing or repairing the Products sold or supplying the services again. 14.8 Trade Practices Act The benefits conferred by the warranties in 14.1, 14.2 and 14.6 are in addition to all other rights and remedies in respect of the Products and services supplied by Weir Minerals which the Purchaser has under the Trade Practices Act and similar State and Territory laws, and the exceptions and limitations in 14.1 to 14.6 do not apply to such statutory rights and remedies.
10. LATE DELIVERY PENALTY If Weir Minerals has agreed in writing to accept a penalty for late delivery, the delivery period quoted will date from acceptance of the Purchaser’s order or from receipt of the Purchaser’s final technical data and drawings or from receipt of the Purchaser’s written approval of Weir Minerals working drawings, whichever is the late r. 11. INSURANCE Insurance cover is the responsibility of the Purchaser and all goods will be at the Purchaser’s risk from the point of delivery as defined in Clause 8. Weir Minerals will not be responsible for
14.9 14.9 Implied Conditions Where the Trade Practices Act or similar State or Territory legislation implies into these General Conditions of Sale any term, condition or warranty, and that legislation avoids or prohibits provisions in a contract excluding or modifying them, then the term, condition or warranty shall be deemed to be included in these conditions of sale Provided That Weir Minerals liability for a breach of any such term, condition or warranty, including any consequential loss which the Purchaser may sustain, shall be limite d, at the option o f Weir
3.
4.
5.
6.
Page 1 of 2
Revised: June 2006
WEIR MINERALS AUSTRALIA LTD ABN 69 009 701 802
GENERAL CONDITIONS OF SALE Minerals, to either replacing or repairing the goods or, in the case of services, to supplying the services again. 14.10 Exceptions Except as expressly set out in these conditions of sale, and subject to 14.9: 14.10.1 All conditions, warranties, terms, undertakings, representations and obligations, whether expressed or implied, and whether arising under statute, common law, equity, custom, trade usage or otherwise (including without limitation, any implied condition, warranty, term or representation as to the correspondence of the Products with any contract description or as to merchantable quality, fitness for any purpose or safety of the Products, or operating performance where such performance is conditional on empirical factors or on the whole installation or on the individual or overall operation or on the skills of an operator), whether made known or not and any liability of Weir Minerals to compensate or indemnify any person or persons in respect of the foregoing, are expressly
Minerals to the Purchaser until the Purchaser has paid Weir Minerals in full for the Products and for all other goods supplied by Weir Minerals. 21.2 Product Identification Until title in the Products has passed pursuant to clause 21.1 the Purchaser holds the Products as bailee in the capacity of a fiduciary for Weir Minerals. The Purchaser shall keep the Products supplied to it by Weir Minerals in its possession and take good care of them and store them and mark them in a manner that identifies the Products supplied and clearly shows that they belong to Weir Minerals. 21.3 Products Incorporated into other Objects If the Products in any way become attached to or a part of another object before the Purchaser has paid Weir Minerals in full for the Products and for all other goods supplied by Weir Minerals, property in so much of the object as is comprised by the Product shall remain with Weir Minerals and shall n ot pass from Weir Minerals to the Purchaser until the Products and all other goods supplied by Weir Minerals have been paid for in full. Until
negatived excluded.; In no eventand shall Weir Minerals be liable for any: 14.10.2.1 Expenses incurred by the Purchaser in an attempt to repair or rework any allegedly defective Product or service. 14.10.2.2 Losses, costs, expenses, liabilities and damages (including loss of profits, liabilities of the Purchaser to its customers or third persons, and any other consequential damages), whether direct or indirect and whether or not resulting from or contributed to by the default or negligence of Weir Minerals, its agents, employees and subcontractors, which might be claimed as the result of the use or failure of the Product sold or the services supplied.
Weir Minerals isholds paid inany full objects for the Products other goods Minerals the Purchaser to whichand the allProducts are supplied attached by or Weir of which the Products form a constituent part as bailee in the capacity of a fiduciary for Weir Minerals and shall store such objects separately so as to be readily identifiable. 21.4 Third Party Sales If the Products (or any objects to which the Products are attached or of which the Products form a constituent part) are on sold by the Purchaser to a third party prior to payment by the Purchaser in full for the Products and all other goods supplied by Weir Minerals, the Purchaser does so as agent for Weir Minerals and the Purchaser unconditionally agrees to keep the proceeds of such on sale in a separate bank account on trust for Weir Minerals and, at Weir Minerals request, to assign to Weir Minerals any debt owed to the Purchaser in respect of the on sale, until Weir Minerals has been paid in full for the Products and for all other goods supplied by Weir Minerals. Notwithstanding this paragraph, the Purchaser shall not represent to any third parties that it is in any way acting for Weir Minerals and Weir Minerals will not be bound by any contracts with third parties to which the Purchaser is a party. 21.5 Product Recovery If any payment by the Purchaser to Weir Minerals is overdue, in whole or in part, or the Purchaser is otherwise in default under any contract with Weir Minerals, or the Purchaser shall become bankrupt or commit any act of bankruptcy or compound with its creditors or have judgment entered against it in any court or, being a company, have a provisional liquidator, receiver or manager appointed or otherwise suffer some form of insolvency
14.10.2
15. INDEMNITY Subject to clause 14, the Purchaser indemnifies and holds Weir Minerals harmless from and against all liabilities, lo sses, damages, costs or expenses incurred or suffered by Weir Minerals and from and against all actions, proceedings, claims or demands made against Weir Minerals, arising in either case as a result of: 14.1 The Purchaser’s Purchaser’s failure failure to comply with any laws, rules, standards or regulations applicable in relation to the Products or the use of the Products; 15.2 any use of the Products contrary to any instructions or warnings given by Weir Minerals; 15.3 any other negligence or any breach of duty by the Purchaser; 15.4 any compliance or adherence by Weir Minerals with any instructions by the Purchaser in relation to the goods or their manner of preparation; or
16.
17.
18.
19.
20.
15.5 any failures resulting from the incorporation of, or failure of, non-Weir Minerals manufactured or supplied parts in the Products. DRAWINGS AND SPECIFICATIONS All drawings, specifications, descriptions and other documents attached to any quotation are for tendering purposes only and shall not form the basis of nor be part of any contract between the Purchaser and Weir Minerals. After receipt of the Purchaser’s orders, Weir Minerals will provide, if it has agreed in writing to do so, two (2) copies of a certified dimension outline, cross-sectional arrangements, and/or parts list and standard specifications and maintenance manual. The details contained therein will be submitted in good faith as being correct but any errors, omissions or defects therein shall not be grounds for cancellation of the contract nor entitle the Purchaser to make any claim against Weir Minerals. All additional manuals, drawings or documentation requested will be charged to the Purchaser at cost. Weir Minerals retains ownership of the copyright and all other intellectual and industrial property rights in all drawings, specifications, manuals and other documentation provided to the Purchaser. INSPECTION AND TESTING The Purchaser’s Inspectors will be given full access to all relevant areas of Weir Mineral’s works during normal working hours, for the inspection within these areas of all phases of manufacture, assembly and testing of the equipment to be supplied, in order to ensure compliance with specification. Inspectors are required to seek appointments for those inspections through Weir Minerals appointed representative, nominated at the time an order is placed, giving at least twenty-four (24) hours notice and to be accompanied on such inspections at the discretion of Weir Minerals. Following final works inspection, a full compliance release in writing is required from the Purchaser’s Inspector covering design conformity, dimensional accuracy and works test performance. Unless otherwise agreed by Weir Minerals in writing, works testing will comprise satisfactory mechanical operation of moving parts only. All Inspection and testing shall be final at Weir Minerals works. INTELLECTUAL PROPERTY RIGHTS Weir Minerals is the owner of certain patents and registered designs as well as other intellectual property rights, including, but not limited to, copyright (together the “Intellectual Property Rights”). Weir Minerals has also made certain applications for patents. The Purchaser must not directly or indirectly manufacture or purchase from any third party the subject matter of the Intellectual Property Rights or the patent applications, or in any way infringe the Intellectual Property Rights or patent applications. The Intellectual Property Rights remain at all times the exclusive property of We ir Minerals. PURCHASER’S PROPERTY No responsibility is accepted by Weir Minerals for loss or damage to the Purchaser’s patterns or other goods left in Weir Minerals possession. ARBITRATION If at any time any question, dispute or difference whatsoever shall arise between the Purchaser and Weir Minerals upon, in relation to, or in connection with this contract such question, dispute or difference may, if the parties do not agree, be referred to arbitration in Australia by a person to be mutually agreed upon or, in default of agreement, by a person appointed by the President for the time being of the Institution of Engineers, Australia. The submission shall be
administration, all sums then owing by the Purchaser to Weir Minerals in respect of the Products or in respect of other goods supplied by Weir Minerals shall becom becomee immediately due and payable and Weir Minerals may (without prejudice to any of its other rights) recover and resell the Products and any other goods supplied by Weir Minerals and may, for that purpose, enter upon the Purchaser’s premises by its servants or agents, and Weir Minerals is irrevocably authorised to effect such entry, including the use of such reasonable force as is necessary to effect such entry, and to use the name of the Purchaser and to act on behalf of the Purchaser, if necessary, to recover possession of the Products and any other goods supplied by Weir Minerals and to detach the Products and any such other goods from any other object to which the Products have been attached or of which the Products form a constituent part. 22. GENERAL GENERAL The fact that Weir Minerals fails to do, or delays in doing, something it is entitled to do under any contract of which these General Conditions of Sale form part, does not amount to a waiver of any right or remedy with respect to any existing or subsequent breach or default. If any provision of any contract of which these General Conditions of Sale form part is void, voidable, illegal or unenforceable in any state, province or country in which the contract is intended to be effective, or if the contract would, if a particular provision were not omitted, be so void, voidable, illegal or unenforceable, then:a) if the offending provision can be read down so as to make it valid and enforceable without materially changing its effect, it must be read down, in so far as it applies in the state, province or country, to the e xtent necessary to achieve that result:. b) otherwise, that provision shall be severed from the contract in so far as it applies in that state, province or country, and the contract shall be read and construed and shall take effect for all purposes in that state, province or country as if that provision were not contained in the contract, but without in any way affecting the effectiveness, validity, legality or enforceability of the remaining provisions of the contract 22.2. The Purchaser must pay Weir Minerals interest on all overdue payments due to Weir Minerals under these General Conditions of Sale at the Indicator Benchmark Rate – Business (or its successor) from time to time charged by National Bank, plus 3% per annum, calculated on daily rests from and including the due date to and including the date of payment. 22.3. These General Conditions of Sale and each contract of which they form part are governed by and must be construed in accordance with the laws of New South Wales.
deemed be State a submission to arbitration the the meaning theplaced. Commercial Arbitration Act in force intothe or Territory in Australiawithin in which order of was 21. RETENTION OF TITLE 21.1 Passing of Title The Products shall remain the sole and absolute property of Weir Minerals as legal and equitable owner, and the property in and title to the Products shall not pass from Weir
Page 2 of 2
Revised: June 2006
Twin Disc, Incorporated Exclusive Limited Warranty, Transmission A.
Twin Disc, Incorporated warrants all assembled products and parts (except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original customer, as to which Twin Disc, Incorporated makes no warranty and assumes no liability) against defective materials or workmanship for over a period of twenty four (24) months from the date of shipment by Twin Disc, Incorporated to original customer, but not to exceed twelve (12) months of service, whichever service, whichever occurs first. This is the only warranty made by Twin Disc, Incorporated and is in lieu of any and all other warranties, express or implied, including the warranties of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin tests sts or Disc, Incorporated. The original customer does not rely upon any te inspections by Twin Disc, Incorporated’s application engineering.
B.
The exclusive remedy provided by Twin Disc, Incorporated, whether arising out of warranty within the applicable warranty period as specified, or otherwise, (including tort liability), shall at the sole option of Twin Disc, Incorporated by either the repair or replacement of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective and the labour to perform that work and to remove and reinstall (or equivalent equivalent credit). In this context, lab labour our is defined as the flat rate labour hours established by Twin Disc, Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair, reassemble, reinstall and test the Twin Disc, Incorporated product only. Authorised re reasonable asonable travel and living expenses expenses will be considered for payment. Under no circums circumstances, tances, includin including g a failure of the exclusive reme remedy, dy, shall Twin Disc, Incorporated be liable for economic loss, consequential, incidental or punitive damages. The above warranty and remedy are subject to the following terms and conditions:
1.
2.
3. 4.
Complete parts or products upon request must be returned, transportation prepaid and also the claims submitted to Twin Disc, Incorporated within sixty (60) days after completion of the warranty repair. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse, neglect, improper maintenance or accident. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc, Incorporated. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment to the date placed in service.
5.
6.
The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices, methods and instructions approved or provided by Twin Disc, Incorporated. The warranty is void unless all required replacement parts of products are of Twin Disc origin or equal, and otherwise identical with components of the original equipment. Replacement parts or products not of T Twin win Disc origin are not warranted by Twin Disc, Incorporated.
C.
As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for injury to persons or property, including without limitation, the original customer’s and subsequent purchaser’s employees and property, due to their acts or omissions or the acts or omissions of their agents, and employees in the installation, transportation, maintenance, use and operation of said equipment.
D.
Only a Twin Disc, Incorporated authorised factory representative shall have authority to assume any cost or expense in the service, repair or replacement of any part of product within the warranty period, except when such cost or expense is authorised in advance in writing by Twin Disc, Incorporated.
E.
Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior prior manufacturer. The original customer and subsequent subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials.
F.
If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on a no-charge basis and these parts will by the remainder of the unexpired warranty, which remains in effectbe oncovered the complete unit. 1 July 1998
PART 1
Installation
Weir Minerals Multiflo
Pump Unit Data Sheet _____________________________ ______________ ____________________________ ____________________________ _________________________ __________ OWNER: OWNER:
PT Saptaindra Sejati Graha Saptaindra Lt 5-8 Jl T.B. Simatupang Kav. 18 Cilandak Barat Jakarta 12430 Indonesia
ORDER NUMBER:
1901044
UNIT MODEL: MODEL:
MFVC-420
UNIT TYPE: TYPE:
200mm x 150mm, High Performance, Vactronic Vacuum Primed, Diesel Driven, Base Chassis Pump Unit
PUMP UNIT SERIAL NUMBER:
MFVC-420-089-05.19
ORIGINAL DESPATCH DATE: DATE:
July 2008
ENGINE MODEL: MODEL: ENGINE SERIAL NUMBER: NUMBER:
Caterpillar 3412 DITTA 38S25060
ENGINE ARRANGEMENT NUMBER:
7W-7541
BARE SHAFT PUMP MODEL:
MF 8/6 FF-HX
BARE SHAFT PUMP SERIAL NUMBER:
SY76291
BARE SHAFT PUMP MATERIAL:
A49 (C26 Impeller)
BARE SHAFT PUMP GLAND SEALING:
Gland Packed
BARE SHAFT PUMP AUTO GREASER UNIT:
Pico Beka Max SEP4
AUTO GREASER UNIT SERIAL NUMBER:
P217101
TRANSMISSION MODEL:
Twin Disc MG5202SC
TRANSMISSION SERIAL NO:
3BM-071
TRANSMISSION B.O.M. NO:
42550
TRANSMISSION ELEMENT NO:
SAE-1
TRANSMISSION RATIO:
1.53:1
DRIVE COUPLING:
F180
TRANSMISSION OIL COOLER MODEL:
Model: Diecon 125450 Serial No: 0230819
NON RETURN VALVE TYPE:
NRV150-01SS
NON RETURN VALVE MATERIAL:
Stainless Steel
VACUUM PUMP MODEL:
MVP150-200 (57)
VACUUM PUMP SERIAL NUMBER:
MVP-934
VACUUM TANK TYPE:
VT390V6200TSS
VACUUM TANK MATERIAL:
Stainless Steel
PRIMING SYSTEM:
Vactronic Primed
Weir Minerals Multiflo Model 420 – SIS Pump Unit 89
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
Mass, Dimensions, and Fuel Capacity ___________________ _________ ___________________ ___________________ ____________________ ____________________ ____________________ _______________ _____ PUMP UNIT ONLY HEIGHT: HEIGHT:
3,060mm
LENGTH:
6,210mm
WIDTH:
2,040mm
MASS: (Unit Dry) Dry)
11,750kg
MASS: (Unit Wet) Wet)
15,750kg
FUEL CAPACITY:
4,000ltr
Weir Minerals Multiflo Model 420 – SIS Pump Unit 89
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
Recommended Lubricants ________________________ ___________ _________________________ __________________________ __________________________ ________________________ _____________ _
Grades and Frequency of Lubrication
Item
Recommended Lubricant
Frequency
Maximum Capacity
3412 Engine Oil
Mobil Delvac MX 15W40 Shell Rimula 15W40
Checked Daily
68 litres
MG5202SC Transmission Oil
Mobil HD50 Shell Donax TC50
Checked Daily
26.5 litres
Piston Type Vacuum Pump Oil Oil
Mobil Delvac MX 15W40
Checked Daily
2.2 litres
Bare Shaft Pump Bearing Assembly
Multiflo Pump Grease Shell Alvania RL2 Grease SKF LGMT 2
Check Automatic unit grease level weekly
Multiflo Model 420 Pump Unit – Recommended Lubricants
1.2 kg
1
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
PART 1 & INSTALLATION COMMISSIONING 1.1
Pump Unit Delivery 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 SI GNING 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 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.
Weir Minerals Multiflo Model 420 Pump Unit – Installation Ins tallation Manual (Unit fitted with Model 57 Vacuum Pump) Rev 03.08
1
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
1.1.1.2
Transmission
INFORMATION !
It is sometimes necessary to store Twin Disc transmissions. In order to prevent corrosion damage, the following procedures are recommended.
Storage Maintenance Procedures Short Term Storage (Less Tha Than n One Year) Transmission installed on an engine that can be run. 1. To the extent possible, store in a location that minimizes exposure to the elements. 2.
Prior to storage, drain oil and refill to full level on the dipstick with recommended new oil. Install new filter, if ap applicable. plicable.
3.
Use only recommended oils to maintain proper levels. Do not use preservative-type oils.
4.
Every three months, check oil level and availability of coolant. Start engine and run approximately 1000 rpm to bring oil temperature up to normal operating range. range. Run engine at least five minutes, shifting into each range and shut down.
5.
Drain and refill with recommended oil and change filters if applicable, prior to returning unit to regular service.
Long Term Storage (More Than One Year) Transmission installed where the engine cannot be run. 1. Use standard recommended oil for the following procedures: Once each year, remove dipstick and plug dipstick tube. Completely fill the transmission transmission with oil. Rotate the output shaft at leas leastt five revolutions. Partially drain oil, reins reinstall tall dipstick, and th then en drain oil d down own to full mark on the dipstick. 2.
Seal breather, dipstick tube and all other openings with waterproof tape.
3.
Grease exposed members that are subject to corrosion.
4.
Every three months rotate output shaft four or five revolutions.
5.
Tag transmission to show date it was placed in storage and current status relating to storage procedure. Weir Minerals Multiflo Model 420 Pump Unit – Installation Ins tallation Manual (Unit fitted with Model 57 Vacuum Pump) Rev 03.08
2
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
6.
To remove from storage and place in regular service: a) Remove waterproof tape from breather, dipstick tube and all openings b) c)
Drain andoilremove oil filter. Install oil new filter and fill transmission with new recommended oil to full mark on the dipstick.
Heat Exchanger Storage When storing a heat exchanger, oil and water ports must be kept sealed. 1.1.1.3
Belts
‘V’ Belts should be stored in a dry stockroom, and contact with hot pipes and direct sunlight carefully avoided. avoided. Where possible, han handle dle the b belts elts loosely in single (or triple) coils. Always av avoid oid tying belts with thin string.
Weir Minerals Multiflo Model 420 Pump Unit – Installation Ins tallation Manual (Unit fitted with Model 57 Vacuum Pump) Rev 03.08
3
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
1.2
Warnings (Regarding Installation & Pre-Operational Pre-Operatio nal Procedures) Procedures) DANGER ! !
1.2.1 1.2.1
Pump unit to be locked out and tagged out before any maintenance or service is performed.
Bare Shaft Pump Safety WARNING ! !
ATTENTION !
It must be checked that the intake and discharge openings are totally isolated from all potentially pressurized connections and that they are and can only be exposed to atmospheric pressure.
The following instructions relate to the 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 and equipment damage could result from the impeller shattering or exploding wheninjury 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. started.
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1.2.2 1.2.2
Vacuum Pump Safety INFORMATION !
Prior to initial operation the vacuum pump oil level must be checked before 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.
1.2.3 1.2.3
Transmission Safety
DANGER ! !
Pump unit to be locked out and tagged out before any maintenance or service is performed.
This information provides general operating information for Twin Disc Transmissions. Specific product details and performance characteristics can be obtained by contacting the nearest Twin Disc authorized Distributor or Service Dealer. All personnel servicing this equipment should employ safe operating practices. Twin Disc, Incorporated will not be responsible for personal injury resulting from careless use of hand tools, lifting equipment, power tools, or unaccepted maintenance/working practices. Because of the possible danger to person(s) or property from accidents that may result from the use of machinery, proper installation, maintenance and operation procedures must be followed. Twin Disc, Incorpora Incorporated ted will not be responsible for personal injury resulting from careless maintenance/working practices. Inspect as necessary necessary to as assure sure safe op operations erations under prev prevailing ailing conditions. Proper guards and other safety devices that may be specified in safety codes should be provided. These devic devices es are neither provided by nor are they the responsibility of Twin Disc, Incorporated.
ATTENTION !
Selecting Neutral disengages transmission clutches but does not prevent propeller shaft rotation. If y you ou require positive neutral ((prop prop shaft locked), a shaft brake or other shaftlocking device must be used.
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1.2.3.1
Ordering Parts & Obtaining Service
INFORMATION !
All replacement parts or products (including hoses and fittings) must be of Twin Disc origin or equal, and otherwise identical with components of the original equipment. Use of any other parts or products will void the warranty and may result in malfunction or accident, causing injury to personnel and/or serious damage to the equipment.
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1.3
Unit Lifting Points Pump unit to be locked out and tagged out WARNING!
before any performed.
WARNING! WARNING!
Lifting of the pump unit should be undertaken by experienced personnel only. Refer to site procedures for lifting, personnel and equipment requirements.
PUMP UNIT MASS (WET) 15,750 KG
maintenance or service is
FIGURE 1 UNIT LIFTING POINTS
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1.4
Installation & Removal Sequences 1.4.1
Moving and Locating The Pump Pump Unit Unit WARNING ! !
WARNING!
INFORMATION !
Pump unit to be moved by experienced personnel only.
Pump unit to be locked out and tagged out before any maintenance or service is performed.
Pump unit moving and locating instructions are intended as a guide only. Site preparation, unit towing and positioning to be undertaken with regard to site conditions and procedures. procedures.
Multiflo Pumps are mounted on a skid 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. 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.
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1.4.1.1
Pump Site Preparation
Proper pump site preparation is important. important. It should prov provide ide a good approach for the finalAlso, positioning of thea pump and allow access for fuel and to service vehicles. when using skid mounted pump in areas prone flash flooding after heavy rainfall, quick access to the unit maybe 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. °
1.4.1.2
Moving the Pump Unit WARNING ! !
Pump unit to be moved by experienced 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 c can an also be use used d 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. 1.4.1.3
Preparation for Towing
WARNING ! !
Pump unit to be connected to prime-mover by suitable towing apparatus. of towing apparatus to be Suitability 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.
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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 o off 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 p possible ossible to the left side side.. Don't tow or push the pump over rough, uneven ground. Unhitch the do dozer zer and lev level el the way. Final positioning will usually involve pushing the pump, either with the dozer blade or the excavator bucket. bucket. For launching pon pontoon toon pumps, an e excavator xcavator 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 b bar ar only and not on the base chassis chassis push beam. Under no circumstan circumstances ces 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 discharge line. (It is extremely difficult to connect up hoses hoses and pipes in deep water). If layflat hose is to be c connected onnected to the initial disc discharge harge pipe, then this connection can be made be before fore the pump is launc launched. hed. If poly pipe 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. 1.4.1.4
Procedure for the Movement, Locating and Launching of Dewatering Pumps WARNING ! !
Pump unit to be moved by experienced personnel only.
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.
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Procedure For For Towing Towing
1.4.1.5 1.
Ensure appropriate towing chains are available for the particular pump type.
2.
Ensure that pipes and hoses are disconnected from th the e wet end pump discharge.
3.
Secure any loose items of pump hardware such as clamps, connectors, lengths of pipe etc. that may be laying 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.
1.4.1.6. 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.
Pumpsorshould be positioned/launche positioned/launched d using a wheel dozer, small track dozer small excavator.
4.
The operator of the d dozer ozer or excavator must be able to see the point a att which the blade or bucket bucket is making cont contact act 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 person directing. Skid mounted pum pumps ps must only be pushed on the push beam assembly provided. Pontoon mounted pumps must only be pushed on the pontoon push bar, and not 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).
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5.
Before launching, consideration should be given to connecting layflat or polypipe discharge 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.
INFORMATION !
Graphical description intended as a guide only.
FIGURE 2 BLADE CONTACT POINT ON PUMP PUSH BAR
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FIGURE 3 BLADE CONTACT POINT ON PONTOON PUSH BAR
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1.4.1.7. Incorrect Pump Unit Positioning
Pump Position – Not on Flat ground Discharge Hose is Kinked Distance from Pump to Water Surface is more than 10 metres
FIGURE 4 EXAMPLES OF INCORRECT PUMP UNIT POSITIONING Weir Minerals Multiflo Model 420 Pump Unit – Installation Ins tallation Manual
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1.4.1.8. Correct Pump Unit Positioning
Pump Position – Flat ground
Suction Lift less than 10 Metres
Discharge Hose Curved where Possible
FIGURE 5 EXAMPLES OF CORRECT PUMP UNIT POSITIONING
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1.4.1.9
Pumping Operation Observations
Are the hose couplings at the wet end pump, both suction and discharge, completely sealed? Is the pump unit 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). Is the suction strainer free from blockage and fully submerged in the fluid? Is the largest possible pipe diameter, both at suction and discharge, being used? Is the vacuum tank gauge reading within the normal range (depending on suction height)? Is the wet end pump operating without cavitating? Is the engine set at the correct speed (RPM) to give maximum pump efficiency? When using "layflat" hose, is it free f ree from kinks and sharp turns? When the wet end is primed and pumping does the vacuum pump stop operating? Does the vacuum prime indicator light (on the vactronic module) go out and the water loss light and power light stay illuminated? Is the pump unit situated in a safe position and not operating at an angle of °
more than 10 ? Is there a good rate of liquid flow f low 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 of flooding?
INFORMATION !
If Cavitation is experienced during 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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1.4.2
Installation Checks Pump unit to be locked out and tagged out WARNING ! !
ATTENTION !
1.4.2.1
before any performed.
maintenance or service is
On-site pump unit alignment checks to be carried out prior to pump unit operation.
Direct Coupled Units
Alignment All units are assembled, aligned and test run at Weir Minerals Multiflo 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 2.1
OPERATION
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 MFVC-420 pump unit has been designed to provide aand safe working environment for operators, maintenance personnel 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 2.1.2
General Safety Recommendations
The accompanying documentation supplied with the Weir Minerals Multiflo MFVC-420 utilises the following safety symbols to highlight potentially harmful situations to personnel and the environment.
SYMBOL
WORDING
DEFINITION
DANGER !
Imminent risk of fatal or crippling injuries
HARMFUL TO Persons
CONSEQUENCES Fatal or crippling injuries likely to result from any exposure
WARNING !
Risk of fatal or crippling injuries
Persons
Fatal or crippling injuries possible
CAUTION !
Possibility of a harmful situation
Persons
Minor or slight injuries possible
ATTENTION !
Possibility of a harmful situation
Property and or the Environment
INFORMATION !
Application Hints and other useful Information
Nil
Damage possible to the product or the Environment
Nil
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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 p prime rime 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, dy dynamic namic head los loss s in the suction sy system. stem. 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 1.
Operation
As the unit used 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 possibl possible e 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 is fitted to the suction hose. hose. NOTE: The suction 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.
Weir Minerals Multiflo Model 420 Pump Unit – Op Operation eration Manual
Weir Minerals Multiflo Model 420 Pump Unit Operation Op eration Manual (Unit fitted with Model 57 Vacuum Pump) Rev 07.07
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Weir Minerals Multiflo
2.1.4
Orientation of Major Unit Components INFORMATION !
Pump Unit Front End (Radiator End)
The front en end d o off the pump unit is the radiator end. end. The back (or rear) en end d is 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 Right Side
Pump Unit Left Side
Pump Rear End (Vacuum Tank End)
FIGURE 6 PUMP UNIT ORIENTATION GUIDE
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2.2
Normal Operating Procedures DANGER ! !
DANGER ! !
CAUTION !
Engine and bare shaft pump 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 maintenance are carried out. out. Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
2.2.1
Daily Pre-Start Checks
2.2.1.1
Transmission
Ensure that the transmission is co cold. ld. Remove the trans transmission mission dipstick. Ensure the oil level is between the low and full mark stamped on the reverse side of the dipstick. Prior to starting the engine, check the transmission as follows:1.
Check that there is oil in the transmission.
2.
Check transmission for leaks, cracks and obvious damage.
3.
Check mountings for tightness or damage such as cracks.
4.
Tighten loose mountings and replace damaged parts.
5.
Inspect heat exchanger oil lines for leaky connections, kinks, cracks and other damage. Replace damaged lines lines..
6.
Check pressure and temperature gauges where applicable.
7.
Inspect drive line and input and output shaft oil seals for signs of leakage. leakage. Replace parts as required.
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8.
Inspect unit identification plate and lube plate for looseness and corrosion. Tighten mounting screws that are loose and replace corroded plates.
INFORMATION !
2.2.1.2
Should you need to replace a plate, assure that all pertinent information is transcribed to the new plate. Failure to do so could result in the loss of important information necessary to obtain parts and service.
Engine Oil
Maintain oil level between ‘add’ and ‘full’ marks on the dipstick dipstick 2.2.1.3
Bare Shaft Pump Auto Lubrication System System (If Fitted) Fitted)
ON.. If the Green While the engine is running, check that the Green indication light is ON indication light is not on, then the grease unit is not pumping grease and a fuse may have blown.
2.2.1.4
Vacuum Pump Oil
Maintain level between ‘high’ and ‘low’ mark on the dipstick. 2.2.1.5
Gland Oil Tank Tank (If Fitted) Fitted)
Fill to 10mm below the filler pipe opening. 2.2.1.6
Coolant Level
Make sure the the engine is stopped and cold. Maintain level in range ab above ove baffle plate and filler neck. 2.2.1.7
Fuel Tank
Fill as required. Use dipstick 2.2.1.8
Battery
Maintain level in range above plates and filler bridge.
ATTENTION !
The engine must not be run when disconnected from the battery!! Doing so may damage the Vactronic Module.
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2.2.1.9
Drive Belts (Fan / Generator / Vacuum Pump)
Check condition and re-tension if required or replace if necessary. 2.2.1.10
Water Trap
Drain and clean the bowl. 2.2.1.11
Air Cleaner Indicator (If Fitted) Fitted)
If the indicator piston locks in the UP position, service the element. 2.2.1.12
Suction Strainer
Check the suction hose and and strainer for blockages or damage. damage. Make sure that the strainer is properly submerged.
2.2.2
Starting Procedures WARNING ! !
1. 2. 3. 4. 5. 6.
Override Mechanism on the shutdown should be activated prior to, or during starting. Turn master disconnect switch to on. Press low engine oil pressure override button. Turn start switch to start the engine and idle at 750-800 RPM. Engage no more than 800RPM. Increasethe thetransmission RPM to 1000atuntil the wet end primes (approximately –20 to –40) on the vacuum gauge). gauge). When primed, increase RPM to achieve the desired duty point.
2.2.2.1 1. 2. 3. 4.
Pump unit to be operated by experienced personnel only.
Start Up Procedure
Check all engine gauges. Check for oil or water leaks etc around the engine Check that the engine protections system is set. The vacuum prime light will go out when the vacuum pump starts pumping.
Weir Minerals Multiflo Model 420 Pump Unit – Operation Op eration Manual (Unit fitted with Model 57 Vacuum Pump) Rev 07.07
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2.2.2.2
Operating Speed (To Set the Operating Speed).
1.
Increase the engine RPM until the pump starts to cavitate. The pump will vibrate and a crackling sound will be heard at the t he pump volute. Decrease the RPM slowly until the pump stops cavitating completely. The vibration and crackling sound will go away.
2.
This is the correct engine operating speed for this application. 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 casing.. Also poor w water ater 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
7
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FIGURE 7 RESULTING EFFECTS OF CONTINUOUS CAVITATION
2.2.3
To Shutdown
1.
Decrease engine RPM slowly to idle.
2.
Dis-engage the transmission at idle RPM.
3.
Allow the engine to idle for 2 – 3 minutes before shutting down. (turbo charged models only)
4.
Stop the engine
5.
Turn the master switch key to the ‘off’ position.
6.
Drain down the pump if it has been used for pumping slurry.
8
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2.2.4
Shutdown Protection
2.2.4.1
Pump Shutdown System
The bare Shaft Pump protection system consists of a probe fitted into the vacuum tank and a Multiflo control module which connects to the engine shutdown. The control module has an inbuilt six minute timer which activates when the water level in the vacuum tank falls below the probe. The red indicating light will flash. The unit will remain in this mode for six minutes before a activating ctivating the engine shutdown. Once this has occ occurred, urred, the red indicatin indicating g light w will ill switch off. Should the pump pick up water within the six minutes after being activated, the unit will automatically reset. 2.2.4.2
Waterloss Shutdown System
One of the unique safety features provided to protect the Multiflo pump during operations is a “water loss” loss” wet end shutdown s system. ystem. A probe situated in the vacuum tank (below the vacuum probe) activates the Vactronic Control Module when it detects detects water or fluid loss at the wet end pump. If this water loss situation remains for six minutes, the engine will be automatically shut down. This is designed to minimize unnecessary unnecessary operation o off seals (gla (gland) nd) and bearings. When or if there is sufficient water available within the six minute period, the shutdown system automatically resets.
FIGURE 8 VACTRONIC MODULE, WATERLOSS SHUTDOWN
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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 and the impeller is constructed from Duplex C26 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
420
Bare Shaft Pump Model
8/6 FF-HX
Maximum Pumping Speed RPM
1200rpm
Bare Shaft Pump Operating Speed
900 rpm
Wet End Material Impeller
Ultrachrome A49 Duplex C26
Bearing Assembly
FFG005M
Weir Minerals Multiflo Model 420 Pump Unit – Operation Op eration Manual (Unit fitted with Model 57 Vacuum Pump) Rev 07.07
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FIGURE 9 BARE SHAFT PUMP WETTED PARTS
11
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Weir Minerals Multiflo
FIGURE 10 BARE SHAFT PUMP BEARING HOUSING
FIGURE BARE SHAFT11 PUMP PEDESTAL ASSEMBLY
12
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2.3.2
Transmission
While most Twin Disc transmissions are forward/reverse reduction units, some units provide speed speed increasing capa capability. bility. All may be used with standard (right hand) rotation engines and certain models may be modified to accommodate non-standard (left hand) hand) rotation engines. Contact your Twin Disc distributor iiff you anticipate using non-standard engines.
INFORMATION !
Engine direction of rotation is determined by facing the front of the engine (opposite engine flywheel). From this viewpoint, clockwise crankshaft rotation is defined as right hand rotation.
All current Twin Disc transmissions can be operated through either primary or secondary clutch at full-rated horsepower for forward (ahead) propulsion using standard engines. engines. Contact Twin D Disc isc for the rated horsepower if you anticipate using non standard engines. Transmission clutches are hydraulically applied using regulated oil pressure. All bearings, clutches and gears are lubricated and cooled with oil. 2.3.2.1
Oil Pump Drive
For most transmissions, transmissions, the sec secondary ondary clutch shaft drives the oil pump. The only exception is the MG540. It has two pumps - one driven by the primary shaft and one driven by the t he secondary shaft. 2.3.2.2
Lubrication Features
The transmission case serves as the reservoir (sump) for all oil used in the transmission. Bearings and cl clutches utches on the primary and secon secondary dary shafts are lubricated and c cooled ooled through pass passageways ageways in the shafts. Output shaft bearings are gravity and/or splash lubricated. Some transmissions use pressurized oil spray to lubricate gears and bearings. 2.3.2.3
Suction Screen
All units have a suction strainer located between the sump and oil pump in the hydraulic circuit. Its purpose is to prevent debris from entering the inlet side of of the pump. The suction strainer must be cleaned as a part of every oil change.
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2.3.2.4
Heat Exchanger
The heat exchanger is required to maintain the oil temperature in the hydraulic system within the recommende recommended d operating range. Proper oil temperature is maintained by passing coolant through the heat exchanger. 2.3.2.5
Identification Plate
All Twin Disc transmissions are equipped with an Identification Plate. In addition to information identifying the unit (i.e. model number, bill of material number, ratio, serial number etc) the identification plate provides information on oil capacity, and oil check/oil change intervals for your particular transmission. All operators of this equipment are respons responsible ible to read and apply the information provided on the transmission identification plate.
FIGURE 12 TWIN DISC TRANSMISSION DATA PLATE
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2.3.3
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 unit.
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 13 PISTON TYPE VACUUM PUMP MAJOR COMPONENTS
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2.3.3.1
Model 57 Parts Assembly
Illustration No: 1 2 3 4 5 6 7 8 2.3.3.2
Description Elbow Non Return Valve Nut Keeper Plate (Arm) Keeper Plate (Top) Vacuum Pump Pulley Bolt Washer Complete Clutch Assembly
Model 57 Specifications
Type – 2 cylinder splash feed Cylinder Bore
90mm bore Standard
Piston
Oversize Standard Oversize Engine Gap Min Max Clearance Max 0.2mm
Piston Ring Piston to Bore Crankshaft Journal
108mm stroke 90mm +0.05 0.00 1mm 89.95mm + 0.03 0.02 1mm 0.1mm 1.0mm
Standard 44.5mm Wear Limit 44.459 - 44.475mm Under Size 44.460 Nil Clearance Standard 0.025mm Max 0.07mm Deep Groove Ball Bearings
Journals to Conrod Main 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
16
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2.3.4
Vacuum Tank
FIGURE 14 VACUUM TANK The high lift vacuum tank is manufactured from 6mm mild steel 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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2.3.5
Vacuum Gauge
A vacuum whichdynamic is mounted the invacuum tank system. indicates, while the pump unit isgauge operating, headinloss the suction The normal operating range depicted by the gauge should be within -20kPA to -80kPA.
FIGURE 15 VACUUM GAUGE
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2.3.6
Non Return ‘Vooom’ Valve
Incorporated on the discharge side of the pump is a discharge line non-return valve. valve, alve, ope open n d during uring pumping, will automatica automatically lly close w when hen pumping This stops.v 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 valv valve e 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 s seals eals 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 used 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 t o 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 lev level el 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 sucti suction on straine strainer r should should be be no les les
INFORMATION INFORMATI ON !
than 1 metre metre below below the surf surface ace o off th 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 16 NON RETURN “VOOOM” VALVE, FLAP IN CLOSED POSITION
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Multiflo ‘Vooom’ Hinged Flap Valve
FIGURE 17 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 ta tank. nk. 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 ball float rising to close off the vacuum pump intake port.
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2.3.7
Vactronic Vacuum Prime System
The Vactronic Vacuum Prime System consists of a probe fitted into the vacuum tank, an electric clutch fitted to the vacuum pump and the Multiflo control module. 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 occu occurs, rs, the electric clutch disengages disengages and th the e vacuum pump 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 o off a shutdown, when the dis discharge charge line n non-return on-return valve fails and floods the vacuum tank, the ball will rise in the krundimendt valve and stop water from entering the vacuum vacuum pump. The one way chec check k valve fitted in the vacuum line, stops air being pulled back into the vacuum tank from the vacuum pump.
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FIGURE 18 VACTRONIC CIRCUIT DIAGRAM
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2.3.8
Hydrau-Flo Fuel Pressure Control Valve
What is Hydrau-Flo Fuel Pressure Control? The Hydrau-Flo Fuel Pressure Control Valve has been designed to be used in conjunction with existing “fast fill” sys systems. tems. The Hydrau-Flo system consists o off several main components; the flow control valve, pilot line float valve, breather and mounting hardware.
FIGURE 19 HYDRAU-FLO FUEL VALVE COMPONENTS
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Hydrau-Flo System Operation The Hydrau-Flo Valve is activated via fuel level, not fuel pressure. When the correct fuel level is attained, the system pressure build-up required to trigger the fuel nozzle to shutoff is contained between the Hydrau-Flo assembly and the fuel nozzle, not in the fuel tank. tank. The fuel nozzle cannot be over-ridden as no matter what the pressure of the fuel INFORMATION ! trying to open the piston is, it will always be higher under the piston due to the addition of spring pressure. HYDRAU-FLO SYSTEM OPERATION
FIGURE 20 HYDRAU-FLO SYSTEM RE-FUELLING IN PROGRESS Fuel enters the system through a "fast fill" receiver and into the Hydrau-Flo Valve body. Fuel pressure forces the shut-off piston open against spring pressure allowing fuel to flow through the porting into the fuel tank.
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An orifice in the piston also allows a metered amount of fuel to bleed off through a capillary line to a float valve located in the tank. This creates a pres pressure sure drop under the piston. Spring pressure will force the piston to close the fuel ports preventing any extra fuel from entering the fuel tank. When the fuel level in the tank rises and closes the float valve, the fuel pressure is equalized on both sides of the piston. By preventing over filling above the pre-set float level in the tank, an air space is maintained to allow for fuel expansion (due to temperature rise) and thus prevent the possibility of fuel weeping through the air vents.
FIGURE 21 HYDRAU-FLO SYSTEM COMPONENTS
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FIGURE 22 HYDRAU-FLO SYSTEM RE-FUELLING FINISHED
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2.3.9
1000FH Turbine Series Fuel Filter/Water Separators Separators (If Fitted)
2.3.9.1
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
W ATER FUEL FIGURE FILTER /23 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 oneone-piece piece clamp-type mounting brackets, with grade 5 fasteners, are included for ensured ensured durability. The 1000FH uses two mounting brackets. The see-thru contamination collec collection tion bowl allo allows ws the o operator perator to check for water and solid contamination at a glance. 2.3.9.2
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° 10°
90°
FIGURE 24 FUEL FILTER / WATER SEPARATOR MOUNTING INSTRUCTIONS
INFORMATION !
Mount the filter assembly as close to vertical (V) as possible. Do not exceed 10 from vertical or the assembly may not function properly. 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. possible. If the FH filter asse assembly mbly 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 INLE INLET. T. This will be used when servicing the replacement element. Before Installing the Filter Assembly:
CAUTION !
Obtain good ventilation and lighting. Maintain a safe working w orking 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 ass assembly embly will mount. Leaving these filters in place w will ill 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 restriction valves to a minimum. Always use the maximum size fuel hose possible. Do not make sharp bends with flexible fuel h hose ose as kinks may occur. Avoid the use of two 45° 45°elbow elbow fittings where one 90° 90°elbow elbow will work. When routing hose, avoid surfaces that will move, sharp edges, or will get hot (such as exhaust piping). piping).
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FIGURE 25 FUEL FILTER / WATER SEPARATOR INSTALLATION INSTRUCTIONS
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2.3.9.3
Racor Fuel Hose Hose
Racor fuel hose is fire resistant and meets SAEJ1527 Type ‘A’ class and SAEJ1527 standards. standards. This hose deliv delivers ers test proven performance in a w wide ide operating temperature range, constant working pressure in popular sizes, long-lasting reinforced construction, kink and cut resistance, and compatibility with a variety of standard fittings.
FIGURE 26 RACOR FUEL HOSE Part Number
Hose ID
Burst Pressure
Min Bend Radius
½” (12.5)mm 5/8” (16mm)
Working Pressure 500 PSI (3.5 MPa) 500 PSI (3.5 MPa)
CGH-10 CGH-12
2,000 PSI (14 Mpa) 2,000 PSI (14 Mpa)
2 ¼” (55mm) 2 ¾” (70mm)
CGH-16
7/8” (22mm)
500 PSI (3.5 Mpa)
2,000 PSI (14 Mpa)
3 ½” (90mm)
Additional sizes are available.
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Additional Features High tensile steel wire braid
No-skive – does not require the removal of the outer cover to install.
USCG-rated for gasoline, diesel, lube oil and hydraulic systems. Workin Wor king g te tempe mperatu ratures res of -4°F to +212 +212° °F ((-20° 20°C to +1 00°C)
2.3.9.4
Priming Instructions 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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2.3.9.5
Specifications - Model 1000FH 1000FH
Maximum Flow Rate Port Size (SAE J1926)
180 GPH 9681 LPH) 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 Assembly
2 inches (51mm)
Height
22.0 inches (559mm)
Depth
6.0 inches (152mm)
Width
7.0 inches (178mm)
Weight (dry) (dry)
10.0lb (4.5kg)
Clean Element Pressure Drop Maximum Allowable Pressure ¹
0.43 PSI (2.97 kPa) 15 PSI (103 kPa) 305ml
Water in Bowl Capacity Available Options ² Water Sensor
Yes
Heater Heater
Yes
Operating Temperature
INFORMATION !
-40°to -4 0°to +25 + 255° 5°F / -40°to -4 0°to 1 121 21° °C
' Pressure installations are applicable up to a maximum PSI shown. Vacuum installations are recommended. ² Not for applications.
use
on
gasoline
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2.4
Test & Performance Data
FIGURE 27 VACTRONIC MODULE TESTER
2.4.1
Vactronic Module Tester
1.
Set both switches to normal and connect the Red/Black Red/Black leads leads to 12 or 24 volt supply. Red Red to to positive and Black Black to to negative. Green light Green ON.. Plug in module. Red Red water light should be ON water loss light should be ON ON and and vacuum prime light should be OFF OFF
2.
Turn vacuum prime switch OFF OFF.. After a 4 second delay, Yellow Yellow light light should come ON ON Yellow light should go out Turn vacuum prime switch to normal, Yellow immediately.
3.
Turn water loss switch OFF OFF.. Tester Red Red light should stay ON ON for approximately 6 minutes or as set on adjustable models. During this time, the Red Red light light on the vactronic module should FLASH FLASH After 6 minutes in this mode, the Red Red lights on the vactronic module and the tester should go out. Turn the water loss switch to normal. Red Red lights should come ON ON immediately. NOTES:
a)
If the Green light does not com ON, ON, check that the battery leads are connected correctly, and that the fuse or breaker has not blown.
b)
This test requires a module tester – Part Number: VT93-MTU1
c)
This module is a power to run the shutdown system and the Red lights lights indicate power ON to the engine.
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2.4.2
Test for Operation of Vactronic & Waterloss Control Module Using Test Light INFORMATION !
The vacuum pump solenoid relay connected to vacuum prime terminals ‘1’ and ‘2’, and the shutdown relay connected to shutdown system terminals ‘3’ and ‘4’ must not have any other wires connected to them. (i.e. no other earths). This is a power to run shutdown system.
Connect positive power (12 volts or 24 volts) to terminal ‘5’; Connect earth to terminal ‘6’; Green power Green power light light will show. With no wires c connected onnected to ter terminals minals 1,2,3,4,7, & 8, the Yellow Yellow vacuum vacuum prim prime e lig light ht will show. The Red Red water loss light will show.
Connect one wire from the test light to terminal ‘1’ and the other wire to terminal ‘2’. The ttest est lig light ht will illuminate. (In this mode the solenoid valve will activate. The solenoid valve is normally closed; upon activatio activation n it will open to create a vacuum prime). prime).
Connect terminal ‘7’ to earth (this simulates prime has bee achieved). achieved). The Yellow vacuum prime light and test light will go out. (In this mode, the Yellow solenoid valve will not activate. The vac vacuum uum pump will pump ag against ainst its own head). head).
Remove test light wires from terminal ‘1’ and ‘2’ and earth from terminal ‘7’.
Connect one wire from test light to terminal ‘3’ and the other wire to terminal ‘4’. The test light will be ON ON and the Red Red water loss light will FLASH (unless the Green power light has been on for more than six FLASH minutes). After approximately six minutes of the RED minutes). RED water loss light flashing, the Red Red water loss loss light w will ill then exting extinguish. uish. Now the shutdown has been activated and the test light will also extinguish.
Connect terminal ‘8’ to earth, (this simulates return of water to the system). The Red Red water water loss will come back ON ON (ON but NOT FLASHING). FLASHING). The test light will come back ON ON.. The six minute timer in water loss is reset. The six minute timer may also be reset by removing and re-connecting the power supply.
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Disconnect terminal ‘8’ from earth and the Red Red light light will FLASH. FLASH. The test ON. After six minutes the Red Red light light will remain ON. light and the test light will go out indicating engine shutdown.
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2.4.3
Design & Operating Limits
Operating Limits Item Description
Maximum Limit
Warman 8/6 FF-HX Bare Shaft Pump Maximum Pump Speed Maximum Pump Inlet Suction Pressure Maximum Pump Discharge Pressure
1,200 rpm - 80 kPA 1,400 kPA
Caterpillar 3412 Engine Maximum Engine rpm
1,800 rpm
Maximum Engine Oil Pressure
40-85 psi
Minimum Engine Oil Pressure @ Low Idle
20 psi
Maximum Engine Coolant Temperature
99 C °
Twin Disc MG5202SC Transmission Maximum Oil Pressure @ 1,800 rpm
270 psi
Minimum Oil Pressure @ 1,800 rpm
250 psi
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2.5
Electrical 2.5.1
Electrical Drawings/Schematics Drawings/Schematics WARNING ! !
Pump unit to be locked out and tagged out before any maintenance or service is performed.
WARNING ! !
Pump unit power supply to be isolated 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 following sheets for the Schematic Wiring Diagram. INFORMATION !
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MFVC-420-89-05.19
Weir Minerals Multiflo
2.5.2 2.5.2.1
Monitoring Instruments Transmission Temperature Shutdown Murphy Gage Installation
WARNING ! !
Disconnect the Battery Negative Cable Before Wiring or Service
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** Yellow wire is optional for gage illumination and does not need to be connected for the gage to operate.**
Sender Wiring
Swichgage Wiring
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2.5.2.2
Coolant Level Detector
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PART 3
Maintenance
43
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PART 3 MAINTENANCE 3.1
Normal Maintenance Procedures Procedures 3.1.1 3.1.1
Safety Procedures DANGER ! !
WARNING! WARNING!
CAUTION !
INFORMATION !
Engine and bare shaft pump 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 maintenance are carried out. out. Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
Observe for unusual gauge leaks and general condition condition of the unit. If condition exists, determine the cause and have necessary repairs made.
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3.1.2
Disassembly Disassembl y & Assembly Procedures WARNING! WARNING!
CAUTION !
INFORMATION !
INFORMATION !
INFORMATION !
INFORMATION !
The assembled bare shaft pump and the 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 worn when operating or servicing this unit.
Names and basic part numbers are used 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 complete overhaul, all parts should be closely inspected and new parts checked for correct identification. Used parts being replaced should be thoroughly cleaned and repainted where required.
Mating faces and spigots should be free 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 threads should INFORMATION ! be coated It with graphite grease that before assembly. is also recommended all rubber seals should be replaced during major overhauls as rubber tends to harden and seals lose their effectiveness.
3.1.2.1
Model 420G Assembly Procedure Procedure
FIGURE 28 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.
CAUTION! CAUTION!
Heavy Components – appropriate lifting 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 WASH WA SHER ER (011) over ea each ch bolt (domed sid side e up) and screw on nu nuts. ts.
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.
WARNING! WARNING!
6.
Heavy Components – pump must be secured to prevent pump from falling forward.
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
CAUTION! CAUTION!
Heavy Components – appropriate lifting techniques to be used.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
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Fitting Adaptor Plate 1. Insert AD ADAPTOR APTOR 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 29 BARE SHAFT PUMP GLAND ASSEMBLY
3.
Place STUFFING BOX (MK121333) flat on bench (Gland side up).
4.
Drop NECK RING (067) in gland reces recess s to rest on retaining lip.
5.
Stand SH SHAFT AFT S SLEEVE LEEVE (075) on end an and ds slide lide through neck ring.
4
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6.
Fit the following items in turn: a) First PACKING RING (PAK-DWF193) of correct leng length th to fill annulus. Flatten packing ring then fit two more packing rings with the joints staggered. Flatten each one separately. b) Fit LANTERN R RING ING (063). If the gland assembly is grease lubricated, fill LANTERN RING (063) prior to assembly. c) Fit final packing ring with the join 180° 180°away 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).
INFORMATION !
a) To assist in holding the last ‘O’ Ring in 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.
CAUTION! CAUTION!
Heavy Components – appropriate lifting 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 30 BARE SHAFT PUMP IMPELLER & BOWL ASSEMBLY
a)
Screw and tension STUD (026) into tapped holes provided in back liner.
CAUTION! CAUTION!
Heavy Components – appropriate lifting techniques to be used.
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b) Suspend LIFTING TUBE (FH (FH4302E02) 4302E02) 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 iin n groove in in shaft spacer.
CAUTION! CAUTION!
Heavy Components – appropriate lifting 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 B BOWL OWL SE SEAL AL (124) over rrim im of BAC BACK K LINER (041)
FIGURE BARE SHAFT31 PUMP BEARING ASSEMBLY
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4. Fitting BOWL (131) and CLAMP RING (135): Heavy Components – appropriate lifting techniques to be used. CAUTION! CAUTION! 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 ov over er 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°). 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 describes 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.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
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FIGURE 32 BARE SHAFT PUMP VOLUTE ASSEMBLY
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FIGURE 33 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 80.
FIGURE 34 BARE SHAFT PUMP COMPLETE ASSEMBLY
Impeller end clearance has yet to be adjusted. 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 35 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’. ‘1’.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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INFORMATION !
Impeller adjustment is a key element in extending the wear life. Field tests on certain pumps indicate if impellers are adjusted right forward when fitted and again at regular intervals during the wear life, then an increase of 40-50% 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)
d)
re-adjust a further two or three times at regular intervals during the wear life of the pump. After adjustment of the impeller, it is important to tighten the bearing housing clamp to 185Nm.
ATTENTION !
INFORMATION !
Before applying power, verify that the available power source matches the configuration settings of the product as described in the manual.
Packing will require during initial start-up.
adjustment
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Impeller Removal Heavy Components – appropriate lifting CAUTION! CAUTION!
techniques to be used.
CAUTION !
Personal Protective Equipment must be worn when operating or servicing this unit.
INFORMATION !
All Warman ‘HX’ pumps utilize a threaded 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)
3.1.3
Maintenance Model 420 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.
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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 desi rable from the newly pack packed ed 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 four rows of ¾ gland packing. The part number for the set of packing is PAK-DWF193 PAK-DWF193 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 36 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. rings. Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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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. 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. Eg. 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” it’s 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 remain open while the pump is in operation. If the pump is not being used for an extended period of time, the tap should be turned off until the pump is operated again. 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.
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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:
3.1.3.2
Gland packing requires replacement. Shaft sleeve requires replacement. Incorrect gland adjustment.
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. This adjustment can be car carried ried our in a few minutes without any dismantling. The procedure is:1. 2. 3. 4. 5. 6. 3.1.3.3
loosen drive on pump shaft loosen bearing housing clamp bolts adjust impeller forward so it “just touch the door lock adjusting bolts re-tighten bearing housing clamp bolts to 185Nm tighten pump drive components. Lubrication
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 bearing assembly should be opened at regular intervals (no longer that 12 months) to inspect the bearing and grease. Multiflo recommend the use of automatic lubrication systems to ensure the correct amount of grease is supplied to the bearings and labyrinths, however, if units are to be greased manually, then the following schedule gives the suggested grease requirements. Drive End Bearing Pump End Bearing
145g of grease per ‘X’ hours 115g of grease per ‘Y’ hours
Pump Speed 900
‘X’ Hours
‘Y’ Hours
3500
700
Grease purging of the maintains a barrier to contaminantsintervals enteringfor thelabyrinth bearing assembly resulting in labyrinth longer bearing life. The recommended grease purging are as follows:
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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Continuous Operation
16 hr day
8 hr day
Pump End Labyrinth
4 shots/12 hours
4 shots daily
2 shots daily
Drive End Labyrinth
4 shots/120 hours
4 shots weekly
2 shots weekly
The shots are from a standard hand operated grease gun (approximately 1cc). The grease used for both bearings and labyrinths should be a lithium complex soap thickener grease with EP additives and oxidant inhibitors. If the bearing as assem sembl blie ies s rrun un at ab above ove 85 85° °C, the then n a high tempe temperatu ratu re greas grease e should be used used..
FIGURE 37 BARE SHAFT PUMP MANUAL LUBRICATION POINTS
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
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Bare Shaft Pump Automatic Lubrication System OUTLET CONNECTIONS AND TIMER SETTINGS FOR MULTIFLO MODEL 420 (FF-HX) PUMPS Outlet Connections Connect the distributor block outlets to the ports on the Multiflo Multif lo pumps as follows:•
Top outlet stamped with with '25' to pump driv drive e end labyrinth (1 gram)
•
Second outlet stamped with '75' to pump impeller end bearing (7 grams)
•
Third outlet stamped with ‘25’ to pump drive end bearing (2 grams)
•
Bottom outlet stamped with ‘75’ to pump impeller end labyrinth (6 grams)
1 gram
25
7 grams
75
2 grams
25
6 grams
75 Timer Settings Ensure unit is set to the following time settings:•
Lubrication Time – 22 seconds
•
Cycle time – 1 hour FIGURE 38 AUTOMATIC GREASING GUIDE, OUTLET CONNECTIONS & TIMER SETTINGS
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3.1.4
Maintenance Model 57 Piston Vacuum Pump Pump WARNING ! !
CAUTION !
Personal Protective Equipment must be worn when operating or servicing this unit.
WARNING ! !
Heavy Components – appropriate lifting techniques to be used.
INFORMATION !
3.1.4.1
Pump unit to be locked out and tagged out before any maintenance or service is performed.
Oil level the must be checked before operating vacuum pump. Running the vacuum pump without oil will cause damage.
Vacuum Pump Piston & Re-Ringing Instructions
It is advisable that the ridge be removed from the top t op of worn cylinders prior to removing the piston. Failure to do so may result in cracked 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 t he 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 (0.06 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.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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Poor cleaning after honing accounts for most of today’s wear out / oil consumption problems. Petrol and k kerosene erosene are not suitable. Soap and hot water with a nylon nylon scrubbing brus brush h are best. Check with a clean w white hite cloth which should should not co come me out grey. Finally, swab with a lig light ht 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. diameter.
INFORMATION !
Maximum gap condition is not especially 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 q quality uality 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 39 WINDING ON PISTON OIL RING EXPANDER
•
Hold the expander end in place w with ith thumb. Wind on lower rail then wind on upper rail.
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FIGURE 40 UPPER & LOWER RAIL OF EXPANDER
•
Both ends of the expander should be visible and not over lapped
FIGURE 41 UPPER & LOWER RAIL GAP
•
•
Align gaps as per can the diagram above. ove. (gaps must not be lined up). Checkallthe assembly rotate in ab the groove. When fitting the compression rings, make sure they are fitted the correct
way up as per the diagram on the following page. Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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FIGURE 42 CORRECT FITMENT OF COMPRESSION RINGS •
To avoid breakage, do not wind on the compression rings
X FIGURE 43 INCORRECT FITMENT OF COMPRESSION RINGS •
Use a ring expander or expand with the thumbs before placing in piston grooves.
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FIGURE 44 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, pus push h the rings again against st 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 clearanc clearance e between rings and edge should be 0.3mm for compression rings and 0.15mm fir oil rings.
FIGURE 45 CORRECT RING BACK CLEARANCE
Correct running in of rings rings is essential, esp especially ecially 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 Tensioning WARNING ! !
CAUTION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be 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, to catalogue value if n necessary. ecessary. a pro properly perly designed drive for re-setting the application there will be no need for anyOn further attention during the life of the drive. Belt Tension Indicator applied to mid span
FIGURE 46 BELT TENSIONING INDICATOR OPERATION
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1.
Calculate the deflection distance in m mm m on a bas basis is of 16mm (5 (5/8”) /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 tens tension ion indicat indicator or on top of the belt at the centre of sp span, an, 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.** INFORMATION !
For single belt drives a straight edge 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 sh ould be satisfactory. A measured force should below the lower value indicates under-tensioning. A new driv drive e shou should ld 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 v value alue 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 Tens Tension ion Indica Indicator tor is not available, a spring balance and rule will suffice.
FIGURE 47 BELT TENSIONING
INDICATOR Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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Belt Tensioning Forces Pump unit to be locked out and tagged out WARNING ! !
CAUTION !
before any performed.
maintenance
or
service
is
Personal Protective Equipment must be worn when operating or servicing this unit.
Force required to deflect belt 16mm per metre of span
BELT SECTION
Small Pulley Diameter (mm)
Newton (N)
Kilogram Force (kgf)
95
10 to 15
1.0 to 1.5
SPZ
3.1.5.2
Installation & Operation of Wedge & V-Belt Drives Drives
WARNING ! !
Pump unit to be locked out and tagged out before 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 edges and all dimensio dimensions ns co conform nform to the relev relevant ant standard. The Taperlock Bush is the starting point when it comes to assembly and installation. Drive installation is a straight forward job with Tape Taperlock, rlock, but the stages set out on the installation leaflet provided with every Taperlock bush should be followed closely.
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Alignment WARNING ! !
Pump unit to be locked out and tagged out before any maintenance or service is performed.
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear. The diagram be below low shows some of the com common mon alignment faults. You should only be satisfied if the conditions in sketch 4 prevail. A.
Figure A. Shafts are not parallel to one another.
B. B.
Figure B. Shafts are not in correct alignment although they appear parallel when seen from above.
C. C.
Figure C. Shafts are parallel and in alignment but pulleys are not in alignment.
D. D.
Figure D. Correct installation both shafts and pulleys are parallel and in alignment
FIGURE 48 BELT ALIGNMENT
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Belts WARNING ! !
CAUTION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be 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 driv drive e 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 b be e easily damaged by us using ing 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. stretch.
Installation And Take-Up Allowance Belt Pitch Length (mm) (mm)
Installation Allowances
Take-Up (mm) (mm) SPZ
2030
20
30
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3.1.5.3
Taperlock Bushes Bushes WARNING ! !
CAUTION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
Removing a Taper Lock Bush Removing a Taper Lock Bush
FIGURE 49 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 tthread hread 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 of hub. After ensu ensuring ring that the mating tapered s surfaces urfaces are completely clean and free from oil or dirt, insert bush in hub so that holes line up.
FIGURE 50 50 ABOVE INSERTING TAPERLOCK BUSH TO HUB HUB FIGURE 51 51 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 loos loosely ely in holes threaded in hub, sh shown own in diagram below. 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 52 52 ABOVE & & FIGURE 53 53 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). bore). Screws will 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 Screw Tightening Torque Screw Qty Screw Size (BSW) Screw Hex Socket Size (mm) Large End Diameter (mm) Approximate Mass (kg)
4535 190 Nm 3 1/8” 14 162.0 7.5
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3.1.5.4
Taperlock Flanges Flanges
FIGURE 54 TAPERLOCK FLANGE DIMENSION CHART Dimensions of Fenaflex Flanges Types F & H F180
F
H
Bush No. Max Bore mm L E J† A C D F G§ M¶ Mass Kg
4535 125 112 89 89 470 398 205 94 19 23 42.2
4535 125 112 89 89 470 398 205 94 19 23 42.2
Notes
§: G is the amount by which clamping screws need to be withdrawn to release tyre
†: J is the spanner clearance to allow for tightening the bush on the shaft and the clamp ring screws ¶: M is half the distance between flanges. Shaft ends (normally Mx2) can project beyond the flanges. In this event allow sufficient space
34
Inertia kgm²
42.2
42.2
0.847
0.847
between shaft ends for end float misalignment.
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3.1.5.5
Tyre Couplings Couplings
Installation Instructions
WARNING ! !
CAUTION !
INFORMATION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
Satisfactory performance depends on 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.) Bushes.) Locate flanges to that dimension ‘M’ ‘M’ is is obtained (see para 3). 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’ ‘M’ is is obtained (Refer Figure 55 & Table 1, Page 37). 37). If shaft end float is to occ occur, ur, locate the s shafts hafts at midposition of end float when checking dimension ‘M’. ‘M’. Note that shaft ends may project beyond beyond the faces of the flange flanges s if required. In this event, allow sufficient space between shaft ends for end float and misalignment. Flanges should be fitted flush with the end o off the shaft when used with Mill-Motor flanges.
4.
Check parallel alignment by laying a straight edg edge e across the flanges at several positions around around the circumferenc circumference. e. Check angular alignm alignment ent 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 ty tyre re and fit ov over er coupling flanges ensuring that the tyre bea beads ds seat properly on the flanges and/or clamping ring rings. s. 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 b between etween the ends o off the tyre as shown in Figure in Figure 56 & Table 2, Page 38.
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 55 55 TABLE 1 INTERNAL CLAMP RING TORQUE
Table 1 Coupling Size F180
M mm 46
Screw Size M16
Clamping Screw Torque Nm 105
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
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FIGURE 56 56 TABLE 2 INTERNAL CLAMP RING TORQUE
Table 2 Coupling Size
F180
Tyre Gap mm
6
37
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3.1.5.6
Model MG5202SC Transmission Transmission Pump unit to be locked out and tagged out WARNING ! !
before any performed.
CAUTION !
Personal Protective Equipment must be worn when operating or servicing this unit.
ATTENTION !
INFORMATION !
INFORMATION !
maintenance
or
service
is
Selecting Neutral disengages transmission clutches but does not prevent propeller shaft rotation. If you require positive neutral (prop shaft locked), a shaft brake or other shaft-locking device must be used. used.
All replacement parts or must products (including hoses and fittings) be of Twin Disc origin or equal, and otherwise identical with components of the original equipment. Use of any other parts or products will void the warranty and may result in malfunction or accident, causing injury to personnel and/or serious damage to the equipment. Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble free operation. Schedules and c charts harts are provided in the manual for recommended maintenance of the equipment.
Renewal parts, service parts kits, optional equipment and product service assistance may be obtained from any authorized Twin Disc distributor or service dealer. Contact Twin Disc for the distributor or s service ervice dealer near you. Twin Disc, having stipulated the bill of material number on the unit’s nameplate, absolves itself of any responsibility resulting from any external, internal, or installation changes made in the field without the express written approval of Twin Twin Disc. All returned parts, new or old, emanating from an any y of the above stated changes will not be accepted accepted for c credit. redit. Furthermore, any equipment that has been subjected to such changes will not be covered by a
Twin Disc warranty.
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General Maintenance CAUTION !
Personal Protective Equipment must be worn when operating or servicing this unit.
ATTENTION !
Failure to follow thi Failure this s procedure procedure may re resul sul in transmission damage and/or failure.
ATTENTION !
Under no circumstances should the oil level be above the “FULL” mark on the oil level gauge with the engine running and the transmission in neutral. Drain the oil if necessary to achieve a level between the “LOW” mark and the “FULL” mark with the engine at idle and the transmission neutral and at OPERATING TEMPERATURE. NOTE: Engine warm-up in neutral is NOT a sufficient warm-up period for the transmission.
Oil Level Setting Procedure 1.
Fill the empty transmission with the proper viscosity oil (Mobil Trans HD50) to the the “LOW” mark on the oil lev level el gauge. If the cooler and hoses are empty, fill the transmission to the “FULL” oil mark on the oil gauge.
2.
Start the engine and let it run for about 30 seconds with the engine running at idle and the cold transmission in neutral. Add oil until it reaches the “LOW” mark on the oil level gauge with the engine running and the transmission in neutral.
3.
Run under load so the transmission reaches its operating temperature (transmission oil temperature between 65 °C and 85°C (150°F and 180°F). The oil level in the HOT trans transmission mission should be between the “LOW” mark and the “FULL” mark with the engine at idle, the transmission in neutral and at operating temperature.
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Lubrication If your end unit of is the equipped with a output lubrication grease the oil sealsthrough at the output transmission shaftfitting, with water pump grease the lube fitting. Apply grease every 100 hours. No other lubrication is required.
FIGURE 57 TWIN DISC TRANSMISSION LUBRICATION POINTS
INFORMATION !
Preferred grease is one with lithium soap, NGLI consistency #2 for component temperatures above 20°C (68°F).
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Filter and Oil Change Interval With a new transmission, change the oil and filter element within the first 50 hours of operation. Change oil and filter element after each 1000 hours thereafter or more often if conditions warrant. For a rebuilt transmission, check the suction screen and filter element after eight hours of of operation. Look for lint or other material that may collect collect from rags or towels used in the parts cleaning proc process. ess. Look for chips or s shavings havings particularly if the transmission has had a problem that caused debris in the system. (For units with s spin-on pin-on filters, this w will ill require cutting the filter element element apart to access the element c core.) ore.) If the filter is clean, install a new filter element and then change the oil and filter element after 1000 hours of service. If the filter is dirty, change the element and operate for another eight hours. Check the filter again. Continue this cycle until the filter is clean and then change the oil and filter after 1000 hours of service or more often if conditions warrant.
INFORMATION !
Situations involving debris in the hydraulic system will require that heat exchangers and all connecting lines and hoses be be thorough thoroughly ly cleaned. If the heat exchanger cannot be disassembled, or if it cannot be assured that all debris is removed, the heat exchanger should be replaced.
Draining Drain the transmission by removing the oil drain plug from the rear/bottom of the transmission. Filling 1.
Remove the breather or the oil fill closure from the top of transmission case.
2.
Pour new oil through breather or closure opening. Fill with recommended clean oil, taking necessary precautions to prevent entry of dirt and debris.
Oil Capacity See lubrication plate on transmission. Capacity given will be internal quantity required to fill transmission to proper level, but may NOT include quantity to fill external hoses and heat exchanger.
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Heat Exchanger Check for leak s. not Heat works in c conjunction onjunction with engine cooling system, andleaks. does useExchanger pit water for cooling. Suction Strainer Remove and clean the suction strainer at every oil change or sooner if necessary. Flexible Input Coupling Do not obstruct the flywheel housing vents preventing the free flow of air for cooling the coupling. Life of th the e coupling may be reduced iiff the ambient temperature of the air around the coupling is outside the operating range. Operating air temperatures above -6°C (22°F) and below 82°C (180°F) should be maintained. If possible, visually inspect the coupling after the first 100 hours of operation and every 2000 hours thereafter, or every six months, whichever occurs first. Torsional vibration, misalignment, degradation by contaminants (oil), heat, ultraviolet radiation, and excessive system torque can cause cracks or other signs of distress to appear appear on the surface of the rubber. The above-desc above-described ribed items affect the life of the coupling element. If coupling access is restricted, inspection may be possible only at engine overhaul or whenever the transmission is separated from the engine. Frequently check check the flywheel housing vents. Coupling deterioration, from a variety of causes may be indicated by an accumulation of residue at the vents. Should this be evident, inspect to determine the cause. Overhaul Interval Overhaul the transmission at the same time the engine is overhauled.
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3.1.5.7
1000FH Series Fuel Filter / Water Separator Service Instructions 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 NOT leave the drain open too long as it will eventually completely drain the entire entire filter assembly of water AND AND fuel. 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 contaminants with a suitable collecti collection on 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 NOT leave the drain open too long as it will eventually completely drain the entire filter assembly of water AND AND fuel, and
possibly drain the entire tank. Element Replacement: Frequency of element replacement is determined by the t he contamination level of fuel. Replace the elements every 10,000 miles, ev every ery 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. first.
INFORMATION !
Always carry extra replacement elements as one tank full of excessively dirty fuel can plug a filter.
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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 o off 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.
INFORMATION !
Above ground tanks or transfer pump applications may use head pressure to prime the filter assembly.
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Replacement Parts Item 1.
Part Number RK 11-1945 11350
Description T - handle & O’ring kit T - handle & O’ring
2.
RK 11-1927-01 11007
Lid & Lid Gasket 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 24 vdc Heater w/Body Feed Thru Body Feed Thru Ass’y (for heater) Body Feed Thru Plug (not shown) Square Cut Gasket (Lid & Bowl)
RK 11-1800-02 9.
RK 21067 RK 11-1679
10.
11007
11.
RK 11028B
Check Ball and Seal
12.
RK 11-1939
Turbine Centrifuge/Conical Baffle
13.
RK 11-1938
See-thru Bowl Plug w/Drain &
14.
RK 32204 RK 22838
Water Sensor Water Sensor Plug
15.
RK 11-1776
Body 7/8” – ¼
16.
RK 11037A
Bowl Ring 5” Diameter
17.
RK 11542
Capscrew Kit (4)
18.
RK 30476
Self-venting Drain
Additional Parts RK 11-1952 RK 31605 (various)
FIGURE 58 FUEL FILTER / WATER SEPARATOR PARTS IDENTIFICATION
FH Assembly Seal Kit Parker Super O’Lube Racor Additives (see chart on next page) page)
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
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Additive
Diesel Biocide Diesel Conditioner Plus +
Diesel Winter Plus +
Part Number ADT 2116
Size
Treatment
16 oz Bottle
1,280 Gallons
ADT 2201
1 Gallon Bottle
10,240 Gallons
ADT 1116
16 oz Bottle
320 Gallons
ADT 1201
1 Gallon Bottle
2,560 Gallons
ADT 4116
16 oz Bottle
128 Gallons
ADT 4201
1 Gallon Bottle
1,024 Gallons
Benefits •
Concentrated formula
•
Kills bacteria & fungi
•
Prevents corrosion
•
Enhances engine
performance •
Stabilizes the fuel
•
Quieter engine operation
•
Inhibits waxing, icing &
gelling •
Protects Protect s down d own to -3 -30° 0°F ((-
34°C) Enhances engine performance •
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3.1.6
Frequency of Routine General Maintenance DANGER !
WARNING! WARNING!
CAUTION !
Engine and bare shaft pump 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 maintenance are carried out. out. Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
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3.1.6.1
Every 10 Engine Hours or Daily
EVERY 10 ENGINE HOURS OR DAILY SCHEDULE
MAINTENANCE
Bare Shaft Pump Auto Lubrication System (If fitted)
While the engine is running, r unning, check that the Green indication ON light is ON If the Green indication light is not on, then the grease unit is not pumping grease and a fuse may have blown.
Engine Oil
Maintain oil level between “add” and “full” marks on the dipstick. Use SAE15W40 SAE15W40 or refer to Lube List List. (Refer to the Engine Manual)
Vacuum Pump Oil
Maintain between “high” and Oil “low” the List dipstick. level Use SAE15W40 Engine Engine or marks refer toon Lube
Transmission
With the engine running at low idle and the transmission in Neutral, the oil level should be maintained between the “low” and “full” marks on the oil level gauge. Use Mobil HD50 or refer to Lube List.
Gland Oil Tank (If Tank (If fitted) fitted)
Fill to 10mm (3/8”) ( 3/8”) below filler pipe opening. Use SAE15W40 or refer to Lube List.
Gland
Inspect and adjust if necessary.
Coolant Level (Engine Stopped and Cold)
Maintain level in range above baffle plate and filler neck.
Fuel Tank
Fill as required
Battery
Maintain level range above plates and filler bridge
Drive Belts
Check condition and tension if required
Water Trap
Drain and clean bowl
Observe for unusu unusual al gauge leaks and general general condition condition of the unit. unit. determine the cause and have necessary repairs made.
If condition exists, exists,
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3.1.6.2
After First 100 Engine Hours
AFTER FIRST 100 ENGINE HOURS SCHEDULE MAINTENANCE Transmission
Change Transmission Oil and Oil Filter
3.1.6.3
Every 250 Engine Hours
EVERY 250 ENGINE HOURS Perform in addition to Daily Schedule Items
SCHEDULE
MAINTENANCE
Engine Oil & Filters
Change the oil and filters f ilters (Refer to Engine Manual)
Engine Fuel Filters
Change Filters (Refer to Engine Manual)
Bare Shaft Pump Auto Lubrication System (If fitted) fitted)
Check the grease level in the t he Automatic Greasing Unit. It must not be allowed to be completely empty! Use Multiflo Pump Grease Or refer to Lube List List
Non Return Valve
Inspect condition. condition. Repair ifif necessary.
Drive Coupling
Inspect condition. Re-tension bolts and grub screws if required.
Engine Air Cleaner Element
Inspect condition. condition. Replace if necessary. necessary.
Vacuum Tank Probes (Vactronic & Waterloss)
Inspect and clean.
Mounting Bolts
Check all bolts on Engine, Bare Shaft Pump and Vacuum Pump. Tighten if necessary. necessary.
49
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3.1.6.4
Every 1000 Engine Hours
EVERY 1000 ENGINE HOURS Perform in addition to 250 Hours Service Items
SCHEDULE
MAINTENANCE
Bare Shaft Pump Auto Lubrication System (If fitted)
Check the grease level in the t he Automatic Greasing Unit. It must not be allowed to be completely empty! Use Multiflo Pump Grease Or refer to Lube List List
Bare Shaft Pump
Condition/Adjustment Inspection of impeller, wear plate(s), volute, and packing
Transmission
Change transmission oil and oil filter
Refer to Transmission Manual Vactronic Control
Check condition of wires and probes etc
Radiator
1. Clean core finning 2. Inspect condition condition of radiator hoses. hoses.
Auto Shutdown System
1. Test shutdown shutdown operation 2. Inspect condition condition of wiring, wiring, hoses etc.
Vacuum Pump
Change the Oil Use SAE15W40 Engine Oil Or refer to Lube List
Non Return Valve
Replace Flap if Required.
3.1.6.5
Every 2000 Engine Hours
EVERY 2000 ENGINE HOURS Perform in addition to 1000 Hour 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.
50
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3.2
Troubleshooting 3.2.1 3.2.1
Finding and Diagnostic Guide (Including Details of Normal Readings)
3.2.1.1
Pump Unit Unit
WARNING ! !
CAUTION !
ATTENTION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
The engine must not be run when disconnected from the battery!! Doing so may damage the Vactronic Module
Failure to Prime Check Vacuum Gauge Reading
FIGURE 59 VACUUM GAUGE – HIGH READING
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SYMPTOM 1.
CAUSE
High Vacuum Gauge Reading
(-80 and above)
SYMPTOM
Static suction lift too high Obstruction in suction hose or strainer Suction hose kinked or collapsed Suction hose collapsed internally Suction hose stuck low into the mud
REMEDY
Lower suction lift Remove obstruction hose and/or strainer
Unkink suction hose
Replace suction hose
Remove suction hose from mud
CAUSE
from
REMEDY
2. Low or No Reading
(-20 and below)
If Vacuum Pump is Operating with Air Being Exhausted
Air leak in the suction line Discharge reflux valve not sealing Air leak in vacuum line from tank Leaking gland packing
Repair suction line Replace seal
Repair vacuum line
Adjust gland packing
FIGURE 60 – VACUUM GAUGE
LOW READING
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SYMPTOM 3. If Vacuum Pump is Operating with no Air Being Exhausted
CAUSE
REMEDY
Krundimendt valve ball sticking Non-return valve sticking Vacuum pump faulty
Clean or replace valve ball
Check and seal Repair vacuum pump
Dirty probes – fault in probe wiring
Clean probes & check probe wiring
Faulty vactronic module
Faulty clutch
Repair or replace vactronic module Repair or replace clutch
Faulty clutch relay
4. If Vacuum Pump Electro-Magnetic Clutch fails to Open
Repair relay
or
replace
clutch
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 vacuum tank inlet inlet and the pump discharge. discharge. Start the engine 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 leak in the vacuum vacuum tank 2. An air leak leak in the bare bare shaft pump 3. Leaking gland packing 4. Faulty vacuum pump
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
Normal Operating Range
FIGURE 61 VACUUM GAUGE NORMAL OPERATING RANGE
54
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
55
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
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 (1800 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.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
56
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
3.2.1.2
Vacuum Pump
Sticking valves, and pump exhaust, or bothorare visually evident by aor popping noise emitted from theinlet vacuum exhaust, uneven exhaust pulses 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.
INFORMATION !
To valves,(diesel) place upside down and fill withtest kerosine 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.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
57
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
When replacing a crankcase seal, it is to be inserted as per the diagram here.
FIGURE 62 CORRECT REPLACEMENT OF VACUUM PUMP CRANK SEAL Worn Rings For conventional rings, gapused should beone 0.1mm when Where one groove of segmental is the being with groove of assembled. 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. necessary.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
58
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
3.2.1.3
‘V’ Belt Trouble Shooting Shooting Pump unit to be locked out and tagged out WARNING ! !
before any performed.
CAUTION !
Personal Protective Equipment must be worn when operating or servicing this unit.
Symptom
maintenance
or
service
Remedy
Small cracks on ‘V’ Belt side and base
Generally caused by shortage of belt tension but excessive heat and/or chemical fumes can also give same failure.
‘V’ Belt swelling or softening
Caused by excessive contamination by oil, certain cutting fluids or rubber solvent.
Whipping during running
Usually caused by incorrect tensioning, 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
is
Hydrau-Flo Valve Troubleshooting Troubleshooting
DANGER! DANGER!
Pump unit fuel system may contain diesel fuel. Pump unit fuel system should be isolated and drained prior to any work on the fuel system being undertaken.
WARNING ! !
CAUTION !
Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
Symptom Fuel nozzle shutting off prematurely
Fuel nozzle not shutting off.
Fuel weeping from breather after tank has been filled.
Cause
Remedy
Nozzle or receiver spring setting too low.
Check rating of spring, condition replace if and necessary.
Back pressure in filler pipe too high.
Ensure there is no 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 valve set too too low low in tank.
Adjust to desired desired fill height.
Restriction in capillary line.
Check line for damage, kinks, or crushing. Replace if necessary.
Float valve not closing capillary line.
Check operation of float 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 breather
Lower float lever below
height.
height of breather.
Float level set too high, not allowing enough air space for fuel expansion due to rise in temperature.
Lower float level setting.
59
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
60
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
3.2.1.5
1000FH Turbine Series Fuel Filter / Water Separator Fitted) Troubleshooting (If Fitted) Troubleshooting
ATTENTION ATTENTI ON !
Correct external fuel leaks immediately ! These conditions will result in reduced engine performance performance such a as: s: 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 procedures or damag damage e to the unit or fuel system. The result is either internal air suction or ex external ternal fuel leakage. Diagnosis sh should ould be in the following steps: 1.
Checkposition the fuelaslevel and make sure any fuel delivery valves are in the open 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 red reduce uce efficiency and de-gas (pull are 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. change. Always carry ex extra tra replacement elements w with ith your equipment as one tank full of excessively contaminated fuel can plug an element. When clogged to the maximum capacity, eleme elements nts will have a brow brown n to black colour or tar like 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 of microbiological contamination. This condition must be treated immediately. Severe conditions must be corrected by a repair facility. facility.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
61
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
ATTENTION ATTENTIO N!
Never operate the filter assembly without 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 thethe quick-help instructions or refer to procedures on the below previous page.
All Racor FH filter assemblies are 100% tested to ensure a leak-proof, quality product.
INFORMATION !
Apply Parker Super O-Lube (part number 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.
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
FIGURE 63 FUEL FILTER / W WATER ATER SEPARATOR TROUBLESHOOTING
62
HINTS
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08
63
(Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
3.3 Lubrication Schedule 3.3.1
Grades & Frequency of Lubrication DANGER ! !
DANGER ! !
CAUTION !
Engine, bare shaft pump and transmission 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 maintenance are carried out. out. Pump unit to be locked out and tagged out before any maintenance or service is performed. Personal Protective Equipment must be worn when operating or servicing this unit.
Grades and Frequency of Lubrication Item
Recommended Lubricant
Frequency
Maximum Capacity
3412 Engine Oil
Mobil Delvac MX 15W40 Shell Rimula 15W40
Checked Daily
Engine Turbo Saviour (If Fitted)
Mobil Delvac MX 15W40 Shell Rimula 15W40
Upon Installation
MG5202SC Transmission Oil
Mobil HD50 Shell TC50
Checked Daily
26.5 litres
Piston Vacuum Pump Oil
Mobil Delvac MX15W40
Checked Daily
2.2 litres
Bare Shaft Pump Bearing Assembly
Multiflo Pump Grease Shell Alvania RL2 Grease SKF LGMT 2
Check Automatic unit grease level weekly
68 litres
Weir Minerals Multiflo Model 420 Pump P ump Unit – Maintenance Manual (Unit fitted with Model 57 Vacuum Vac uum Pump) Rev 04.08 (Always quote Model and Serial Number of Unit when Ordering Parts)
PART 4
Spare Par P arts ts Parts
64
Weir Minerals Multiflo
PART 4 SPARE PARTS MFVC-420
Weir Minerals Multiflo
BARE SHAFT PUMP ITEM
DESCRIPTION
PART NUMBER
QTY
1
BARE SHAFT PUMP
WA86FFHX420A49/C26
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 1 of 58
Weir Minerals Multiflo
BEARING HOUSING ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
SHAFT KEY PISTON RINGS LABYRINTH (DRIVE END) BEARING (DRIVE END) GREASE NIPPLE BEARING HOUSING BEARING END COVER GASKET LABYRINTH
S070 YE108-G02 FF062D-10E62 S009D M12A2-30H FF004D21 S009 FF025-S14 FF062-10E62
1 4 1 2 4 1 1 2 1
10 11
LABYRINTH SEAL END COVER
FF089-10S10 FF024-10E62
2 2
12
MFVC FVC-4 -420 20
FFG073ME05
SHAFT
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
1
Dec-07
Page 2 of 58
Weir Minerals Multiflo
SHAFT SLEEVE & GLAND PACKING ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8
SHAFT SLEEVE SPACER SHAFT SLEEVE SHAFT SPACER GLAND (2 PIECE) GLAND BOLT c/w 1 BOLT 1 WASHER W ASHER NECK RING PACKING O'RING
FG179C11 F075C21 FG117C21 F044C23 F045MC23 F067C23 PAK-DWF193 F109S10
1 1 1 1 2 1 1 3
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 3 of 58
Weir Minerals Multiflo
TUNGSTEN CARBIDE SHAFT SLEEVE(OPTIONAL) ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3
O'RING SHAFT SLEEVE SHAFT SPACER
F109S10 FG076J31 FG179C11
3 1 1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 4 of 58
Weir Minerals Multiflo
WETTED PARTS ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
BOWL SEAL FRONT DOOR CLAMP RING (4 PIECE) VOLUTE IMPELLER BACKLINER BOWL SEAL CLAMP BOLT c/w 1 NUT O'RING
FX6124S00 FX6013HET1A49 F10135E02 FX66131A49 FX6145HET1C26 FX66041A49 FX6124S00 F129ME62 FH122S01
1 1 2 1 1 1 1 8 1
10
STUFFING BOX
MK121333AA55
1
11
MFVC FVC-4 -420 20
FX66032D21
ADAPTOR PLATE
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
1
Dec-07
Page 5 of 58
Weir Minerals Multiflo
GLAND GUARD ITEM
DESCRIPTION
PART NUMBER
QTY
1 2
GLAND GUARD TOP GLAND GUARD BOTTOM
MSA420A001 MSA420A002
1 1
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 6 of 58
Weir Minerals Multiflo
MODEL 57 VACUUM PUMP ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7
COMPLETE VACUUM PUMP EXHAUST PIPE OIL DRAIN c/w O' RING REDUCING BUSH HOSE GUARD GASKET
MVP150-200 MVP150-254 MVP150-223 MVP150-278 MVP250-279 MVP150-282 MVP150-215
1 1 1 1 1 1 1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 7 of 58
Weir Minerals Multiflo
CRANK CASE GROUP ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
REAR BEARING CAP GASKET BEARING SUPPORTER BOLT DIPSTICK COVER PLATE CRANK CASE STUD GASKET INSPECTION PLATE
MVP150-242 MVP150-234 MVP150-245 BLTM06020 MVP150-254DA MVP150-220 MVP150-265 MVP150-218 MVP150-219
1 2 2 12 1 1 6 2 1
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 8 of 58
Weir Minerals Multiflo
CRANK CASE GROUP(CONTINUED) ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
DIPSTICK GASKET CRANKSHAFT BEARING SHAFT KEY BOLT FRONT BEARING CAP OIL SEAL BOLT
MVP150-252 MVP150-222 MVP150-247 MVP150-239 MVP150-235 BLTM10025 MVP150-240 MVP150-238 BLTM10025
1 1 1 2 1 4 1 2 16
10
O'RING
MVP150-253
1
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 9 of 58
Weir Minerals Multiflo
CYLINDER BLOCK GROUP ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
GASKET STUD CYLINDER BLOCK CIRCLIP RING SET NUT PISTON PIN CONNECTING ROD
MVP150-216 MVP150-265 MVP150-217 MVP150-228 MVP150-261 BLTMCN10 MVP150-231A MVP150-229 MVP150-232
1 2 1 4 1 6 2 2 2
10
SLIPPER SET
MVP150-233
4
11 12 13 MFVC-420
MVP150-275 MVP150-276 MVP150-248
BIG END BOLT NUT SPLASHER
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
4 4 2 Dec-07
Page 10 of 58
Weir Minerals Multiflo
CYLINDER HEAD GROUP ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
DISCHARGE VALVE DISCHARGE CAGE DISCHARGE TRIANGLE GASKET PUSH BOLT CAP NUT BLIND NUT GASKET HEAD
MVP150-213 MVP150-212 MVP150-201 MVP150-209 MVP150-208 MVP150-207 MVP150-277 MVP150-206 MVP150-214
2 2 2 2 2 2 1 4 1
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 11 of 58
Weir Minerals Multiflo
CYLINDER HEAD GROUP ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 6 7
BOLT BOLT PLUG DIAMOND GASKET INLET TRIANGLE O'RING INLET VALVE
BLMTC10030 BLTMC08035 BSPP 1/8 MVP150-201 MVP150-202 MVP150-204 MVP150-203 MVP150-205
12 4 2 2 2 2 2 2
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 12 of 58
Weir Minerals Multiflo
VACUUM PUMP CLUTCH ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
CIRCLIP CIRCLIP SHIM KIT BEARING MOUNTING FLANGE ROTOR TRANSMISSION FLANGE WAVE WASHER BEARING
540-140-717 540-140-716 540-140-719 540-140-713 540-140-708 540-140-711 540-140-709 540-140-722 540-140-705
1 1 1 1 1 1 1 1 2
10
COIL CARRIER
10 11 12
MFVC FVC-4 -420 20
540 140 712 24 540-140-702 540-140-701
COIL CARRIER CIRCLIP CIRCLIP
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
1 1 1
Dec-07
Page 13 of 58
Weir Minerals Multiflo
VACUUM TANK ITEM
DESCRIPTION
1 2 3 4 5 6 7 8 9
VACUUM TANK NIPPLE WATER TRAP COUPLING SEAL LID SEAL PROBE HOSE
PART NUMBER
QTY
VT390V6200TSS HFS27-1212 200-0345 MFF200BC MFF200BS MCITEE200B F8132S01 VT2002-01 HHB1221123B12 (SPECIFY LENGTH)
1 1 1 1 1 1 1 2 1
10 11 12 13
KRUNDIMENDT VALVE INSPECTION LID SCREW GASKET
14
REDUCING BUSH
MFVC-420
VT2002 02 VT88-051 VT2002-02-11 VRA150-20 FGM032X020RB
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
1 1 1 1 1 Dec-07
Page 14 of 58
Weir Minerals Multiflo
TRANSMISSION ITEM
DESCRIPTION
PART NUMBER
QTY
1
TRANSMISSION
TDMG5202SC
1
2
TRANSMISSION MOUNT L.H.
MSD2004-01
1
3
TRANSMISSION MOUNT R.H.
MSD2004-02
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 15 of 58
Weir Minerals Multiflo
TRANSMISSION OIL COOLER ITEM
DESCRIPTION
PART NUMBER
QTY
1
TRANSMISSION OIL COOLER
OCD125450
1
2
ELBOW
HF3340-2024
2
3
ELBOW
HFS76-2026
2
4
NIPPLE
HFS24-3324
1
5
REDUCING BUSH
HFS24-3224
1
6
HOSE CLAMP
RSC4347
2
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 16 of 58
Weir Minerals Multiflo
TRANSMISSION OIL COOLER ITEM
DESCRIPTION
PART NUMBER
QTY
1
NIPPLE
HFM7-3326
2
2
HOSE
MSD420A003
1
3
HOSE
MSD420A002
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 17 of 58
Weir Minerals Multiflo
TRANSMISSION OIL COOLER ITEM
DESCRIPTION
PART NUMBER
QTY
1
HOSE CLAMP
RSC4347
1
2
HOSE
HHSR20-00550
1
3
HOSE
HHSR20-01100
1
4
ELBOW
HFS25N-1616
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 18 of 58
Weir Minerals Multiflo
TRANSMISSION OIL DRAIN ITEM
DESCRIPTION
PART NUMBER
QTY
1
NIPPLE
HFS27-1616
1
2
BALL VALVE
BVF 1-0
1
3
ELBOW
HFS49N-1616
1
4
HOSE
HH1B161161B16-03050
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 19 of 58
Weir Minerals Multiflo
TRANSMISSION OIL DRAIN ITEM
DESCRIPTION
PART NUMBER
QTY
1
NIPPLE
HFS27-1612
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 20 of 58
Weir Minerals Multiflo
ENGINE BREATHER ITEM
DESCRIPTION
PART NUMBER
QTY
1 2
CLAMP BREATHER PIPE (NEW STYLE)
CLAMP538/38PP MSC420A001-1
2 2
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 21 of 58
Weir Minerals Multiflo
ENGINE OIL DRAIN ITEM
DESCRIPTION
PART NUMBER
QTY
1
NIPPLE
HFS27-1616
1
2
BALL VALVE
BVF 1-0
1
3
ELBOW
HFS49N-1616
1
4
HOSE
HH1B161161B16-01450
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
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Weir Minerals Multiflo
ENGINE OIL DRAIN ITEM
DESCRIPTION
PART NUMBER
QTY
1
NIPPLE
HFS27-1612
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 23 of 58
Weir Minerals Multiflo
FUEL / WATER SEPARATOR ITEM
DESCRIPTION
PART NUMBER
QTY
1
FUEL WATER SEPARATOR
1000FH2
1
2
CARTRIDGE
1000FH
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 24 of 58
Weir Minerals Multiflo
EXHAUST & TURBO GUARD ITEM
DESCRIPTION
PART NUMBER
QTY
1
MUFFLER
REFER CAT MANUAL
1
2
CLAMP
REFER CAT MANUAL
1
3
GASKET
3412-G03
1
4
ADAPTOR
REFER CAT MANUAL
1
5
TURBO GUARD
MSC420A002
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 25 of 58
Weir Minerals Multiflo
THROTTLE CABLE ITEM
DESCRIPTION
PART NUMBER
QTY
1
P-CLIP
MCCTCB2819
1
2
BRACKET
MSC420A004
1
3
THROTTLE CABLE
0043VB0310
1
4
BRACKET
MCCTCB2818
1
5
CLEVIS
029025
1
6
BALL
029104
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 26 of 58
Weir Minerals Multiflo
DRIVE COUPLING ITEM
DESCRIPTION
PART NUMBER
QTY
1
TAPERLOCK
TL4535-120
2
2
COUPLING FLANGE
F180F
1
3
ELEMENT
F180ST
1
4
COUPLING FLANGE
F180H
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 27 of 58
Weir Minerals Multiflo
DRIVE GUARD ITEM
DESCRIPTION
PART NUMBER
QTY
1
DRIVE GUARD
2004-420DG-01
1
2
BOLT SET
2004-420DG-BS
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 28 of 58
Weir Minerals Multiflo
BATTERY BOX ITEM
DESCRIPTION
PART NUMBER
QTY
1
BATTERY
BATCENT200
2
2
BATTERY BOX
BB24V6B-01
1
3
BATTERY HOLD DOWN BRACKET
MSE000N004
2
4
TERMINAL COVER RED
TPS16R
2
5
TERMINAL COVER BLACK
TPS16B
2
6
BATTERY HOLD DOWN TIE
MGBHD
2
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 29 of 58
Weir Minerals Multiflo
BATTERY ISOLATOR ITEM
DESCRIPTION
PART NUMBER
QTY
1
BATTERY ISOLATOR
0341003004
1
1
BATTER ISOLATOR LOCKOUT
LS11003-01
1
2
BATTERY ISOLATOR BOX
MSE-2000-01
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 30 of 58
Weir Minerals Multiflo
EMERGENCY STOP ITEM
DESCRIPTION
PART NUMBER
QTY
1
EMERGENCY STOP NC CONTACT (IF REQUIRED)
ES-03-01 ES-03-02
1 1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 31 of 58
Weir Minerals Multiflo
COOLANT LOSS ITEM
DESCRIPTION
PART NUMBER
QTY
1
SENDER
RCT2205
1
2
DETECTOR
RCT7320
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 32 of 58
Weir Minerals Multiflo
MONITORING INSTRUMENTS ITEM
DESCRIPTION
PART NUMBER
QTY
1
VACUUM PRESSURE GAUGE
200-0365PM
1
2
TRANSMISSION PRESSURE GAUGE
MGXB1703C
1
3
ENGINE OIL PRESSURE
MG7W-2060
1
4
COOLANT TEMPERATURE
MG5L-7442
1
5
HOUR METER
MG9W1494
1
6
TACHOMETER
197-7348
1
7
VOLTMETER
MG105-1457
1
8
TRANSMISSION TEMPERATURE
MGEGS21T-300
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 33 of 58
Weir Minerals Multiflo
CONTROL BOX ITEM
DESCRIPTION
PART NUMBER
QTY
1
TERMINAL STRIP
M4722
A/R
2
CHANGE OVER RELAY
R24VCOAS-01
A/R
3
RELAY CONNECTOR
H4973
A/R
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 34 of 58
Weir Minerals Multiflo
ELECTRICAL COMPONENTS ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7
FUSE HOLDER FUSE (1AMP) FUSE (2AMP) FUSE (4AMP) FUSE (5AMP) FUSE (10AMP) FUSE (15AMP)
5442BL 302-9219-01AMP 302-9219-02AMP 302-9219-04AMP 302-9219-05AMP 302-9219-10AMP 302-9219-15AMP
A/R A/R A/R A/R A/R A/R A/R
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 35 of 58
Weir Minerals Multiflo
ELECTRICAL COMPONENTS ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6 7 8 9
CIRCUIT BREAKER (2AMP) CIRCUIT BREAKER (3AMP) CIRCUIT BREAKER (4AMP) CIRCUIT BREAKER (5AMP) CIRCUIT BREAKER (10AMP) CIRCUIT BREAKER (15AMP) CIRCUIT BREAKER (20AMP) CIRCUIT BREAKER (30AMP) CIRCUIT BREAKER (40AMP)
CB-02K CB-03K CB-04K CB-05K CB-10K CB-15K CB-20K CB-30K CB-40K
A/R A/R A/R A/R A/R A/R A/R A/R A/R
10 11
MFVC FVC-4 -420 20
CB-50K CB-60K
CIRCUIT BREAKER (50AMP) CIRCUIT BREAKER (60AMP)
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
A/R A/R
Dec-07
Page 36 of 58
Weir Minerals Multiflo
HYDRAU-FLO ITEM
DESCRIPTION
PART NUMBER
QTY
1
WIGGINS RECEIVER
ZNC2A
1
2
VALVE ASSEMBLY
FBS-03A
1
3
ELBOW
HF807-0609
2
4
HOSE
HH1J061062J06-6000
1
5
HOSE
HH1J061062J06-0600
1
6
MOUNTING PLATE
FBS-08
2
7
ELBOW
HFS8-0409
2
8
FLOAT ASSEMBLY
FBS-66-110
2
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 37 of 58
Weir Minerals Multiflo
HIGH WALL FUEL FILLER ITEM
DESCRIPTION
PART NUMBER
QTY
1
ELBOW
HFS49-0804
1
2
NIPPLE
HFS27-1208
1
3
HOSE
HH1B081081B08-00223
1
4
MOUNTING PALTE
FBS-08
1
5
O'RING
FBS-22
1
6
FLOAT LOCK NUT
FBS-29
1
7
FLOAT
HWFV2002-01
1
8
PLUG
TP68
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 38 of 58
Weir Minerals Multiflo
GLAND OIL TANK ITEM
DESCRIPTION
PART NUMBER
QTY
1
GLAND OIL TANK
2
CAP
3
NEEDLE VALVE
4
NIPPLE
5
PUSH ON HOSE FITTING
6
WASHER
7
NUT, NYLOC
8
SPRING WASHER
9
FLAT WASHER
VT-97-OTWAR-01 200-0356 200-0354-38 HFS27-0606 HF802-0606 VT92-OT-99 BLTCNN12 BLTSW12 BLTW12
1 1 1 2 2 2 2 2 2
10 11
NON RETURN VALVE ELBOW
12
HOSE
MFVC-420
VT84-015A HFS49-0604 HHP16-160
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
1 1 1
Dec-07
Page 39 of 58
Weir Minerals Multiflo
MANUAL FUEL FILLER ITEM
DESCRIPTION
PART NUMBER
QTY
1 1 2 3
BREATHER (RADIATOR END) BREATHER (VACUUM TANK END) DUST CAP KAMLOK
MSH420A001 MSH420A002 KL50-DC KL50-A
1 1 1 1
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 40 of 58
Weir Minerals Multiflo
AUTO-GREASING UNIT ITEM
DESCRIPTION
PART NUMBER
QTY
1
GREASING PUMP (SUIT FF FRAME)
MFAGU-01-0124V-390DB
1
COMPLETE KIT
MFAGU-01-3942-24K
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 41 of 58
Weir Minerals Multiflo
AUTO-GREASING UNIT ITEM
DESCRIPTION
PART NUMBER
QTY
1 2 3 4 5 6
DIVIDER BLOCK HOSE END SLEEVE GREASE FILLED HOSE HOSE END STUD ELBOW TUBE
MFAGU-01-02-3942DB MFAGU-01-07 MFAGU-01-03 MFAGU-01-08 MFAGU-01-06 MFAGU-01-04
1 1 1 1 1 A/R
MFVC FVC-4 -420 20
PLEA PLEASE SE QUOTE UOTE MOD ODEL EL AND AND S SER ERIIAL NUM NUMBER BER O OF FP PUM UMP P WHEN WHEN ORDER RDERIING SPAR SPARE EP PAR ART TS
Dec-07
Page 42 of 58
Weir Minerals Multiflo
SUCTION BOOM ITEM
DESCRIPTION
PART NUMBER
QTY
1
WIRE ROPE
WR8-25
1
2
WIRE ROPE GRIP
WRG-8
1
3
SPREADER BAR
H250JSB-3000
1
4
SUCTION HOSE
H25002204JL
1
5
SUCTION HOSE
H25002204JL
1
6
BOOM
MFB8
1
7
CHAIN
CH80ZP10-02200
1
8
SUCTION STRAINER
MFS250-40SS
1
9
UNISTRUT CLAMP
UN31-273LE
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 43 of 58
Weir Minerals Multiflo
SUCTION BOOM ITEM
DESCRIPTION
PART NUMBER
QTY
1
PULLEY
MFBP1
1
2
HAMMERLOCK
HL12
4
3
CHAIN
CH80ZP13-06600
2
4
BOLT SET
2004BS-04
1
5
ECCENTRIC REDUCER
MFL250X200ERSS
1
6
BOLT SET
2004BS-03
1
7
HAMMERLOCK
HL10
2
8
BOLT SET
2004BS-02
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 44 of 58
Weir Minerals Multiflo
DISCHARGE DISCHARG E PIPEWORK ITEM
DESCRIPTION
PART NUMBER
QTY
1
NON RETURN VALVE
NRV150-01SS
1
2
DISCHARGE ELBOW
D2004-01
1
3
RUBBER HOSE
D2004-03
1
4
DISCHARGE SPOOL
D2004-06
1
5
DISCHARGE ELBOW
D2004-02
1
6
ONYX RING
MSF-200-01-FLE
1
7
DISCHARGE PIPE
D2004-07
1
8
ISOLATION VALVE
MF200-BFV-KGO
2
9
REDUCER
D2004-08
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 45 of 58
Weir Minerals Multiflo
DISCHARGE PIPEWORK ITEM
DESCRIPTION
PART NUMBER
QTY
1
BOLT SET
2004BS-05
1
2
BOLT SET
2004BS-06
1
3
DISCHARGE BRANCH
D2004-05
1
4
BOLT SET
2004BS-05
1
5
BOLT SET
2004BS-06
1
6
UNISTRUT CLAMP
MSJ000N008
5
7
BOLT SET
2004BS-07
1
8
BOLT SET
2004BS-08
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 46 of 58
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
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 47 of 58
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
HC003-057
1
6
HOSE TAIL
S21-025
1
7
BRACKET
MSLWH42001
1
8
SAFETY HOSE
MSLWH42001-01
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 48 of 58
Weir Minerals Multiflo
WORKLIGHTS ITEM
DESCRIPTION
PART NUMBER
QTY
1
WORKLIGHT BODY
1096
2
2
WORKLIGHT BEAM
9150901
2
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 49 of 58
Weir Minerals Multiflo
STROBE LIGHT ITEM
DESCRIPTION
PART NUMBER
QTY
1
AMBER STROBE LIGHT
PRE3414SL
1
2
BLUE STROBE LIGHT
BR95QBS
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 50 of 58
Weir Minerals Multiflo
NORDIC WORK LIGHT ITEM
DESCRIPTION
PART NUMBER
QTY
1 2
NORDIC WORK LIGHT
N400HID
1
LIGHT BULB
N400HID-1
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 51 of 58
Weir Minerals Multiflo
BACKSAVER CRANE ITEM
DESCRIPTION
PART NUMBER
QTY
1
BACKSAVER CRANE
S350-F19001
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 52 of 58
Weir Minerals Multiflo
DISCHARGE PRESSURE GAUGE ITEM
DESCRIPTION
PART NUMBER
QTY
1
DISCHARGE PRESSURE KIT (7MT CAPILLARY)
MSF200-K02
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 53 of 58
Weir Minerals Multiflo
CHASSIS (NEW STYLE) ITEM
DESCRIPTION
PART NUMBER
QTY
1
CANOPY
MSL2004-05
1
2
MESH
MSL2004-04
2
3
ONYX RING CAPILLARY GUARD
MSL2004-07
3
4
MESH
MSL2004-03
4
5
MESH
MSL2004-02
5
6
STEPS
MSL2004-01
6
7
LADDER
MSL2004-06
7
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 54 of 58
Weir Minerals Multiflo
ACCESS PLATFORMS (NEW STYLE) ITEM
DESCRIPTION
PART NUMBER
QTY
1
HANDRAIL
HR2004-01
1
2
HANDRAIL
HR2004-02
1
3
WALKWAY SUPPORT BRACKET
MCL420APB03
4
4
ACCESS PLATFORM
AP2004-01
1
5
HANDRAIL
HR2004-04
1
6
ACCESS PLATFORM
AP2004-02
1
7
HANDRAIL
HR2004-03
1
MFVC MFVC-4 -420 20
PLEA PLEASE SE QUO UOTE TE MODE MODEL L AND AND SERI SERIAL AL NU NUMB MBER ER OF PU PUM MP WHEN WHEN ORD RDER ERIN ING G SP SPAR ARE E PA PART RTS S
Dec-07
Page 55 of 58
Weir Minerals Multiflo
CHASSIS (OLD STYLE) ITEM
DESCRIPTION
PART NUMBER
QTY
1
HANDRAIL
MCL420HR07
1
2
HANDRAIL
MCL420HR08
1
3
ACCESS PLATFORM
MCL420AP05
1
4
UNISTRUT CLAMP
MCL420APB03
4
5
CANOPY
MCL420CA01
1
6
LADDER
MCL420AL01
1
7
ACCESS PLATFORM
MCL420AP02
1
8
PLUG
BSPP5-0
1
9
ACCESS PLATFORM
MCL420AP04
1
10
HANDRAIL
11
HANDRAIL
MCL420HR05 MCL420HR06
1 1
12
ACCESS PLATFORM
MCL420AP03
1 1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 56 of 58
Weir Minerals Multiflo
PONTOON ITEM
DESCRIPTION
PART NUMBER
QTY
1
PONTOON
MF-P18T-SA
1
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Dec-07
Page 57 of 58
Weir Minerals Multiflo
HIGH LIFT SKID ITEM
DESCRIPTION
PART NUMBER
QTY
1
HIGH LIFT SKID
MSLKCS420-1
1
NOTE: TOW CHAIN KIT (NOT SHOWN) P/N: SAC26-4.5KIT
MFVC-420
PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS
Page 58 of 58
PART 5
Accompanying Manuals
Dec-07
Weir Minerals Multiflo
Accompanying Manuals MFVC-420-089-05.19 MFVC-420-089-05.19
__________________________________________________________________ 1 x Compact Disc Copy Copy
Caterpillar Parts Manual 3412C Industrial Engine
(August 2003)
2 x Hard Copies Copies
Caterpillar Parts Manual 3412C Industrial Engine Volume I (Pages 1-624) Volume II (Pages 625 – 1386)
(May 2007)
1 x Hard Copy Copy
Caterpillar Operation & Maintenance Manual 3408C & 3412C Industrial & E.P.G. Diesel Engines (December 1999) 1 x Hard Copy Copy
Caterpillar Commercial Diesel Engine Fluids Recommendations Recommendations (June 2007) 2 x Hard Copies Copies
Twin Disc MarineIncorporated Transmission Service & Installation Manual (#1017462) Suit Model MG5202SC Original Issued May 1997 – Revision B: March 2003 1 x Hard Copy Copy
Twin Disc Incorporated Marine Transmission Owner’s Manual (Revision 4, May 2004)
(#1016313)
MFVC-420-089-05.19 – S.I.S. Accompanying Manuals Manuals (Always quote Model and Serial Number of Unit when Ordering Parts)
Weir Minerals Multiflo
Accompanying Manuals MFVC-420-089-05.19 MFVC-420-089-05.19
__________________________________________________________________ 1 x Compact Disc Copy Copy
Containing:-
Warman International - Pump Instructions Supplement M1
-
Supplement M9
-
General Instructions Applicable to all Warman Pumps Gland Sealing
Supplement BA3 Supplement P42
-
Modified Basic Bearing Assembly Mine De-Watering Pumps Type HX
FF Bearing Assembly Instructional Maintenance
Multiflo Model 420 Bare Shaft Pump Assembly Procedure (8/6 FF-HX Wetted Parts Assembly Procedure) Model 57 Vacuum Pump – Assembly & Disassembly Procedure Electromagnetic Robatic Clutch - Assembly Procedure
Pico Beka Max S-EP4 Automatic Lubricator
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