MF-385G SS IOM, PARTS & Accompanying Manuals 2011

Weir Minerals Multiflo
INSTALLATION, OPERATION, MAINTENANCE

AND PARTS MANUAL
WITH ACCOMPANYING MANUALS
DIESEL POWERED PUMP UNIT

MODEL MF-385G SS
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo i

TABLE OF CONTENTS
Table of Contents ....................................................................................................................................................... ii
Table of Figures ..........................................................................................................................................................vi
Copyright © 2011 Weir Minerals Multiflo................................................................................................................. viii
Introduction ............................................................................................................................................................... ix
Contact Us: ..................................................................................................................................................................x

In Australia:- ................................................................................................................................................................... x
In Indonesia:- ................................................................................................................................................................. x
Safety ........................................................................................................................................................................ xi
Safety Symbols .............................................................................................................................................................. xi
Safety Management Plan for Installation Work............................................................................................................xii
WARNING! ...................................................................................................................................................................xiii
Pump performance curve ......................................................................................................................................... xiv
Electrical wiring diagrams .......................................................................................................................................... xv
PART 1. INSTALLATION ........................................................................................................................... 1
1.1 Pump Unit Delivery .......................................................................................................................................... 2
1.2 Storage Procedures ........................................................................................................................................ 2

V’ Belts ........................................................................................................................................................................... 2
1.3 General Safety of Major Equipments ............................................................................................................. 3

Bare Shaft Pump Safety ................................................................................................................................................. 3
Vacuum Pump Safety ..................................................................................................................................................... 3
1.4 Unit Lifting Points ............................................................................................................................................ 4
1.5 Assembly Instructions ...................................................................................................................................... 5

Assembly of Pump and Skid (If Fitted) ........................................................................................................................... 5
Assembly of Pontoon (If Fitted) ..................................................................................................................................... 7
1.6 Installation of Suction Assembly ...................................................................................................................16

Correct Position of Suction Boom ................................................................................................................................ 19
1.7 Installation of Discharge Pipe work.................................................................................................................19
1.8 Fitting Pontoon Handrail (If Fitted) .................................................................................................................20
1.9 Moving and Locating the Pump unit ...............................................................................................................21

Pump Site Preparation ................................................................................................................................................. 21
Moving the Pump Unit ................................................................................................................................................. 22
Procedure for Towing .................................................................................................................................................. 22
Positioning and Launching ........................................................................................................................................... 23
Incorrect Pump Unit Positioning .................................................................................................................................. 25
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo ii

Correct Pump Unit Positioning .................................................................................................................................... 26

Pumping Operation Observations................................................................................................................................ 27
Installation Checks ....................................................................................................................................................... 27
PART 2. OPERATION .............................................................................................................................. 28
2.1 General Function of the Pump Unit.................................................................................................................29
2.2 Pump unit Orientation ....................................................................................................................................29
2.3 Daily Pre-Start Checks .....................................................................................................................................30

Engine Oil ..................................................................................................................................................................... 31
Bare Shaft Pump Auto Lubrication System .................................................................................................................. 31
Vacuum Pump Oil ........................................................................................................................................................ 31
Gland Oil Tank (If Fitted) .............................................................................................................................................. 31
Coolant Level................................................................................................................................................................ 31
Fuel Tank ...................................................................................................................................................................... 31
Battery ......................................................................................................................................................................... 31
Drive Belts (Fan, Generator, Vacuum Pump) ............................................................................................................... 31
Water Trap ................................................................................................................................................................... 31
Air Cleaner Indicator (If Fitted) .................................................................................................................................... 31
Suction Strainer............................................................................................................................................................ 31
Probes .......................................................................................................................................................................... 31
2.4 Starting procedure ..........................................................................................................................................32
2.5 Operating Speed .............................................................................................................................................32
2.6 Cavitation .......................................................................................................................................................32
2.7 Shutdown Procedure ......................................................................................................................................33

Shut Down Protection .................................................................................................................................................. 34
2.8 Description of Major Components ..................................................................................................................34

Bare Shaft Pump .......................................................................................................................................................... 34
Model 57 Piston Type Vacuum Pump .......................................................................................................................... 34
Vacuum Tank ............................................................................................................................................................... 37
Vacuum Gauge ............................................................................................................................................................. 37
Non Return ‘Vooom’ Valve .......................................................................................................................................... 38
Vactronic Vacuum Prime System ................................................................................................................................. 40
First Out Indication Panel............................................................................................................................................. 41
Hydrau-Flo Fuel Pressure Control Valve ...................................................................................................................... 43
Engine Turbo Charger Protection (If Fitted) ................................................................................................................. 46
Turbine Series 1000FH Fuel Filter/Water Separators (If Fitted) .................................................................................. 48
Installation Instructions: .............................................................................................................................................. 49
Specifications 1000FH .................................................................................................................................................. 52
Engine Monitoring System (EMS) ................................................................................................................................ 53
2.9 Electrical .........................................................................................................................................................53

Monitoring Instruments ............................................................................................................................................... 53
PART 3. MAINTENANCE ........................................................................................................................ 56
3.1 General Safety ................................................................................................................................................57
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo iii

3.2 Bare Shaft Pump Assembly and Disassembly Procedure .................................................................................57

Bare Shaft Pump Disassembly Procedure .................................................................................................................... 58
Bare Shaft pump Assembly Procedure – 6A Pedestal .................................................................................................. 59
Special Tools & Clearances........................................................................................................................................... 63
Wetted Parts Assembly Procedure .............................................................................................................................. 65
Bolt Tension Settings ................................................................................................................................................... 66
3.3 Bare Shaft Pump Maintenance .......................................................................................................................68

Gland ............................................................................................................................................................................ 68
Impeller ........................................................................................................................................................................ 70
Lubrication ................................................................................................................................................................... 71
Recommended Grease for 6A PEDESTAL ..................................................................................................................... 71
Pico Auto Grease Unit Outlet Connections and Timer Settings ................................................................................... 72
3.4 Model 57 Piston Vacuum Pump Maintenance ...............................................................................................73

Vacuum Pump Piston & Re-Ringing Instructions ......................................................................................................... 73
Pieces Oil Ring Assembly .............................................................................................................................................. 74
Leak in Balance Tube.................................................................................................................................................... 77
Vacuum Leaks in Crankcase ......................................................................................................................................... 78
3.5 Drive Components Maintenance ....................................................................................................................79

Drive Belt Tensioning ................................................................................................................................................... 79
Installation & Operation of Wedge & V-Belt Drives..................................................................................................... 81
Taper Lock Installation Instructions ............................................................................................................................. 82
Taper Lock Screw Torque Setting................................................................................................................................. 84
Taper Lock Flanges ....................................................................................................................................................... 85
Tyre Couplings.............................................................................................................................................................. 86
3.6 1000FH Series Fuel Filter Instructions (If Fitted) ..............................................................................................88

Draining Water: ............................................................................................................................................................ 88
Vacuum Side Application: ............................................................................................................................................ 88
Pressure Side Application: ........................................................................................................................................... 88
Element Replacement: ................................................................................................................................................. 88
CAUTION ...................................................................................................................................................................... 89
Replacement Parts ....................................................................................................................................................... 91
3.7 Routine General Maintenance Frequency .......................................................................................................93

EVERY 10 ENGINE HOURS OR DAILY ............................................................................................................................ 93
EVERY 250 ENGINE HOURS (Perform in addition to Daily Schedule Items).................................................................. 94
EVERY 500 ENGINE HOURSE (Perform in addition to Daily Schedule Items)................................................................ 94
EVERY 1000 ENGINE HOURS (Perform in addition to Daily Schedule Items)................................................................ 95
EVERY 2000 ENGINE HOURS (Perform in addition to Daily Schedule Items)................................................................ 95
3.8 Pump Unit Troubleshooting ............................................................................................................................96

VACUUM GAUGE READINGS – BASIC FAULTS .............................................................................................................. 97
ENGINE – BASIC FAULTS ............................................................................................................................................... 99
‘V’ Belt Troubleshooting ............................................................................................................................................ 100
Hydrau-Flo Valve Troubleshooting ............................................................................................................................ 101
Bare Shaft Pump Lubrication Oil Troubleshooting..................................................................................................... 102
Turbine Series 1000HF Fuel Filter / Water Separator Troubleshooting (If Fitted) ..................................................... 103
3.9 Lubricants ................................................................................................................................................106
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo iv

PART 4. SPARE PARTS ....................................................................................................................... 107
MF-385G SS MAJOR COMPONENTS........................................................................................................................... 108

MF-385G SS PEDESTAL ASSEMBLY ............................................................................................................................. 109
MF-385G SS BEARING ASSEMBLY .............................................................................................................................. 110
MF-385G SS WETTED PARTS ...................................................................................................................................... 111
PRIMING ASSEMBLY ................................................................................................................................................... 112
VACUUM PUMP MODEL 57 ....................................................................................................................................... 113
VACUUM PUMP - CRANK CASE GROUP ..................................................................................................................... 114
VACCUM PUMP-CYLINDER BLOCK GROUP ................................................................................................................ 115
VACUUM PUMP- CYLINDER HEAD GROUP ................................................................................................................ 116
VACUUM PUMP CLUTCH ........................................................................................................................................... 117
VACUUM PUMP MOUNTING PLATE .......................................................................................................................... 118
DRIVE ASSEMMBLY .................................................................................................................................................... 119
VACUUM PRESSURE GAUGE ...................................................................................................................................... 120
BATTERY BOX ............................................................................................................................................................. 121
BATTERY ISOLATORS .................................................................................................................................................. 122
CONTROL BOX OUTSIDE ............................................................................................................................................. 123
CONTROL BOX INSIDE ................................................................................................................................................ 124
ELECTRICAL COMPONENTS 1 ..................................................................................................................................... 125
EMERGENCY STOP AND FIRE EXTINGUISHER ............................................................................................................. 129
HYDRAU-FLO .............................................................................................................................................................. 130
HIGH WALL FUEL FILLER ............................................................................................................................................. 131
FUEL FLOAT SWITCH ASSEMBLY ................................................................................................................................ 132
FUEL FILLERS .............................................................................................................................................................. 133
FUEL FILTERS / WATER SEPARATOR ........................................................................................................................... 134
FUEL BREATHER ......................................................................................................................................................... 135
AUTO-GREASING UNIT ............................................................................................................................................... 136
AUTO-GREASING UNIT (CONTINUED) ........................................................................................................................ 137
SUCTION ASSEMBLY ................................................................................................................................................... 138
DISCHARGE ASSEMBLY (OPTION 1 – IF FITTED) ......................................................................................................... 139
DISCHARGE ASSEMBLY (OPTION 2 – IF FITTED) ......................................................................................................... 140
NON- RETURN VALVE (STAINLESS STEEL) .................................................................................................................. 141
WORK LIGHT AND STROBE LIGHT .............................................................................................................................. 142
HIGH LIFT SKID (OPTIONAL) ....................................................................................................................................... 143
TOW CHAINS (OPTIONAL) .......................................................................................................................................... 144
BACKSAVER CRANE (OPTIONAL) ................................................................................................................................ 145
PONTOON (OPTIONAL) .............................................................................................................................................. 146
PART 5. ACCOMPANYING MANUALS ................................................................................................ 147
Appendix 1 / WMM Pico Auto Greaser Manual

Appendix 2 / WMM Vacuum Pump Model 57
Appendix 3 / Electro Magnetic Clutch
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo v

TABLE OF FIGURES
- Pump Unit Lifting Points .................................................................................................................................. 4
-Skid Chassis lifting points ................................................................................................................................. 5
-Installing pump Unit onto Skid Chassis ............................................................................................................ 6
-Pontoon Centre Hull ......................................................................................................................................... 7
-Left Hand Pontoon Hull with Locating Pin & Mounting Pedestal ..................................................................... 8
- Left Hand Pontoon Hull Bolting Points ............................................................................................................ 9
-Right Hand Pontoon Hull with Locating Pin & Mounting Pedestal ................................................................. 10
-Right Hand Pontoon Hull Bolting Point........................................................................................................... 11
-Pump Unit Base Mounting Pad Indicating ...................................................................................................... 12
-Positioning the Pump Set over the Mounting Pad .......................................................................................... 13
-Alignment of Pump Set Bolt Holes with Mounting Pad Bolt Holes ................................................................. 14
-Where to Install the Non Return Valve ........................................................................................................... 15
-Non Return Valve Installed on the Pump Set ................................................................................................. 15
-Fitting the Suction Boom ................................................................................................................................ 16
-Attaching Winch Rope to Boom Pulley........................................................................................................... 17
- Fitting the Boom Chain and Suction Strainer ................................................................................................ 18
-Correct Position of Suction Boom .................................................................................................................. 19
-Attaching the Left Hand Side Handrail ........................................................................................................... 20
-Attaching the Right Hand Side Handrail ......................................................................................................... 20
-Blade Contact Point on Pontoon Push Bar .................................................................................................... 24
-Incorrect Pump Unit positioning ..................................................................................................................... 25
-Correct Pump Unit Positioning ....................................................................................................................... 26
-Pump Unit Orientation .................................................................................................................................... 30
-Resulting Effects of Continuous Cavitation .................................................................................................... 33
-Piston Type Vacuum Pump Major Components ............................................................................................ 35
-Vacuum Tank ................................................................................................................................................. 37
-Vacuum Gauge ............................................................................................................................................... 38
-Non Return Valve, Flap in Close and Open Positions ................................................................................... 39
-Vactronic Circuit Diagram ............................................................................................................................... 41
-First Out” Indication Panel .............................................................................................................................. 42
-Hydrau Flo Fuel Valve Components .............................................................................................................. 43
-Hydrau-Flo System Re-Fuelling in Progress .................................................................................................. 44
-Hydrau-Flo System Components ................................................................................................................... 45
-Hydrau-Flo System Re-Fuelling Finished....................................................................................................... 45
-Engine Turbo Saviour ..................................................................................................................................... 46
-Installation of the Engine Turbo Saviour ........................................................................................................ 47
-Fuel Filter/Water Separator ............................................................................................................................ 48
-Fuel Filter/Water Separator Mounting Struction ............................................................................................. 49
-Fuel Filter/Water Separation Installation Diagram ......................................................................................... 51
-Multi Voltage Coolant Level Detectors ........................................................................................................... 55
-Pedestal Assembly ......................................................................................................................................... 60
-Model 385 Gland Packed Bare Shaft Pump Parts Assembly ........................................................................ 61
-Shaft Spanner ................................................................................................................................................. 63
-Impeller Clearance 1 mm ............................................................................................................................... 63
-Impeller Locking Tool ..................................................................................................................................... 63
-Tool A ............................................................................................................................................................. 64
-Tool B ............................................................................................................................................................. 64
-Bolt Tension Settings...................................................................................................................................... 66
-Bolt Tension Settings...................................................................................................................................... 67
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo vi

-Packing Removal Tool.................................................................................................................................... 69

-Manual Greasing Guide for Bare Shaft Pump ................................................................................................ 71
-Automatic Greasing guide for Bare Shaft Pump ............................................................................................ 72
-Winding on Piston Oil Ring Expander ............................................................................................................ 74
-Upper and Lower Rail of Expander ................................................................................................................ 74
-Upper and Lower Rail Gap ............................................................................................................................. 75
-Incorrect Fitting of Compression Rings .......................................................................................................... 75
-Correct Expansion Method for Compression Rings ....................................................................................... 76
-Correct Ring Back Clearance ......................................................................................................................... 76
-Correct Replacement of Vacuum Pump Crank Seal ...................................................................................... 78
-Belt Tension Indicator applied to mid span .................................................................................................... 80
-Belt Tensioning Indicator ................................................................................................................................ 80
-Belt Alignment ................................................................................................................................................ 81
-Taper Lock Installation and removal .............................................................................................................. 83
-Taper Lock Flange Dimension chart .............................................................................................................. 85
-Internal Clamp ring Torque ............................................................................................................................. 87
- Element Replacement ................................................................................................................................... 89
- Racor 3-Wire Schematic Shown ................................................................................................................... 90
-Vacuum Gauge Normal Operating Range ..................................................................................................... 96
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo vii

COPYRIGHT © 2011 WEIR MINERALS MULTIFLO

All rights reserved
This manual contains proprietary information of Weir Minerals Multiflo; it is protected by
copyright law. Reverse engineering of any products supplied by Weir Minerals Multiflo is
prohibited.
Due to continued product development this information may change without notice. The
information and intellectual property contained herein is confidential between Weir
Minerals Multiflo and the client and remains the exclusive property of Weir Minerals
Multiflo. If you find any problems in the documentation, please report them to us in writing.
Weir Minerals Multiflo does not warrant that this document is error-free.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording or otherwise
without the prior written permission of Weir Minerals Multiflo.

15 Dacmar Rd
PO Box 1410
Coolum Beach DC QLD 4573 Australia
+61 7 54493000
www.weirminerals.com
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo viii

INTRODUCTION
The purpose of this Manual is to advise and instruct installers, operators and repairers of
Weir Minerals Multiflo Pump Units in the recommended installation, operation and
maintenance of this equipment. You have purchased a quality product which has been
manufactured with utmost care and the finest materials, reflecting many years of
engineering knowledge and design.
The following information will aid you in the installation, operation and maintenance of your
new Weir Minerals Multiflo Pump Unit. To ensure long life and trouble-free operation, you
should read and understand these instructions and provide regular, periodic maintenance.
The Weir Minerals Multiflo Pump Unit is of a robust construction and is designed to be used
as a mine dewatering pump in accordance with the pump performance data contained in
this manual. When they correctly installed and operated, will give long, and 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.
WEIR MINERALS MULTIFLO PUMPS

• EXCELLENCE THROUGH DESIGN
• EXCELLENCE THROUGH ENGINEERING
• EXCELLENCE THROUGH PERFORMANCE
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo ix

CONTACT US:
In Australia:-
In Queensland:- In Western Australia:- In New South Wales:-
Head Office Kimberley, Pilbara, Mid-West, Hunter Valley Authorised Service

Weir Minerals Multiflo Murchison Region Provider
15 Dacmar Road Weir Minerals Australia Ltd. Weir Minerals Australia Ltd.
Coolum Beach Qld 4573 WA Head Office Beresfield Service Centre
Ph: 07 5449 3032 41 Kewdale Road. 9 Arunga Drive.
Fax: 07 5446 4304 Kewdale WA. 6105 Beresfield NSW. 2322
Email: Ph: 08 9366 2700 Ph: 02 4032 9412
[email protected] Fax: 08 9366 2766 Fax: 02 4032 9497
Bowen Basin South West Region

Weir Minerals Multiflo Authorised Authorised Service Provider
Dealer Weir Minerals Australia Ltd.
For Service, Repair and Bunbury Service Centre
Spare Parts Supply 1 Shanahan Road
NQ Water Services Bunbury WA 6230
319 Nebo Road Mackay Qld.
Ph: 07 4952 2252 Ph: 08 9726 2301
Fax: 07 4952 2126 Fax: 08 9726 2303
Email: [email protected]
Rockhampton Kalgoorlie & Goldfields Authorised

Authorised Service Provider Service Provider
Weir Minerals Service Centre Weir Minerals Australia Ltd.
80 McLaughlin Street Kalgoorlie Service Centre
North Rockhampton Qld. 4701 30 Atbara Street.
Ph: 07 4924 7700 Kalgoorlie WA. 6430
Fax: 07 4924 7799 Ph: 08 9021 1454
Email: Fax: 08 9021 1468
[email protected]
Perth Metro
Authorised Service Provider
Weir Minerals Australia Ltd
Henderson Service Centre
20 Stuart Drive.
Henderson WA. 6166
Ph: 08 9410 7500
Fax: 08 9410 7510
In Indonesia:-
PT Weir Minerals Multiflo Banjarbaru Branch Office
Jl Mulawarman No 29A RT Jl. Ahmad Yani Km 33,6 Ruko No. 04 RT.
003 Batakan Kecil Kelurahan Manggar 003 RW.001 Kelurahan Loktabat Selatan
Balikpapan 76117 Banjarbaru 70712
East Kalimantan South Kalimantan
Indonesia Indonesia
Ph: 62 542 746098 Ph: 62 511 4773027

Fax: 62 542 746099 62 511 4772357
Fax: 62 511 4773583
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo x

SAFETY
The Weir Minerals Multiflo pump unit is designed to be used as a mine dewatering pump in
accordance with the pump performance data contained in this manual.
It is the user’s responsibility to be aware of and comply with all federal and state
occupational health and safety requirements.
The Weir Minerals Multiflo 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 and precautions may also result
in equipment and environmental damage.
Safety Symbols
The accompanying documentation supplied with the Weir Minerals Multiflo pump unit
utilizes the following safety symbols to highlight potentially harmful situations to personnel
and the environment.
SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES
Imminent risk of Fatal or crippling injuries

DANGER ! fatal or crippling Persons likely to result from any
injuries exposure
WARNING ! Risk of fatal or Persons Fatal or crippling injuries

crippling injuries possible
Possibility Property Damage possible to the

ATTENTION ! of a harmful and or the product or the Environment
situation Environment
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo xi

Safety Management Plan for Installation Work
Good, robust Health, Safety and Environmental Systems, Process and Practices are
undoubtedly an important aspect of operating safely.
Good process or practice in the world cannot guarantee safety unless the people in the
organization make the decision to work and behave safely in all that they do.
Living by our five key safety values and commitment to following safety procedures will
enable us all to make the work place a safer environment.
Our Five Key Safety Values are:-
• My colleagues and my own safety are paramount;

• No task is so important or urgent that it cannot be undertaken safely;
• I will only undertake tasks that I am trained, competent and properly prepared for;
• I will never cut corners, nor take shortcuts at the expense of safety;
• I will stop the job if I believe it is unsafe to continue.
Site Installation Responsibilities
To use trained, competent people to assess all site OHSE risks involved with the
installation of this equipment in accordance with the Installation and Operations Manual
supplied by Weir Minerals Multiflo.
To use correct, safe and appropriate equipment related to the site conditions.
Any aspect of the installation of which the Customer is unsure we advise the customer to
discuss with a Weir Minerals Multiflo Representative.
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo xii

WARNING!
REMOVE SHAFT LOCKS (IF FITTED)

FROM
BARE SHAFT PUMP
AND / OR
ELECTRIC MOTOR BEFORE START-UP
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo xii

i
PUMP PERFORMANCE CURVE
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo xiv

ELECTRICAL WIRING DIAGRAMS
For more information regarding electrical wiring, Please refer to attached wiring drawings.
(In case of no attachments, please contact Weir Minerals Multiflo Head Office for further
information).
Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo xv

PART 1. INSTALLATION
Installation Manual MF 385G SS –Jan 2011 ©Copyright Weir Minerals Multiflo 1

1.1 PUMP UNIT DELIVERY

Each order or shipment is double checked before leaving the factory. All parts, pieces and
components are listed item by item on our packing list, which accompanies each order.
The number and description of each item, package, container, skid, etc., is listed on the bill
of lading.
IN SIGNING THE BILL OF LADING, THE CARRIER ASSUMES FULL RESPONSIBILITY

FOR SAFE DELIVERY OF ALL GOODS TO DESTINATION.
In the 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.
1.2 STORAGE PROCEDURES

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.
NOTE:
The purchaser assumes full responsibility for the pump unit and any associated
equipment when stored, handled and transported on-site.
V’ Belts
V Belts should be stored in a dry stockroom, and contact with hot pipes and direct sunlight
carefully avoided.
Where Possible, handle the belts loosely in single (or triple) coils. Always avoid tying belts
with thin string.
Installation Manual MF 385G SS– Jan 2011 ©Copyright Weir Minerals Multiflo 2
1.3 GENERAL SAFETY OF MAJOR EQUIPMENTS

Bare Shaft Pump Safety
• 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.
• Shaft Locks (If Fitted) must be removed from the bare shaft pump before the
unit is started.
Do not operate the pump at low or zero flow conditions for prolonged periods, or under any
circumstance that could cause the pumping liquid to vaporize. Personnel injury and
equipment damage could result from the pressure created.
Do not apply heat to impeller boss or nose in an effort to loosen the impeller thread prior to
impeller removal. Personnel injury and equipment damage could result from the impeller
shattering or exploding when the heat is applied.
Do not feed very hot or very cold liquid into a pump which is at ambient temperature.
Thermal shock may cause the pump casing to crack.
Tapped holes (for eye bolts) and lugs (for shackles) on Warman Parts are for lifting
individual parts only.
Vacuum Pump Safety

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.

1.4 UNIT LIFTING POINTS
Lifting of the pump unit should be undertaken by experienced personnel only.

Refer to site procedures for lifting, personnel and equipment requirements.
Multiflo Pump Model MF385
Bare Shaft Pump Model 385G SS

Maximum Pumping Speed RPM 1800 RPM
Bare Shaft Pump Operating Speed 1800 RPM
Wet End Material / Impeller 316 SS (AS 2704)
MF-385
Unit Mass (Wet) 7500 KG
Unit Mass (Dry) 5700 KG
High Lift Skid
Skid Mass 1050 KG
Figure 1:1- Pump Unit Lifting Points
NOTE:
Lifting points on the High Lift Skid Chassis are designed for lifting of the skid chassis
only.
Figure 1:2-Skid Chassis lifting points
1.5 ASSEMBLY INSTRUCTIONS
NOTE:
All assembly and installation is to be performed on solid level ground.
The following graphical descriptions are intended as a guide only. The following
instructions may contain information & illustrations regarding the installation of items
not specifically for use with some pontoons and pump units.
Assembly of Pump and Skid (If Fitted)
• Lifting of the pump unit should be undertaken by experienced personnel only.

• Do not stand under suspended load.
• Do not place any part of body under suspended load.

1. Using suitable lifting equipment, lift pump base over high lift skid.
2. Make sure the skid is clean of all rocks and debris.
3. When pump base is suspended over skid, gently lower base into skid. Be sure that
base moves into position freely and does interfere with skid sides.
4. Make sure the pump unit is sitting flat in the skid.
5. When base is sitting on skid frame, on one side only, insert spacers between the skid
and the pump unit (approximately 6mm). Fit the bolts and tighten that side. Repeat with
the other side fitting the required shim for the gap left between the skid and pump unit.
Do not attempt to insert bolts until pump base is sitting on skid frame and is not
suspended by lifting equipment.
Figure 1:3-Installing pump Unit onto Skid Chassis
Assembly of Pontoon (If Fitted)

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

Pontoon Centre Section Right
Hand Side
Pontoon Centre Section Left

Hand Side
Pontoon Front/ Push Bar
Figure 1:4-Pontoon Centre Hull

2. Using a crane, lift the left hand side pontoon into position
(See Figure 1:5).
Locating pin
Mounting pedestal
Figure 1:5-Left Hand Pontoon Hull with Locating Pin & Mounting Pedestal
Each “bolt on hull” locates to a mounting pedestal protruding from the underside of the
central pontoon hull. Each “bolt on hull” has a number of locating pins welded on the
bottom of each hull along the in board side of the hull. All locating pins must locate into
each pedestal correctly as shown, prior to installing the securing bolts.
3. Align the bolt holes at either end of the pontoon and install the appropriate bolts
(See Figure 1:6).
NOTE:
Make sure to use Anti-seize on all bolt threads before tightening the bolts.
Figure 1:6- Left Hand Pontoon Hull Bolting Points

4. Using a crane, lift the right hand side pontoon into position
(See Figure 1:7)
Access Steps
Figure 1:7-Right Hand Pontoon Hull with Locating Pin & Mounting Pedestal
(See Figure 1:8).
Figure 1:8-Right Hand Pontoon Hull Bolting Point

6. There are a number of mounting pads welded onto the pontoon deck to which the
pump unit base is bolted. These are marked on the diagram below.
Prior to installation of the pump base, remove any surface rust or debris from the
threaded holes in each pad. This will ensure that the bolts do not “cross thread” when
they are tightened.
(See Figure 1:9)
Bolt Hole
Pump Base Mounting Pad
Figure 1:9-Pump Unit Base Mounting Pad Indicating
7. Using a crane equipped with a “spreader bar”, lift the pump set into position over the
deck mounting pads on the pontoon deck.
(See.Figure 1:10)

Figure 1:10-Positioning the Pump Set over the Mounting Pad

8. Carefully align the bolt holes on the pump set with the mounting pad holes on the
pontoon.
Bolt with Flat and spring washers.
(See.Figure 1:11).
Figure 1:11-Alignment of Pump Set Bolt Holes with Mounting Pad Bolt Holes
9. Now the discharge pipe work can be fitted to the pump unit. If not already done, firstly
install the Non Return Valve to the pump discharge elbow.
The Non Return Valve inspection plate must be installed in the UP position.
Figure 1:12-Where to Install the Non Return Valve
10. The Non Return Valve must be fitted as shown in the diagram below, with the
inspection plate in the “UP” position and the green arrow showing the direction of water
flow through the valve.
Figure 1:13-Non Return Valve Installed on the Pump Set

PART 1. INSTALLATION

1.1 PUMP UNIT DELIVERY

Each order or shipment is double checked before leaving the factory. All parts, pieces and
components are listed item by item on our packing list, which accompanies each order.
The number and description of each item, package, container, skid, etc., is listed on the bill
of lading.
IN SIGNING THE BILL OF LADING, THE CARRIER ASSUMES FULL RESPONSIBILITY

FOR SAFE DELIVERY OF ALL GOODS TO DESTINATION.
In the 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.
1.2 STORAGE PROCEDURES

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.
NOTE:
The purchaser assumes full responsibility for the pump unit and any associated
equipment when stored, handled and transported on-site.
V’ Belts
V Belts should be stored in a dry stockroom, and contact with hot pipes and direct sunlight
carefully avoided.
Where Possible, handle the belts loosely in single (or triple) coils. Always avoid tying belts
with thin string.
1.3 GENERAL SAFETY OF MAJOR EQUIPMENTS

Bare Shaft Pump Safety
• 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.
• Shaft Locks (If Fitted) must be removed from the bare shaft pump before the
unit is started.
Do not operate the pump at low or zero flow conditions for prolonged periods, or under any
circumstance that could cause the pumping liquid to vaporize. Personnel injury and
equipment damage could result from the pressure created.
Do not apply heat to impeller boss or nose in an effort to loosen the impeller thread prior to
impeller removal. Personnel injury and equipment damage could result from the impeller
shattering or exploding when the heat is applied.
Do not feed very hot or very cold liquid into a pump which is at ambient temperature.
Thermal shock may cause the pump casing to crack.
Tapped holes (for eye bolts) and lugs (for shackles) on Warman Parts are for lifting
individual parts only.
Vacuum Pump Safety

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.

1.4 UNIT LIFTING POINTS

Multiflo Pump Model MF385
Bare Shaft Pump Model 385G SS

Maximum Pumping Speed RPM 1800 RPM
Bare Shaft Pump Operating Speed 1800 RPM
Wet End Material / Impeller 316 SS (AS 2704)
MF-385
Unit Mass (Wet) 7500 KG
Unit Mass (Dry) 5700 KG
High Lift Skid
Skid Mass 1050 KG
Figure 1:1- Pump Unit Lifting Points
NOTE:
Lifting points on the High Lift Skid Chassis are designed for lifting of the skid chassis
only.
Figure 1:2-Skid Chassis lifting points
1.5 ASSEMBLY INSTRUCTIONS
NOTE:
All assembly and installation is to be performed on solid level ground.
The following graphical descriptions are intended as a guide only. The following
instructions may contain information & illustrations regarding the installation of items
not specifically for use with some pontoons and pump units.
Assembly of Pump and Skid (If Fitted)
• Lifting of the pump unit should be undertaken by experienced personnel only.

• Do not stand under suspended load.
• Do not place any part of body under suspended load.

1. Using suitable lifting equipment, lift pump base over high lift skid.
2. Make sure the skid is clean of all rocks and debris.
3. When pump base is suspended over skid, gently lower base into skid. Be sure that
base moves into position freely and does interfere with skid sides.
4. Make sure the pump unit is sitting flat in the skid.
5. When base is sitting on skid frame, on one side only, insert spacers between the skid
and the pump unit (approximately 6mm). Fit the bolts and tighten that side. Repeat with
the other side fitting the required shim for the gap left between the skid and pump unit.
Do not attempt to insert bolts until pump base is sitting on skid frame and is not
suspended by lifting equipment.
Figure 1:3-Installing pump Unit onto Skid Chassis
Assembly of Pontoon (If Fitted)

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

Pontoon Centre Section Right
Hand Side
Pontoon Centre Section Left

Hand Side
Pontoon Front/ Push Bar
Figure 1:4-Pontoon Centre Hull

2. Using a crane, lift the left hand side pontoon into position
(See Figure 1:5).
Locating pin
Mounting pedestal
Figure 1:5-Left Hand Pontoon Hull with Locating Pin & Mounting Pedestal
Each “bolt on hull” locates to a mounting pedestal protruding from the underside of the
central pontoon hull. Each “bolt on hull” has a number of locating pins welded on the
bottom of each hull along the in board side of the hull. All locating pins must locate into
each pedestal correctly as shown, prior to installing the securing bolts.
(See Figure 1:6).
NOTE:
Make sure to use Anti-seize on all bolt threads before tightening the bolts.
Figure 1:6- Left Hand Pontoon Hull Bolting Points

4. Using a crane, lift the right hand side pontoon into position
(See Figure 1:7)
Access Steps
Figure 1:7-Right Hand Pontoon Hull with Locating Pin & Mounting Pedestal
(See Figure 1:8).
Figure 1:8-Right Hand Pontoon Hull Bolting Point

6. There are a number of mounting pads welded onto the pontoon deck to which the
pump unit base is bolted. These are marked on the diagram below.
Prior to installation of the pump base, remove any surface rust or debris from the
threaded holes in each pad. This will ensure that the bolts do not “cross thread” when
they are tightened.
(See Figure 1:9)
Bolt Hole
Pump Base Mounting Pad
Figure 1:9-Pump Unit Base Mounting Pad Indicating
7. Using a crane equipped with a “spreader bar”, lift the pump set into position over the
deck mounting pads on the pontoon deck.
(See.Figure 1:10)

Figure 1:10-Positioning the Pump Set over the Mounting Pad

8. Carefully align the bolt holes on the pump set with the mounting pad holes on the
pontoon.
Bolt with Flat and spring washers.
(See.Figure 1:11).
Figure 1:11-Alignment of Pump Set Bolt Holes with Mounting Pad Bolt Holes
9. Now the discharge pipe work can be fitted to the pump unit. If not already done, firstly
install the Non Return Valve to the pump discharge elbow.
The Non Return Valve inspection plate must be installed in the UP position.
Figure 1:12-Where to Install the Non Return Valve
10. The Non Return Valve must be fitted as shown in the diagram below, with the
inspection plate in the “UP” position and the green arrow showing the direction of water
flow through the valve.
Figure 1:13-Non Return Valve Installed on the Pump Set

1.6 INSTALLATION OF SUCTION ASSEMBLY
• Pump unit to be locked and tagged before any work is performed.

• Installation of the boom assembly components to be undertaken by
experienced personnel only. Refer to site procedures for lifting, personnel and
equipment requirements.
• Chains to be connected with Hammerlocks only.
Figure 1:14-Fitting the Suction Boom
1. With boom lying flat, insert boom locking bolts in boom and pump base. Tighten bolts.
(See Figure 1:14)
2. If not already done so, attach winch to pump base winch mount.
3. With boom lying flat, run winch rope through boom pulley. Removal of the pulley may
be necessary (See Figure 1:15)
Figure 1:15-Attaching Winch Rope to Boom Pulley
4. Connect boom chains to boom using Hammerlocks
5. Using suitable lifting device, pick up boom and lift into a position that will allow the
boom chains to reach the boom chain mounting points on the pump.
6. Fit boom chains to mounting points using Hammerlocks only.
7. Connect winch rope to spreader bar using an approved shackle.

8. Fit Suction Strainer to hose

(See Figure 1:16)
Figure 1:16- Fitting the Boom Chain and Suction Strainer
Correct Position of Suction Boom
The suction boom supports the suction hose and allows it to be raised and lowered using a
hand winch. The boom is to be installed so that it sits at an angle of 45° to the deck of the
pump unit (See Figure 1:17). It should be checked that the support chains that run back to
the deck of the unit are of equal length (within manufacturing tolerances).
Figure 1:17-Correct Position of Suction Boom
Caution should be exercised when moving the pump unit, especially over rough terrain, in
order to avoid excessive movement of the suction hose.
If there are any questions regarding the positioning of the suction boom, please contact
Weir Minerals Multiflo service centres (provided in Introduction section).
1.7 INSTALLATION OF DISCHARGE PIPE WORK

Installation of discharge pipe-work components should be undertaken by experienced
personnel only.
Refer to site procedure for lifting, personnel and equipment requirements.

1.8 FITTING PONTOON HANDRAIL (IF FITTED)
Figure 1:18-Attaching the Left Hand Side Handrail
Figure 1:19-Attaching the Right Hand Side Handrail
1.9 MOVING AND LOCATING THE PUMP UNIT
• Pump unit to be locked and tagged before any work is performed.

• Pump unit to be moved by experienced personnel only.
NOTE:
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.
Multiflo Pumps are designed and fabricated around a robust base chassis which can then
be mounted onto a heavy duty high lift skid chassis or pontoon. Both the high lift skid
chassis and pontoon have a robust push beam assembly and towing brackets attached to
enable the unit to be pushed or pulled.
For long term pumping operations in deep water or in high rain fall areas, it is
recommended that the pump 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.
Pump Site Preparation

Proper pump site preparation is important. It should provide a good approach for the final
positioning of the pump and allow access for
fuel and service vehicles. Also, when using a skid mounted pump in areas prone to flash
flooding after heavy rainfall, quick access to the unit 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.

Moving the Pump Unit

Moving or relocating a pump unit within the pit is normally done by a wheel dozer or small
track dozer. A small excavator can also be used especially for launching pontoon units.
Obviously, the proper way to move a pump unit is by towing, using appropriate tow chains.
Pushing the pump unit over long distances or over uneven ground is to be avoided.
Procedure for Towing
Pump unit to be connected to prime-mover by suitable towing apparatus.

Suitability of towing apparatus to be determined according to local site
requirements.
1. Ensure no pipes or hoses are connected to the 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
4. The suction boom can remain in its normal suspended position.
5. If not already fitted, attach appropriate towing chains to the towing brackets at the front
of the pump unit skid base, or at the towing brackets at the front end of the pontoon.
The front end is the engine end of the pump unit.
6. Connect towing chains to the draw bar of the towing vehicle.
Towing should be kept at a reasonable safe speed and extra caution should be taken
when towing along haul roads, keeping as close as possible to the left side. Don't tow or
push the pump over rough, uneven ground. Unhitch the dozer and level the way.
Final positioning will usually involve pushing the pump down a ramp at a maximum grade
of 15°, either with the dozer blade or the excavator bucket. For launching pontoon pumps,
an excavator may be the best tool. Pushing must be done with extreme caution and only
on the push beam assembly provided. Pontoon pumps are pushed on the pontoon push
bar only and not on the base chassis push beam. Under no circumstances should any
pump unit be pushed on the sides or at the suction end (rear).
Before launching a pontoon pump, consideration should be given to the best method of
connecting up the discharge line. (It is extremely difficult to connect up hoses and pipes in
deep water). If layflat hose is to be connected to the initial discharge pipe, then this
connection can be made before the pump is launched.
If 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.
Positioning and Launching

1. Ensure that a suitable pump location is established which will provide a good approach
for final positioning and safe access for fuel and service vehicles.
2. Skid mounted pumps should be positioned on level ground.
3. Pumps should be positioned/launched using a wheel dozer, small track dozer or small
excavator.
4. The operator of the dozer or excavator must be able to see the point at which the blade
or bucket is making contact with the pump. The pushing operation must be directed by
a person on the ground. The equipment operator and person directing must be clear
on the hand signals being used by the person directing. Skid mounted pumps must
only be pushed on the push beam assembly provided.
NOTE:
Pontoon mounted pumps must only be pushed on the pontoon push bar, and not on
the pump push beam. (See Figure 1:20)
Under no circumstance should any pump unit be pushed on the sides or at the suction
end (rear).
5. Before launching, consideration should be given to connecting layflat or polypipe

discharge lines. Final connections can then be done on land after the pump is floating.
As well, a rope tag line long enough to reach the bank should be fitted to assist in final
pontoon positioning.

NOTE:
Following images intended as a guide only.
Figure 1:20-Blade Contact Point on Pontoon Push Bar
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 1:21-Incorrect Pump Unit positioning

Correct Pump Unit Positioning
Pump Position – Flat ground
Suction Lift less than 10 Metres
Discharge Hose Curved where Possible
Figure 1:22-Correct Pump Unit Positioning
Pumping Operation Observations

Ensure:
• The hose couplings, both suction and discharge, are completely sealed.
• The pump unit is positioned as close as possible to the level of the fluid being pumped.
(If the height of the wet end pump is above 8 metres from the level of fluid, the pump
will not pump).
• The suction strainer is free from blockage and fully submerged in the fluid.
• The largest possible pipe diameter, both at suction and discharge, is being used.
• The vacuum tank gauge reading is within the normal range.
• The bare shaft pump is operating without cavitating.
• The engine is set at the correct speed (RPM) to give maximum pump efficiency.
• When using "layflat" hose, ensure that it is free from kinks and sharp turns.
• The pump unit is situated in a safe position and not operating at an angle of more than
10°.
• There is a good rate of liquid flow coming from the end of the discharge line.
NOTE:
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.
Installation Checks
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.
NOTE:
On-site pump unit alignment checks to be carried out prior to pump unit operation.

PART 2. OPERATION
Operation Manual MF 385G SS – Jan 2011 ©Copyright Weir Minerals Multiflo 28

2.1 GENERAL FUNCTION OF THE PUMP UNIT

The type of Bare Shaft Pump used on Multiflo pumps is of the centrifugal design. This
type of Pump will not operate until initially filled with water (primed). Multiflo pumps use an
automatic prime system to initially prime and to maintain prime as long as fluid is available.
The automatic prime system consists of the vacuum tank, vacuum pump and fluid level
control.
A vacuum gauge which is mounted in the vacuum tank indicates, while the pump unit is
operating, dynamic head loss in the suction system. As this reading will vary with different
pumping conditions, i.e. varying lengths of suctions hose, height of pump unit above fluid,
quantity of fluid being pumped etc., it is impractical to predict a general vacuum gauge
operating reading.
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.
Although the unit is capable of suction lifts of up to eight metres, it is advisable to install
the pump unit as close as possible to the level of the fluid being pumped to obtain optimum
flow rates.
In all pumping operations, ensure that a Multiflo suction strainer is fitted to the suction
hose.
NOTE:
The suction strainer should be no less than 1 metre below the surface of the water.
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.
2.2 PUMP UNIT ORIENTATION

NOTE:
The front end of the pump unit is the radiator end. The back (or rear) end 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 Left Side
Figure 2:1-Pump Unit Orientation
2.3 DAILY PRE-START CHECKS
• Personal Protective Equipment must be worn when operating or servicing this unit.
• Pump unit to be locked and tagged before any maintenance or service is performed.
• 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 is carried out.

Engine Oil
Maintain oil level between ‘add’ and ‘full’ marks on the dipstick.
Bare Shaft Pump Auto Lubrication System

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

Maintain level between ‘high’ and ‘low’ mark on the dipstick.
Gland Oil Tank (If Fitted)

Fill to 10mm below the filler pipe opening.
Coolant Level
Make sure the engine is stopped and cold. Maintain level in range above baffle plate and filler
neck.
Fuel Tank
Fill as required. Check fuel gauge.
Battery
Maintain level in range above plates and filler bridge (if applicable).
Drive Belts (Fan, Generator, Vacuum Pump)

Check condition and re-tension if required or replace if necessary.
Water Trap
Drain and clean the bowl.
Air Cleaner Indicator (If Fitted)

If the indicator piston locks in the UP position, service the element.
Suction Strainer
Check the suction hose and strainer for blockages or damage. Make sure that the strainer is
properly submerged.
Probes
Clean the probes.

2.4 STARTING PROCEDURE

1. Complete pre start checks.
2. Check emergency stops are out (1 on the Caterpillar engine control box and 1 on the
canopy).
3. Turn the battery isolator to on.
4. Check all applicable discharge and suction valves are open.
5. Turn the ignition to the ON position and allow the gauges and messenger to calibrate
(5-10 seconds).
6. Start the engine and allow to idle for 2 minutes.
7. Bring the revs up to 1000 RPM until the pump is primed. Once the pump is primed set
the revs to suit the duty of the pump.
8. To find the duty, bring the revs up until the discharge pressure gauge reaches its
highest reading or the pump cavitates, this is the maximum discharge. Don’t run the
pump in cavitation for extended periods.
9. Check gland leakage and adjust as required.
10. It is recommended that the unit be monitored for 6 minutes to ensure it doesn’t shut
down on prime or flow.
2.5 OPERATING SPEED

To set the operating speed, you need to:
1. Increase the engine RPM until the pump starts to cavitate. The pump will vibrate and a
crackling sound will be heard at the pump volute.
2. Decrease the RPM slowly until the pump stops cavitating completely. The vibration
and crackling sound will go away.
This is the correct engine operating speed for this application.
If discharge pressure device is fitted, to set the operating speed, you need to:
1. Increase the engine RPM while monitoring the discharge pressure rising on the gauge.
2. Continue to increase RPM until discharge pressure stops rising.
This is the correct engine operating speed for this application.
2.6 CAVITATION
Cavitation is vaporised water in the form of air pockets around the rotating impeller
which can be identified by a bad vibration and rattling noise coming from the pump
casing. Also poor water discharge from the pump outlet will be noticed.

This is caused by the impeller forcing water out of the discharge at a faster rate than
the water can be replaced through the suction of the pump.
Cavitation can be caused by:
• The pump being too high from the water being pumped (Excessive suction lift).
• The engine RPM or pump speed is too high for the required duty.
The resulting effects of cavitation are:

1. Pitting of material surfaces due to continual hammering action.
2. Reduction in pump performance.
3. Damage to pump, if cavitation is severe.
Figure 2:2-Resulting Effects of Continuous Cavitation
2.7 SHUTDOWN PROCEDURE

1. Decrease engine RPM slowly to idle.
2. Allow the engine to idle for 2 – 3 minutes before shutting down.
(Turbo charged models only).
3. Stop the engine.
4. Turn the master switch key to the ‘off’ position.
5. Drain down the pump if it has been used for pumping slurry.

Shut Down Protection
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 activating the engine shutdown. Once this has
occurred, the red indicating light will switch off.
Should the pump pick up water within the six minutes after being activated, the unit will
automatically reset.
2.8 DESCRIPTION OF MAJOR COMPONENTS

Bare Shaft Pump
The Multiflo range of pumps is specifically designed for continuous running in clean water
at varying duties. They are suitable for aggressive water found in mining applications.
The pump discharge can be rotated into 3 positions, vertical, horizontal and underslung
depending on the required application and configuration.
The impellers are closed and semi closed depending on pump size and application with
medium to high efficiencies when used correctly. Wet end parts are available in stainless
steel and mild steel, are gland packed as standard and are available as oil or grease fed
bearings depending on the application.
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.
NOTE:
Prior to initial operation the vacuum pump oil level must be checked before operating.
Running the vacuum pump without oil will cause damage.

Figure 2:3-Piston Type Vacuum Pump Major Components

Model 57 Vacuum Pump Specifications

Type – 2 cylinder
90mm bore 108mm stroke
splash feed
Standard 90mm +0.05
Cylinder Bore 0.00
Oversize 1mm
Standard 89.95mm + 0.03
Piston 0.02
Oversize 1mm
Engine Gap Min
0.1mm
Piston Ring
1.0mm
Max
Piston to Bore Clearance Max 0.2mm
Standard 44.5mm
Crankshaft Journal Wear Limit 44.459 - 44.475mm
Under Size 44.460 Nil
Clearance
0.025mm
Journals to Conrod Standard
0.07mm
Max
Main Bearings Deep Groove Ball Bearings
Torque Settings
Cylinder Head 35 NM + 3 25FT LB + 2

Cylinder to Crankcase 30 NM + 3 20FT LB + 2
Bearing Cap 35 NM + 3 25FT LB + 2
Conrod Big Cap 35 NM + 3 25FT LB + 2
Valve Retainer Cap 35 NM + 3 25FT LB + 2
Model 57 Vacuum Pump Parts

Item No Description
1 Elbow
2 Non Return Valve
3 Nut
4 Keeper Plate (Arm)
Keeper Plate (Top)
5 Vacuum Pump Pulley
6 Bolt
7 Washer
8 Complete Clutch Assembly

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.
Figure 2:4-Vacuum Tank
Vacuum Gauge
A vacuum gauge which is mounted in the vacuum tank indicates, while the pump unit is
operating, dynamic head loss in the suction system. The normal operating range depicted
by the gauge should be within -20kPA to -80kPA.

Figure 2:5-Vacuum Gauge
Non Return ‘Vooom’ Valve

Incorporated on the discharge side of the pump is a discharge line non-return valve. This
valve, open during pumping, will automatically close when pumping stops.
The Non-Return Valve has two purposes:
1. It prevents the fluid already in the discharge line from draining back and flooding the
vacuum tank. It has been known that if the non-return valve is not working properly the
head of water in the discharge pipe will flow back through the pump and may turn the
impeller off the thread of the pump shaft.
2. It seals the discharge line when the pump is priming so a vacuum can be created in the
vacuum tank allowing the pump to prime or re-prime
Therefore the non-return valve is an extremely important part in the pump’s system.
The valve’s flap is manufactured from rubber with an inbuilt steel counterweight (Multiflo
“VOOOM” Valve). The flap should be inspected on a regular basis.
If the pump is not priming and the gland packing is not leaking then maybe the valve flap is
damaged or stuck open.
1. As the unit 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.

2. 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.
3. Although the unit is capable of suction lifts of up to eight meters, it is advisable to install
the pump unit as close as possible to the level of the fluid being pumped to obtain
optimum flow rates.
4. In all pumping operations, ensure that a Multiflo suction strainer is fitted to the suction
hose.
NOTE:
The suction strainer should be no less than 1 meter below the surface of the water.
5. 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.
Figure 2:6-Non Return Valve, Flap in Close and Open Positions

In the event of this non-return valve sticking and failing to close when pumping stops, fluid
would then drain back and flood the vacuum tank. If such a case occurred, fluid will be
prevented from entering the vacuum pump by closing of the vacuum valve by the action of
the ball float rising to close off the vacuum pump intake port.
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 occurs, the electric clutch disengages
and the vacuum pump will not run.
The vacuum pump will remain in this mode under normal pumping conditions.
Should the water level drop below the probe, the vacuum pump will automatically restart
and run until the level in the vacuum tank is restored.
The krundimendt valve, fitted to the top of the vacuum tank, acts as a check valve. In the
event of a shutdown, when the discharge line non-return valve fails and floods the vacuum
tank, the ball will rise in the krundimendt valve and stop water from entering the vacuum
pump. The one way check valve fitted in the vacuum line, stops air being pulled back into
the vacuum tank from the vacuum pump. (See.Figure 2:7).

Figure 2:7-Vactronic Circuit Diagram
First Out Indication Panel

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

General:
1. Keep the unit as clean as possible.
2. Replace the gland packing at regular intervals or as required, replace all of the packing
when doing so. A gradual loss of performance or difficulty priming is an indicator of
worn packing, although these symptoms may have other causes.
3. Set up the unit as close to level as practicable.
4. Periodically check the discharge for adequate flow.
5. Don’t run the pump for extended periods when it is cavitating.
6. Maximum rpm must not be exceeded; vibration from impeller imbalance will lessen
bearing life.
Figure 2:8-First Out” Indication Panel

Hydrau-Flo Fuel Pressure Control Valve

The Hydrau-Flo Fuel Pressure Control Valve has been designed to be used in conjunction
with existing “fast fill” systems. The Hydrau-Flo system consists of several main
components; the flow control valve, pilot line float valve, breather and mounting hardware.
Figure 2:9-Hydrau Flo Fuel Valve Components
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.
NOTE:
The fuel nozzle cannot be over-ridden as no matter what the pressure of the fuel trying
to open the piston is, it will always be higher under the piston due to the addition of
spring pressure.

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.
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 pressure 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 2:10-Hydrau-Flo System Re-Fuelling in Progress

Figure 2:11-Hydrau-Flo System Components
Figure 2:12-Hydrau-Flo System Re-Fuelling Finished

Engine Turbo Charger Protection (If Fitted)

There are two main causes of premature turbo failure. These are (1) oil contamination and
(2) lack of oil (on engine shutdown. The “Turbo Saviour" is the best accessory available to
overcome these problems.
Engine oil receives a secondary filtration before passing through a check valve on its way
to the turbocharger. The accumulator section of the "Turbo Saviour" is charged with oil via
an oil bleed orifice while the engine is running. On engine shutdown the check valve
closes and oil from the accumulator continues to flow to the turbo for up to five minutes
(thus cooling and lubricating the turbo charger for this period).
Figure 2:13-Engine Turbo Saviour
Engine Turbo Saviour Installation Instructions:
1. Secure the "Turbo Saviour" in a convenient location via the mounting bracket. The
unit must be mounted vertically with the large canister at the top.

Do not attach the Turbo Saviour directly to the Engine.
2. Disconnect the turbocharger oil feed line at the turbocharger. If possible use this line
as the oil supply to the "Turbo Saviour" inlet.
3. Manufacture a new oil line to connect the "Turbo Saviour" outlet to the turbo charger.
Fill with new oil before connecting to the turbo charger. Use Mobil Delvac MX 15W40
or Shell Rimula 15W40 oil.
4. Fill the spin-on filter with new engine oil and refit to "Turbo Saviour".
5. If possible, crank the engine without starting to purge oil supply to the turbocharger.
6. Start the engine at idle speed and check for oil leaks.
Figure 2:14-Installation of the Engine Turbo Saviour

Turbine Series 1000FH Fuel Filter/Water Separators (If Fitted)

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.
Turbine Series filter assemblies are designed to be installed on the vacuum side of the fuel
transfer pump for best efficiency (see installation diagram further on). Adjustable one-
piece clamp-type mounting brackets, with grade 5 fasteners, are included for ensured
durability. The 1000FH uses two mounting brackets. The see-thru contamination
collection bowl allows the operator to check for water and solid contamination at a glance.
Figure 2:15-Fuel Filter/Water Separator

Installation Instructions:
The following customer supplied materials should be on hand before beginning installation.
1. Shop Towels
2. Diesel Fuel (about 1 gallon)
3. Thread Sealant (no thread tapes)
4. Parker Super –O Lube (or equivalent)
5. Fuel Hose (see Fuel Hose Chart)
6. Mounting Hardware (3/8” or M10 Fasteners)
7. Inlet/Outlet Fittings (see Fitting Chart)
NOTE:
Mount the filter assembly as close to vertical (V) as possible.
Do not exceed 10° from vertical or the assembly may not function properly.
Figure 2:16-Fuel Filter/Water Separator Mounting Struction

Positioning Filter:
FH filter assemblies should be installed on the vacuum side of the fuel transfer pump for
optimum water separating efficiency.(See Figure 2:16)
• Keep fuel line restrictions to a minimum. Locate the FH filter assembly between the
horizontal planes of the bottom of the fuel tank and the inlet of the fuel pump, if
possible.
• If the FH filter assembly is installed in an application where the fuel tank is higher than
the filter, a shut-off valve must be installed between the tank and the FH filter assembly
INLET. This will be used when servicing the replacement element.
Before Installation:
• Obtain good ventilation and lighting.
• Maintain a safe working environment.
• The engine must be off for installation.
• DO NOT smoke or allow open flames near the installation.
Installing Filter:
• Completely remove any vacuum side filters in the fuel line between the fuel tank and
the fuel pump. This is where the FH filter assembly will mount. Leaving these filters in
place will add to the fuel line restriction. Filter heads cast into the engine or that are
non-removable or hard piped should be serviced with a new element and left in place.
• Keep fuel flow restriction valves to a minimum. Always use the maximum size fuel
hose possible. Do not make sharp bends with flexible fuel hose as kinks may occur.
Avoid the use of two 45° elbow fittings where one 9 0° elbow will work.
• When routing hose, avoid surfaces that will move, sharp edges, or will get hot (such as
exhaust piping).
Priming Instructions
1. Remove the ‘T’ handle and lid from top of filter assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and ‘T’ handle O’ring with clean fuel or motor oil.
4. Replace the lid and ‘T’ handle and tighten snugly by hand only (Do not use tools).
5. If applicable, refer to the equipment operator’s service manual to complete the fuel
priming procedure.
6. Start engine and check for fuel system leaks. Correct as necessary with engine off and
pressure relieved from filter assembly.

NOTE:
Pressure installations are applicable up to a maximum PSI shown. Vacuum
installations are recommended.
Not for use on gasoline applications.
Figure 2:17-Fuel Filter/Water Separation Installation Diagram

Specifications 1000FH
Maximum Flow Rate: 180 GPH (681 LPH)

Port Size 7/8"-14 UNF (SAE J1926)
(female threads)
Minimum Service 10.0 in. (25.4 cm)
Clearance: 2.0 in. (5.1 cm)
(Above Assembly)
(Below Assembly)
Replacement Filter: (1 Per Assembly)
(2 micron) 2020SM-OR
(10 micron) 2020TM-OR
(30 micron) 2020PM-OR
Height 22.0 in. (55.9 cm)
Depth 7.0 in. (17.8 cm)
Width 6.0 in. (15.2 cm)
Weight (dry) 10.0 lb (4.5 kg)
Clean Pressure Drop 0.43 PSI (0.03 bar)
Maximum Pressure¹ 15 PSI (1.03 bar)
Water In Bowl Capacity: 10.3 oz (305 ml)

Available Options: Yes
(water detection kit) ² Yes
Yes
(12 or 24 volt dc heater) ² Yes
(vacuum gauge)
(12 or 24 vdc primer pump)
Water Removal Efficiency 99%
Ambient Temperature -40o to +255oF (-40o to +124oC)
Range
Maximum Fuel 190°F (88°C)
Temperature
¹ Pressure installations are applicable up to the maximum PSI

shown. Vacuum installations are recommended.
² Not for use on gasoline applications.

Engine Monitoring System (EMS)

Please refer to Caterpillar Engine Manual.
2.9 ELECTRICAL
• Pump unit power supply to be isolated before any work is performed on the
pump unit electrical system.
• Personal Protective Equipment must be worn when operating or servicing this
unit.
For more information on electrical wiring, Please refer to attached drawings provided in
Introduction section. (In case of no attachments, please contact Weir Minerals Multiflo
Head Office for further information).
Monitoring Instruments
Sensor/Modules
• Failsafe circuitry
• Incorporates a self testing function on initial power up.
• LED display on unit for fault diagnosis.
• 10 amp switching capability.
• A/C circuitry eliminates electrolysis which causes probe erosion.
• Suitable for 10 – 30VDC systems.
Wiring Code:
RED - ignition supply
Black - earth
White - probe
Brown - N.O contact for relay
Purple - N.C contact for relay
NOTE:
Relay switches can switch negative or positive supply
For this system to operate correctly a conductive coolant must be used.
Fitting instructions:
1. Fit the control unit in a suitable position, preferably in the dash area. Wire as per the
wiring code.

If the top of the tank is of the shallow type, it is recommended that two coolant level probes
be installed, one coolant level probe on the far left of the top tank and the other on the far
right of the top tank. These are then wired in parallel. This will also reduce false indication
of coolant loss due to vehicle tilt.
A hole should be tapped at the probe location only if there is sufficient metal to produce
enough threads. If this is not possible, a bushing can be soldered into the top tank.
For radiators with very thin walls, a light duty coolant level probe is available.
NOTE:
Always ensure the radiator tank is earthed.
Take care installing when installing the probe not to short to earth.
I.E. beware of baffles in the radiator.
Technical:
The detector is a solid state amplifier controlled by the resistance of an electrode
immersed in the coolant.
The amplifier consists of circuitry that convert a resistance value at input to a current
change at the output to switch a relay which has a change over contact, rated at 10 amps.
The relay output can either be constant or intermediate. Cutting the control unit link will
give you intermittent relay output.

NOTE:
System shown without ignition switched on.
MUIRHEAD
MULTI VOLTAGE
COOLANT LEVEL DETECTORS
LCM
(1739)
SUGGESTED FITTING
INSTRUCTIONS
Figure 2:18-Multi Voltage Coolant Level Detectors

PART 3. MAINTENANCE
Maintenance Manual MF 385G SS – Jan 2011 ©Copyright Weir Minerals Multiflo 56

3.1 GENERAL SAFETY

unit.
• Pump unit to be locked and tagged before any maintenance or service is
performed.
• 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 are
carried out.
NOTE:
Observe for gauge leaks and general condition of the unit. If condition exists,
determine the cause and have necessary repairs made.
3.2 BARE SHAFT PUMP ASSEMBLY AND DISASSEMBLY PROCEDURE
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.
NOTE:
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.
It is preferable to renew small bolts and set screws during overhaul and all threads
should be coated with graphite grease before assembly. It is also recommended that
all rubber seals should be replaced during major overhauls as rubber tends to harden
and seals lose their effectiveness.

Bare Shaft Pump Disassembly Procedure
Heavy Components - appropriate lifting techniques to be used.
1. Securely mount PUMP UNIT to anchored work bench.

2. Remove SUCTION COVER PLATE (Figure 3:2/ 31).
3. Remove WEAR PLATE (32) from VOLUTE (29) and discard 'O' RINGS (34) and (33).
4. Remove KEY (17) from SHAFT (2). Using Impeller Locking Tool (Figure 3:5) to lock
IMPELLER (30), remove the IMPELLER by turning the SHAFT with the Shaft Spanner
(Figure 3:3).
5. Remove BLANK DUST CAPS (38) from PEDESTAL (1) and use ¾ UNC BOLTS (28)
through DUST CAP holes to separate VOLUTE (29) from PEDESTAL (1).
6. Remove VOLUTE (29) from PEDESTAL (1).
7. Remove STUFFING BOX (20) from VOLUTE (29) and discard PACKING (23) and 'O'
RING (21).
8. Remove SHAFT SLEEVE (18) and discard 'O' RINGS (19). Withdraw GRUB
SCREWS from LABYRINTH SLINGER (15) and remove from SHAFT SLEEVE (18).
Discard 'O' RING (16).
9. Remove BEARING CAPS (13) and (4). Discard 'O' RING (6) and SEALS (14) and (5).
10. Remove SHAFT LOCK NUT (8) from SHAFT (2).
11. Press SHAFT (2) from PEDESTAL (1) out through Impeller End.
12. Remove BEARINGS (9) from Coupling End of PEDESTAL (1) along with LIP SEAL
GREASE RETAINERS (10).
13. Remove CARB BEARING (12) from SHAFT (2).
14. Thoroughly clean and inspect all parts of pump. Pay particular attention to SHAFT and
IMPELLER. If there is any doubt about serviceability, replace suspect parts.
NOTE:
It is recommended that all bearings, gaskets, 'o' rings, bushes and Nyloc nuts are
replaced when rebuilding pump bare shaft assembly.

Bare Shaft pump Assembly Procedure – 6A Pedestal

1. Fit BEARING (12) to SHAFT (2) Impeller End.
NOTE:
Use an induction heater or similar to heat Bearing (12) to 120°C.
2. The Bearing is an interference fit onto the shaft and transitional fit into the Pedestal.
NOTE:
Use CRC 5.56 for ease of fitting the Shaft Assembly to the Pedestal.
3. Fit SHAFT ASSEMBLY into PEDESTAL (1) from Impeller End, using Tool ‘A’ (Figure
3:6) in front of CARB BEARING (12) to keep it in line. PEDESTAL (1) should be
secured safely in the vertical position. Lower SHAFT ASSEMBLY carefully into
PEDESTAL (1) taking care not to turn LIP SEAL (10) at Impeller End.
4. Once SHAFT ASSEMBLY is in place, remove Tool ‘A’ (Figure 3:6) and grease CARB
BEARING (12) 30% to 50% full with ALVANIA RL2 Grease. Fit END CAP TOOL Turn
PEDESTAL (1) 180°. Pre-load BEARINGS (9) 30% to 50% with ALVANIA RL2 Grease.
5. Fit pre-greased BEARINGS (9) as per Bearing Diagram (Fig 30). Press into place
NOTE:
Shaft is an interference fit and Pedestal is a transitional fit.
6. Once BEARINGS (9) are in place, fit SHAFT LOCK NUT (8) to SHAFT (2) with Loctite
271 and tighten to torque specifications. Raised face against bearing.
7. Oil between bearing (9) and shaft lock nut (8).
8. Fit SEALS (5) & (14) to BEARING CAPS (4) & (13).
9. Fit CORK GASKET (37) to BEARING CAP (4). Using Tool ‘B’ (Figure 3:7) to avoid
damaging LIP SEAL (10), fit BEARING CAP (4) to PEDESTAL (1).
10. Fit BOLT LOCK TABS (36) and BEARING CAP BOLTS (3) to BEARING CAP (4) and
torque BEARING CAP BOLTS (3) to 95Nm (70 ftlbs). Lock BOLTS (3) with LOCK
TABS (36).
NOTE:
Do not over torque bolts (3).It will cause a heat increase.
11. Rotate PEDESTAL 180° Fit CORK GASKET (37) to BEARING CAP (13) and fit
BEARING CAP to PEDESTAL.

12. Fit BOLT LOCK TABS (36) and BEARING CAP BOLTS (3) to BEARING CAP (13). Fit
BEARING CAP to PEDESTAL and torque BEARING CAP BOLTS to 95Nm (70 ftlbs).
13. Fit SHAFT SLEEVE (18) with 'O' RINGS (19). Apply anti seize to inside of SHAFT
SLEEVE (18) and fit to SHAFT (2). Fit ‘O’ RING (16) to LABYRINTH SLINGER (15).
Clearance between LABYRINTH SLINGER (15) and BEARING CAP (13) is 1 +/- 0.5mm.
NOTE:
Fit the Labyrinth Slinger (15) to Bearing Cap End of Sleeve before assembly of sleeve
as it is much easier. Once assembled, set labyrinth slinger (15) and fix with grub
screws.
14. Bearings to be RUN IN at 1800 RPM for ½ hour. At 10 minute intervals temperature
reading to be taken. In a workshop test run TEMPERATURE NOT ALLOWED TO
EXCEED 70°C. Above 70°C strip pedestal to find cause of overheating then RE-RUN.
TEMP RECOMMENDED front and back 60°C +/- 5°C.
Too much grease will cause the bearings to run hot; i.e. above the recommended
temperature.
Figure 3:1-Pedestal Assembly

Figure 3:2-Model 385 Gland Packed Bare Shaft Pump Parts Assembly

Model 385 Gland Packed Bare Shaft Pump Parts

Item NO Description QTY
1 Pedestal 1
2 Shaft 1
3 Bolts (Bearing Caps) 12
4 Bearing Cap (Coupling End) 1
5 Seal 1
6 'O' Ring 2
7 Grease Nipple 1
8 Shaft Lock Nut 1
9 Bearing (Coupling End) 2
10 Plug 2
11 Breather 1
12 Carb Bearing 1
13 Bearing Cap (Impeller End) 1
14 Seal 1
15 Labyrinth Slinger 1
16 'O' Ring 1
17 Key (Coupling) 1
18 Shaft Sleeve 1
19 'O' Ring (Shaft Sleeve) 2
20 Stuffing Box 1
21 'O' Ring (Stuffing Box) 1
22 Gland Follower 1
23 Packing Kit 1
24 Stud & Nut Kit (Gland) 1
25 Bolts 4
27 Shim 5mm As Req'd
Shim 1mm As Req'd
28 Bolts 4
29 Volute 1
30 Impeller 1
31 Suction Cover Plate 1
32 Wear Plate 1
33 'O' Ring (Face) 1
34 'O' Ring (Radial) 1
35 Volute Studs 8
36 Bolt Lock Tab 6
37 Cork Gasket 2
38 Blank Dust Caps 2

Special Tools & Clearances
Figure 3:3-Shaft Spanner
Figure 3:4-Impeller Clearance 1 mm
Figure 3:5-Impeller Locking Tool

Figure 3:6-Tool A
Figure 3:7-Tool B

Wetted Parts Assembly Procedure

1. Assemble GLAND FOLLOWER (22) onto SHAFT (2) of PEDESTAL ASSEMBLY.
2. Install the GLAND STUDS (24) into STUFFING BOX (20) AND INSTALL 'O' RING (21)
onto STUFFING BOX (20). Fit GLAND PACKING (23). Alternate joints of individual
Packing Rings at 180° intervals.
NOTE:
Use oil on Shaft and Packing to assist in assembly of Stuffing Box.
3. Then fit STUFFING BOX (20) with BOLTS (25) into VOLUTE (29) with the GLAND OIL
FEED HOLE to the top.
4. Fit VOLUTE (29) to PEDESTAL (1) using BOLTS (28). Being careful not to cause
damage to SHAFT when fitting. Tension as per bolt specifications. Use anti-seize
between all bolts and bolted surfaces for ease of future disassembly.
5. Apply anti-seize to shaft thread then fit IMPELLER (30) on to SHAFT (2) using Shaft
Spanner (Figure 3:3) to prevent shaft from turning. SPIN IMPELLER HARD HOME
AND ENSURE IT IS NOT FOULING.
6. Insert STUDS (35) using Loctite 620 into face of VOLUTE (29).
7. Without 'O' RING (34), fit WEAR PLATE (32) to VOLUTE (29) to determine clearance
between WEAR PLATE (32) and IMPELLER (30). Use a combination of SHIMS (27) to
ensure a clearance of 1mm between WEAR PLATE (32) AND IMPELLER (30) when
SUCTION COVER PLATE (31) is installed (Figure 3:4).
8. Fit 'O' RING (34) to WEAR PLATE (32) and install into VOLUTE (29).
9. Fit 'O' RING (33) to recess in the back of WEAR PLATE (32) then fit SUCTION COVER
PLATE (31) and secure with VOLUTE NUTS (35).
10. Grease all 'O' RINGS for ease of fitting.
11. Install GLAND NUTS (24). DO NOT OVERTIGHTEN INITIALLY.
12. Install Key (17) to SHAFT (2).
NOTE:
When first running up, loosen gland nuts to allow the shaft to position the packing.
Allow water to pass through the packing with the engine running at idle rpm. Tighten
the gland nuts until a small controlled trickle of water is visible. All new gland packing
should be adjusted in this manner.

Bolt Tension Settings
B - Bearing Cap 95Nm ( 70ft lb)
H - Volute Studs 270Nm (200ft lb)
I - Wet End Mounting Bolts 750Nm (550ft lb)
Figure 3:8-Bolt Tension Settings

B - Bearing Cap 95Nm (70ft lb)
D - Volute Mounting Bolts 270Nm (200ft lb)
I - Wet End Mounting Bolts 750Nm (550ft lb)
J - Shaft Lock Nut Tap Up Tight – Use Loctite
Shaft Lock Nut Grub Screw 15Nm (11ft lb) – Use Loctite
K - Stuffing Box Bolts 270Nm (200ft lb)
Figure 3:9-Bolt Tension Settings

3.3 BARE SHAFT PUMP MAINTENANCE

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
Gland
The Multiflo Pumps' oil feed system provides lubrication and sealing of the gland packing
under snore and high vacuum conditions.
This system requires the use of "Flurograph 193" or equivalent packing, which has been
found, through experience, capable of providing excellent service under the harsh
conditions under which it may be called upon to operate.
The gland should be adjusted regularly to prevent excess leakage. The gland must not be
over tightened as this will lead to over heating of the gland area and short life of the
sealing components.
The pumps will require repacking when the gland follower is tight against the stuffing box.
It is imperative that all packing rings are replaced when repacking. Replacement of only
the first few sets of packing will lead to premature wear of the shaft and priming difficulties.
Each ring of packing should be inserted separately and pushed in place into the stuffing
box. The split opening of the successive packing rings are to be positioned at 180°
intervals. A slight leak is desirable from the newly packed gland to allow the packing time
to bed in. Excessive tightening at this period will result in burning of the packing and
scoring of the shaft.
All these pumps utilise five rows of ¾ gland packing. The part number for the set of
packing is 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.
Gland Packing Installation

New packing rings must be installed one at a time by placing rings on the shaft and
pressing each ring all the way into the stuffing box, ensuring the ends are fitted neatly
together. Successive ring joints must be staggered around stuffing box. Pump models
with Lantern rings should have the lantern ring re-installed. Check with the pump manual
for correct positioning between the gland packing rings.
Fit gland follower to shaft and nip gland nuts up to pack gland packing. Ensure front face
of gland follower has entered the stuffing box housing. If after tightening the gland nuts
the packing has compressed enough to allow space for another ring, remove gland
follower, fit extra packing ring, re-assemble follower and nip gland nuts up again. Back
nuts off and leave finger tight until pump is started.
Figure 3:10-Packing Removal Tool
After pump has been started, the glands must be adjusted to provide reasonable leakage.
When water pressure is at a minimum the gland should leak slightly, therefore when this
pressure rises, leakage will necessarily be excessive. If the gland is adjusted to provide
optimum leakage at higher pump rpm (high pressure), insufficient leakage will occur when
the rpm falls or is less from the point of adjustment.
The gland sealing water should be as clean as possible, as large amounts of abrasive
material can quickly wear the gland components. Always maintain a very small amount of
water leakage along the shaft by regularly adjusting the gland.
As well as lubricating and cooling the gland, the water escaping from the gland also
prevents the ingress of air when the pressure at the shaft falls below atmospheric.
E.g. when a vacuum is required.

If one of the following conditions apply, air may be induced into the pump through the
gland. This may prevent the pump “picking up” its prime or cause it to loose its prime
during operation.
• Packing has insufficient tension.
• Packing is excessively worn.
• Shaft sleeve is excessively worn.
Inspection of the gland will reveal if any of the above faults are occurring.
Gland Oil Tank

The tank oil level should be checked on a regular basis. If the oil level drops at a higher
than normal rate, check the gland packing for adjustment or replacement. The Tap on the
oil feed line should be opened only on initial start up. Once primed, the tap should be
closed.
As stated before the glands are designed for water lubrication and some leakage is
necessary during operation to lubricate and cool the packing and shaft sleeve, however
the oil feed system is used to assist with lubricating the gland and shaft when the presence
of water is limited.
Gland leakage at all times must be clean and free from as much abrasive material as
possible. If there is any sign of excess slurry leaking from a gland then one of the
following must be occurring:
• Gland packing requires replacement.

• Shaft sleeve requires replacement.
• Incorrect gland adjustment.
Impeller
The performance of the pump can change with excessive clearance between the impeller
and the front wear plate/door. For best performance it may be necessary to occasionally
stop the pump and move the impeller forward. The procedure is:-
1. Loosen drive on pump shaft.

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

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.
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 assemblies run at above 85°C, then
high temperature grease should be used.
Recommended Grease for 6A PEDESTAL

Typical Properties:
• Lithium base (not containing Molybdenum or EP additives.)
• Base Oil Viscosity of 75 cST to 120 cST @ 40 degrees Celsius.
• NLGI consistency of 2 (a consistency of 3 can also be used, however it may not be
suitable for Automatic Grease Pumping Units).
Examples of this type of grease are:
1. SHELL ALVANIA RL
2. SKF LGMT 2
Figure 3:11-Manual Greasing Guide for Bare Shaft Pump

Pico Auto Grease Unit Outlet Connections and Timer Settings

Outlet Connections:
Connect the distributor block outlets to the ports on the Multiflo pumps as follows:-
• Bottom outlet stamped with ‘45’ to Pump Labyrinth

• Top and Middle outlets stamped with ‘25’ to Pump Bearings
Timer Settings:
Ensure unit is set to the following time settings:-
• Lubrication Time – 18 seconds

• Cycle time – 8 hour
Figure 3:12-Automatic Greasing guide for Bare Shaft Pump

3.4 MODEL 57 PISTON VACUUM PUMP MAINTENANCE

unit.
• Pump unit to be locked and tagged before any maintenance or service is
performed.
NOTE:
Oil level must be checked before operating the 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 of worn cylinders prior to removing
the piston. Failure to do so may result in cracked or broken piston ring lands.
The ring sets are designed to bed in on both new bores and worn bores. Honing is not
essential but it is recommended to give the optimum result. However, it is essential if one
of the following conditions are present:-
• Excessive wear;
• Bore distortion;
• Polishing or Glazing;
• Scuffing;
• Scratching.
When boring to oversize, allow sufficient honing allowance to completely remove boring
marks (0.06 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.
Poor cleaning after honing accounts for most of today’s wear out / oil consumption
problems. Petrol and kerosene are not suitable. Soap and hot water with a nylon
scrubbing brush are best. Check with a clean white cloth which should not come out grey.
Finally, swab with a light engine oil to prevent corrosion.
Always replace scuffed, cracked, worn or otherwise damaged pistons.
Always check the gap clearance of new rings in the lower unworn portion. The gap should
not be less that 0.003mm per mm of cylinder diameter.

NOTE:
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 quality ring compressor held firm against the
engine block at the time of entry of the rings into the cylinder.
Pieces Oil Ring Assembly

1. Wind on expander.
Figure 3:13-Winding on Piston Oil Ring Expander
2. Hold the expander end in place with thumb. Wind on lower rail then wind on upper rail.
Figure 3:14-Upper and Lower Rail of Expander

3. Both ends of the expander should be visible and not over lapped.
4. Align all gaps as per the diagram above (gaps must not be lined up). Check the
assembly can rotate in the groove.
5. When fitting the compression rings, make sure they are fitted the correct way up as per
the diagram on the following page.
Figure 3:15-Upper and Lower Rail Gap
6. To avoid breakage, do not wind on the compression rings.
Figure 3:16-Incorrect Fitting of Compression Rings

7. Use a ring expander or expand with the thumbs before placing in piston grooves.
Figure 3:17-Correct Expansion Method for Compression Rings
8. All rings must have clearance between the back of the ring and the back of the groove.
To check this, push the rings against the bottom of the groove on the thrust side of the
piston, then place a straight edge against the skirt of the piston. The minimum
clearance between rings and edge should be 0.3mm for compression rings and
0.15mm fir oil.
Figure 3:18-Correct Ring Back Clearance

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

prolonged idling and vary the engine speed and load. The load provides the build-up of
pressure behind the compression rings and helps them to bed in.
Sticking valves, inlet and exhaust, or both are visually evident by a popping noise
emitted from the vacuum pump exhaust, or uneven exhaust pulses or no emission from
exhaust pipe.
Remove inlet and exhaust caps from top of cylinder head. Remove valves.
Clean valves in solvent and check for broken springs, worn valve plates and faces.
Replace faulty components where necessary.
Replace copper washer between valve and valve seat in the cylinder head. Retention
mounting bolts as per specifications.
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

1. Damaged crankcase seal.
2. 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.
NOTE:
To test valves, place upside down and fill with kerosene (diesel) for one (1) minute.
Okay if fluid does not disappear.
When replacing a crankcase seal, it is to be inserted as per the diagram here.
Figure 3:19-Correct Replacement of Vacuum Pump Crank Seal
Worn Rings:
For conventional rings, the gap should be 0.1mm when assembled. Where one groove of
segmental is being used with one groove of a conventional oil ring, the latter is in the
lowest groove. The segments in the centre groove, and the compression in the upper.
Segmental rings, when fitted should be paired.
Gaps should be fitted initially over the end of the gudgeon pin alternating sides, but they
will tend to move around during operation.

The piston ring groove should have a minimum of 0.25mm clearance behind the rings.
Always rough hone a serviceable bore when fitting new rings.
Broken or Slipping Belts

Inspect and replace as necessary.
3.5 DRIVE COMPONENTS MAINTENANCE

Drive Belt Tensioning
Put the belts around the pulleys, set them to the appropriate tension value stated in the
"Tensioning Forces" Table (using the Belt Tension Indicator as shown), run the drive under
load for 30 minutes, stop the drive, check the tension, re-setting to catalogue value if
necessary. On a properly designed drive for the application there will be no need for any
further attention during the life of the drive.
1. Calculate the deflection distance in mm on a basis of 16mm (5/8”) per metre (yard) of
span. Centre Distance (m) x 16 = Deflection (mm).
2. Set the lower marker ring at the deflection distance required in mm on the lower scale.
3. Set the upper marker ring against the bottom edge of the top tube.
4. Place the belt tension indicator on top of the belt at the centre of span, and apply a
force at right angles to the belt deflecting it to the point where the lower marker ring is
level with the top of the adjacent belt.
5. Read off the force value indicated by the top edge of the upper marker ring.
6. Compare this force to the kgf value shown in the attached table.
7. If a Fenner Belt Tension Indicator is not available, a spring balance and rule will suffice.
NOTE:
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 should be satisfactory. A measured force below the lower value
indicates under-tensioning. A new drive should be tensioned to the higher value to
allow for the normal drop in tension during the running-in period. After the drive has
been running for 30 minutes, the tension should be checked and re-adjusted to the
higher value, if necessary.

Figure 3:20-Belt Tension Indicator applied to mid span
Figure 3:21-Belt Tensioning Indicator
Belt Tensioning Forces
Force required to deflect belt 16mm per metre of span

BELT SECTION
Small Pulley Newton (N) Kilogram Force (kgf)
Diameter (mm)
SPZ 56 to 95 13 to 20 1,3 to 2,0
100 to 140 20 to 25 2,0 to 2,5

Installation & Operation of Wedge & V-Belt Drives

Pulleys
Before assembling the drive, check the pulley grooves are free from scores or sharp edges and all
dimensions conform to the relevant standard. The Taper Lock Bush is the starting point when it
comes to assembly and installation. Drive installation is a straight forward job with Taper Lock, but
the stages set out on the installation leaflet provided with every Taper Lock bush should be
followed closely.
Alignment
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear. The
diagram below shows some of the common alignment faults. You should only be satisfied if the
conditions in sketch 4 prevail.
Belt Installation
When the pulleys have been correctly positioned on the shafts, the belts can be installed
to complete the drive. The drive centre distance should be reduced prior to the installation
of the belts so that they may be fitted without the use of force. Under no circumstances
must belts be forced into the grooves. Belts and pulley grooves can be easily damaged by
using sharp tools to stretch the belts over the pulley rim.
The installation allowance given in the table on the following page is the minimum
recommended reduction in centre distance for the various belt section and lengths to allow
for correct fitting. The take-up allowance given in the same table should be added on to
the calculated centre distance to allow for belt stretch.
Figure 3:22-Belt Alignment

Installation And Take-Up Allowance
Installation Allowances Take-Up (mm)

Belt
Pitch Length
(mm) SPZ
1800 20 25
Guards
When guards are necessary it is desirable to use mesh materials to permit adequate
ventilation.
Guards should be generously sized to allow for incidental belt flap.
Tensioning Pulleys
If tensioning pulleys are to be used on wedge belt drives, they must be grooved pulleys
working on the inside of the drive, preferably on the slack side.
The pulley should be positioned as close as possible to the large pulley.
Flat tensioning pulleys, bearing on the outside of the drive are permissible only with V and
not with wedge belts.
They should be positioned within one third of the centre distance from small pulley.
The tensioning pulley must have at least the same diameter as the small pulley of the
drive.
Tensioning pulley movement must allow for passing the belts over the outside diameter of
one drive pulleys on installation, and should also allow for belt stretch/bedding in.
Taper Lock Installation Instructions

To Install
1. After ensuring that the mating tapered surfaces, bore and shaft are completely clean
and free from oil or dirt, insert bush in hub so that holes line up.
2. Sparingly oil thread and point of grub screws, or thread and under head of cap screws.
Place screws loosely in holes threaded in hub, shown thus in diagram.
3. If a key is to be fitted, place it in the shaft keyway before fitting the bush.
It is essential that it is parallel key and side fitting only and has TOP CLEARANCE.
4. 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.
5. Using a hexagon wrench tighten screws gradually and alternately to torque settings
shown in the torque settings table.

6. Hammer against large end of bush using block or sleeve to prevent damage. (This will
ensure that the bush is seated squarely in the bore). Screws will now turn a little more.
Repeat this alternative hammering and screw tightening once or twice to achieve
maximum grip on the shaft.
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.
Figure 3:23-Taper Lock Installation and removal

To Remove
1. Slacken all screws by several turns, remove one or two according to number of
removal holes shown thus • in diagram. Insert screws into removal holes after oiling
thread and point of grub screws or thread and under head of cap screws.
2. Tighten screws alternately until bush is loosened in hub and assembly is free on the
shaft.
3. Remove assembly from shaft.
Taper Lock Screw Torque Setting
Bush Size 3525
Screw Tightening Torque 115Nm
Screw Qty 3
Screw Size (BSW) ½”

Screw Hex Socket Size
10
(mm)
Large End Diameter (mm) 127,0
Approximate Mass (kg) 3,8

Taper Lock Flanges
Figure 3:24-Taper Lock Flange Dimension chart
Dimensions of Fenaflex Flanges Types F & H

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

Tyre Couplings
NOTE:
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.) Locate flanges to that dimension ‘M’ is obtained. Flanges with internal
clamping rings should then have the clamping rings fitted, engaging only two or three of
the threads of the screws at this time.
3. Bring shafts into line until dimension ‘M’ is obtained (Figure 3:25 & Table 1).If shaft
end float is to occur, locate the shafts at mid-position of end float when checking
dimension ‘M’. Note that shaft ends may project beyond the faces of the flanges if
required. In this event, allow sufficient space between shaft ends for end float and mis-
alignment. Flanges should be fitted flush with the end of the shaft when used with Mill-
Motor flanges.
4. Check parallel alignment by laying a straight edge across the flanges at several
positions around the circumference. Check angular alignment by measuring gap
between flanges at several positions around the circumference. It is desirable to align
the coupling as accurately as possible, particularly on high speed applications.
5. Open out tyre and fit over coupling flanges ensuring that the tyre beads seat properly
on the flanges and/or clamping rings. To ensure proper seating, it may be necessary
to strike the outside diameter of the tyre with a small mallet. When seated, there
should be a gap between the ends of the tyre as shown in Figure 3:25 & Table 2.
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 3:25-Internal Clamp ring Torque
Table 1
Internal Clamp Ring Torque
Coupling M Screw Clamping Screw
Size mm Size Torque Nm
F140 32 M12 55
Table 2
Gap between Tyre Ends
Coupling Size F140
Tyre Gap mm 5

3.6 1000FH SERIES FUEL FILTER INSTRUCTIONS (IF FITTED)
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 Side Application:

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

1. Open the self-venting drain on the bottom of the bowl to evacuate water and
contaminants with a suitable collection container in place. Head pressure will push any
water and contaminants out of the drain while keeping the filter primed.
2. Close the drain after all the water and contaminants have been evacuated –
DO NOT leave the drain open too long as it will eventually completely drain the entire
filter assembly of water AND fuel, and possibly drain the entire tank.
Element Replacement:
Frequency of element replacement is determined by the contamination level of fuel.
Replace the elements every 10,000 miles, every 500 hours, every other oil change, when
the vacuum gauge (optional) reads between 6 to 10 inches of mercury (inHg), if power loss
is noticed, or annually, whichever comes first.
NOTE:
Always carry extra replacement elements as one tank full of excessively dirty fuel can
plug a filter.
1. Bypass filter assembly with bypass valves, if applicable.

2. Remove the ‘T’ handle and lid.
3. Remove filter by holding bail handles and slowly pulling upward with a twisting motion.
Dispose of properly.

4. Replace old lid gasket and ‘T’ handle O’ring with new seals (supplied with new
element). Lubricate both seals with motor oil or diesel fuel before installation.
5. Refer to ‘Priming Instructions”, otherwise, fill the unit with clean fuel, then replace the
lid and ‘T’ handle and tighten snugly – by hand only – do not use tools.
Figure 3:26- Element Replacement
CAUTION
1. Ensure wiring diagram is closely followed and proper safety fuse is used. If fuse should
fail, ensure cause is found and corrected prior to using heater again.
2. Prime filter assembly with fuel before applying power to heater.
NOTE:
Never power heater on until fuel is fully primed within filter.
3. During vehicle or equipment servicing always ensure power to heater is shut off to
avoid inadvertent heating of fuel in a static condition.
4. Annually, or every 12,000 miles, inspect all wiring for wear or unsafe conditions.
Inspect heater for proper operation (at temperatures above 85oF, check continuity (with
power off) across power and ground wires - current should be open - no continuity).

Figure 3:27- Racor 3-Wire Schematic Shown

Replacement Parts
Part No Description
1. RK 11-1945 T-handle and O-ring Kit
(includes A)
2. RK 11-1927-01 Lid Kit (includes B)
3.
Replacement Filter (2 Micron)
2020SM-OR
(includes A & B)

2020TM-OR
(includes A & B)
2020PM-OR
(includes A & B)
4. 12 vdc, Heater Body Feed-thru
RK 11-2002 Kit
(includes A, B, & 6)
24 vdc, Heater Body Feed-thru
RK 11-2001 Kit
(includes A, B, & 6)
5. RK 11815-103 Mounting Bracket Kit
6. Body Feed-thru Heater
RK 21067
Assembly Kit
RK 11-1679
Body Feed-thru Plug Kit
7. Conical Baffle and Turbine
RK 11-1939 CentrifugeKit (includes B, C, D,
& E)
8. RK 11-1938 See-thru Bowl with Drain and
Plug Kit (includes B, F, & 10)
9. RK 32204 Water Sensor Kit
10. RK 20126 Bowl Plug Kit
11. RK 11037A Bowl Ring (includes B & G)
G. RK 11542 Cap Screw Kit
Additional Parts (not shown)
RK 11-1952 Complete Seal Service Kit

Racor Additives
Additive Part No Size Treatment Benefits
ADT 2116 16 oz Bottle 1,280 Gallons • Concentrated formula.

• Kills bacteria & fungi.
Diesel • Prevents corrosion.
ADT 2201 1 Gallon Bottle 10,240 Gallons
Biocide
• Enhances engine
Diesel ADT 1116 16 oz Bottle 320 Gallons performance.
Conditioner
• Stabilizes the fuel.
Plus +
ADT 1201 1 Gallon Bottle 2,560 Gallons • Quieter engine operation.
• Inhibits waxing, icing &

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

3.7 ROUTINE GENERAL MAINTENANCE FREQUENCY

NOTE:
Observe for gauge leaks and general condition of the unit. If condition exists,
determine the cause and have necessary repairs made.
EVERY 10 ENGINE HOURS OR DAILY

SCHEDULE MAINTENANCE
Bare Shaft Pump Visually inspect the level in hydraulic oil tank.
Lubrication System Fill with fresh oil if required, to the bottom of the strainer.
Maintain oil level between “add” and “full” marks on the dipstick. Use
SAE15W40 or refer to Lube List.
Engine Oil
(Refer also to the Engine Manual)
Maintain level between “high” and “low” marks on the dipstick. Use
Vacuum Pump Oil SAE15W40 or refer to Lube List.
With the engine running at low idle and the transmission in Neutral,
the oil level should be maintained between the “low” and “full” marks
Transmission on the oil level gauge.
Use Mobil HD50 or refer to Lube List.
Fill to 10mm (3/8”) below filler pipe opening.

Gland Oil Tank
Use SAE15W40 or refer to Lube List.
(If fitted)
Gland Check gland leakage and adjust if required.
Coolant Level
Maintain level in range above baffle plate and filler neck.
(Engine Stopped and Cold)
Fuel Tank Fill as required.
Battery Maintain level range above plates and filler bridge.
Drive Belts Check condition and tension if required.
Water Trap Empty water trap on vacuum tank.
Discharge Check discharge pipe work for leaks.

EVERY 250 ENGINE HOURS (Perform in addition to Daily Schedule Items)

Engine Engine service as prescribed by Caterpillar.
Change the oil and filters. (Refer to Engine Manual)

Engine Oil & Filters
Change Filters. (Refer to Engine Manual)

Engine Fuel Filters RH1000
Bare Shaft Pump Lubrication Change the oil and filters.

System
Gland Check gland packing condition.
Inspect condition. Repair if necessary.

Non Return Valve
Inspect condition.
Drive Coupling Re-tension bolts and grub screws if required.
Engine Air Cleaner Element

Inspect condition. Replace if necessary.
Change the Oil.

Vacuum Pump Use SAE15W40 or refer to Lube List.
Check vacuum pump belt tension and condition.
Vacuum Tank Probes
Inspect and remove and clean the probes.
(Vactronic & Waterloss)
Check all bolts on Engine, Bare Shaft Pump and Vacuum

Mounting Bolts Pump. Tighten if necessary.
EVERY 500 ENGINE HOURSE (Perform in addition to Daily Schedule Items)
Bare Shaft Pump Lubrication

System Change filter on pump bearing lubrication circuit.
Change Filters. (Refer to Engine Manual)

Engine Fuel Filters RH1000



Bare Shaft Pump
Change oil on pump bearing lubrication circuit.
Lubrication System
Condition/Adjustment.
Bare Shaft Pump Inspection of impeller, wear plate(s), volute, and packing.
Change transmission oil and oil filter.

Transmission Refer to Transmission Manual.
Vactronic Control Check condition of wires and probes etc.

1. Clean core finning.
Radiator
2. Inspect condition of radiator hoses.
1. Test shutdown operation.
Auto Shutdown System 2. Inspect condition of wiring, hoses etc.
Non Return Valve Replace Flap if Required.

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.

3.8 PUMP UNIT TROUBLESHOOTING
The engine must not be run when disconnected from the battery!!
Doing so may damage the Vactronic Module
Figure 3:28-Vacuum Gauge Normal Operating Range

VACUUM GAUGE READINGS – BASIC FAULTS

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

collapsed.
• Suction hose collapsed • Replace suction hose.

internally.
• Suction hose stuck low • Remove suction hose from

into the mud. mud.
Low or No Reading • Air leak in the suction line. • Repair suction line.
(-20 and below)
• Discharge reflux valve not • Replace seal.
If Vacuum Pump is Operating with sealing.
Air Being Exhausted
• Air leak in vacuum line • Repair vacuum line.
from tank.
• Leaking gland packing. • Adjust gland packing.

VACUUM GAUGE READINGS – BASIC FAULTS (continued)

• Check gland packing • Change gland packing if
condition. worn or hard.
• Check the gland follower • Tighten if required to show

isn’t loose. small visual leak.
Pump wont prime. • Check suction side of the • Repair if required.
pump for vacuum leaks.
• NRV seat or flap may be • Replace seat and/or flap if

damaged (if the damaged.
discharge is still primed
the flap and seat are ok).
• Check the probe • Replace if damaged.

condition.
• Check the suction • Remove from mud if

strainer isn’t in the mud. required.
Pump keeps shutting down on
• Check the operation of • Ensure continuity between
water loss. common and normally
the flow switch.
closed terminals.
• Check the water loss • Adjust if required.

module (M2) in the
control box has the LED
on.
• Check the suction line for • Clear blockage if required.
blockage.
Prime light won’t go out.
• Check the float in the • Replace valve if required.
krundimendt valve isn’t
shut.
• Check the hydraulic oil • Fill hydraulic oil tank if
tank level. required.
Pump oil pressure light is on • Check and replace the • Replace hydraulic filter if
with the engine shut down. filter. required.
• Check the switch for • Check switch.
operation.
• Check the plug at the • Check plug is correctly
switch under the vacuum inserted in switch.
Low fuel light is on with the tank.
engine shut down (presuming • Remove the float from the • Replace float if damaged.
there is enough fuel). tank and see if the float
floats.
• Check the switch for • Check switch.
operation.

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

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

• Emergency stop may be • Ensure emergency stop is
Engine won’t crank.
pushed. in out position.
• Remove the R5 relay and
run the engine:-
1. If the fault is now 1. Test the Pico for the

gone, the Multiflo side correct outputs.
Engine shuts down with no
diagnostic lights on. of the electrics has
the fault.
2. Refer to the Cat
2. If the fault is still
manual or a Cat
there, the problem is
Representative.
in the Cat side of the
electrics.
Faulty Vacuum Pump

1. Sticking inlet or exhaust valves.
2. Worn rings.
3. Broken crankshaft.
4. Blown head gasket.
5. Blocked exhaust pipe.
6. Broken belts.
Pump Primes but Fails to Deliver Water or Delivers at a Reduced Rate

1. Foreign materials lodged in the impeller.
2. Low bare shaft pump RPM (1400 RPM maximum).
3. Obstruction in discharge hose.

4. Partial obstruction in suction hose, strainer or vacuum tank.

5. Obstruction in non-return valve.
6. Air leak in suction system.
7. Worn pump components.
8. Collapsed suction hose.
9. Pump located too high above water being pumped.
Pump Overloads Engine

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

SYMPTOM REMEDY
Generally caused by shortage of belt tension but excessive
Small cracks on ‘V’ Belt side heat and/or chemical fumes can also give same failure.
and base.
Caused by excessive contamination by oil, certain cutting

‘V’ Belt swelling or softening. fluids or rubber solvent.
Usually caused by incorrect tensioning, principally on long

centre drives. If a slightly higher (or lower) tension does not
Whipping during running. cure the problem there may be a critical vibration frequency
in the system which requires re-design or a Banded belt.
Hydrau-Flo Valve Troubleshooting
Fuel nozzle shutting off • Nozzle or receiver spring • Check condition and rating
prematurely. setting too low. of spring, replace if
• Back pressure in filler necessary.
pipe too high. • Ensure there is no
excessive restriction in the
flow of fuel from the
• Breather blocked. Hydrau-Flo to the tank.
• Check and clean or
• Float valve set too low in replace if necessary.
tank. • Adjust to desired fill height.
• Restriction in capillary
line • Check line for damage,
kinks, or crushing.
Replace if necessary
Fuel nozzle not shutting off. • Float valve not closing • Check operation of float
capillary line. ensuring it does not hit
internal walls of fuel tank.
Check valve seat for
damage or obstruction.
• Piston stuck open. • Check piston operation is
smooth and unrestricted.
• Leakage in capillary line. • Check line and fittings for
leaks or damage.
• Float lever set above • Lower float lever below
breather height. height of breather.
Fuel weeping from breather Float level set too high, not Lower float level setting.
after tank has been filled. allowing enough air space for
fuel expansion due to rise in
temperature.
Bare Shaft Pump Lubrication Oil Troubleshooting
Low pressure/flow at bearings. • Blocked filter. • Change filter.

Check pressure relief
settings.
• Blocked orifice. • Remove fittings from

distribution block and
check for debris.
• Worn hydraulic pump. • Dead head the pump and

check the pressure.
Engine shuts down on low • Faulty switch. • Remove switch and check
pump oil pressure. for open circuit. Replace if
it is faulty.
• Blocked suction filter. • Remove filter from the tank

and inspect. Fill reservoir
with Delvac 1330 Oil.
• Low oil. • Remove pump from the

engine remove the back
plate and inspect pump
components for wear.
• Pump failure. • Check drive rotation in the

engine.
Turbine Series 1000HF Fuel Filter / Water Separator Troubleshooting (If

Fitted)
NOTE:
Correct external fuel leaks immediately! These conditions will result in reduced engine
performance such as: hard starting, stalling, reduced power, and other associated
problems.
New filter installations must be filled with fuel and fuel system must be adequately primed
following the engine manufacturer’s recommendations, if applicable.
Existing installation difficulties are usually associated with improper priming procedures or
damage to the unit or fuel system. The result is either internal air suction or external fuel
leakage.
Diagnosis should be in these following steps:
1. Check fuel tank level and make sure any fuel delivery valves are in open position, as
applicable.
2. Ensure T-handle, bowl fasteners, and fuel fittings are tight. Also verify that bowl drain is
closed.
3. If filter is new, check potential restriction at fuel tank draw tube. An in-tank strainer may
be plugged.
Correct Application
It is very important that filter is not ‘under specified’ for the application. The maximum fuel
flow rating of filter must not be exceeded and engine manufactures maximum fuel inlet
restriction, must not be exceeded. Doing so will reduce efficiency and de-gas (pull air from)
fuel.
Filter
Replacement filters are available in 2, 10, and 30 micron ratings. Filtration needs are
based on application, fuel quality, maintenance schedules, and operating climates. A
simple rule to remember is - the finer the filtration, the more frequent the filter change.
Always carry extra replacement filters with your equipment as one tankful of excessively
contaminated fuel can plug a filter. When clogged to the maximum capacity, filters will
have a brown to black color or tar like contaminants may be present - this is normal. An
appearance of a multi-colored slime (which may have a foul odor) is an indication of
microbiological contamination. This condition must be treated immediately.
Severe conditions must be corrected by a repair facility.
NOTE:
Never operate Racor unit without the filter in place - the 'filter safety valve' will not
expose outlet hole on fuel return tube if filter is removed and fuel will not flow to engine.
Instead, punch emergency tab on the top of filter and leave in place. Puncturing
emergency tab will bypass all filtration and send unfiltered fuel to your engine. Service
filter as soon as possible to avoid harmful contaminants flowing downstream to engine.
Water Sensors
This feature alerts operator of a high-water condition. The bowl is then drained of water at
earliest convenience. Note - a Racor water detection module is needed to work with the in-
bowl sensor. The unit should activate when water reaches sensor tips (and when they
measure between 47,000 and 100,000 ohms of resistance, depending on detection
module used.) If not, tips may be fouled with a coating. Remove water sensor and clean
tips with a cloth. Run a jumper wire between tips with ignition ON to test system.
Difficulties usually lie in the wire connections, power source, or an independent ground.
Heaters
In-filter heaters are starting aids, but may be left on during cold operations to continue to
supply heat. The 300 watt heater is an extremely reliable option, but MUST be powered
via a relay switch due to initial amperage surge at start-up: 25 amps at 12 vdc and 12.5
amps at 24 vdc. They do not activate unless the fuel is below 50°F (10°C) and
automatically deactivate at 80°F (28°C).
Heater Testing
Heaters can only be tested when the thermostat is closed (fuel temperature is below 50°F
or 10°C) . With a ampmeter attached to external wiring, and engine off, amperage should
increase when heater is switched on. (Option - remove heater and place it in a freezer until
the temperature is under 50°F (10°C). Remove heater and repeat the above test).
All Racor FH filter assemblies are 100% tested to ensure a leak-proof, quality
product.
NOTE:
Correct external fuel leaks immediately! In the event difficulties are experienced with
your filter assembly or a problem appears to prevent the engine from running smoothly,
refer to the procedures on the previous page.
- Apply Parker Super O-lube (part number RK 31605) or equivalent to all seals at major
attachment points to maintain integrity, seal elasticity, to fill small voids, and to provide
protection from degradation.
Perform all checks with engine OFF (and applicable valves closed). For replacement
parts, refer to the Replacement Parts section of this manual.
Damaged, worn, or dirty seals will allow air ingestion. Inspect and replace all seals as
needed. Clean the sealing surfaces of dirt or debris every time the filter is replaced.
3.9 LUBRICANTS
Grades and Frequency of Lubrication

Maximum
Item Recommended Lubricant Frequency
Capacity
C13 Engine Oil

Mobil Delvac MX 15W40 Checked Daily 40 litres
Shell Rimula 15W40
Engine Turbo
Saviour Mobil Delvac MX 15W40 Upon Installation
(If fitted) Shell Rimula 15W40
Model 57 Piston Mobil Delvac MX15W40 Checked Daily 2.2 litres

Vacuum Pump Oil SAE15W40
Multiflo Pump Grease Check Automatic Unit

Bare Shaft Pump
Shell Alvania RL2 Grease Grease Level Weekly 1.2 Kg
Bearing Assembly SKF LGMT 2 ( If fitted)
PART 4. SPARE PARTS
Parts Manual MF-385G SS – Jan 2011 ©Copyright Weir Minerals Multiflo 107
MF-385G SS MAJOR COMPONENTS
ITEM DESCRIPTION PART NUMBER QTY

1 BARE SHAFT PUMP 385GSS 1
2 CATERPILLAR C13 CAC13-415HP 1
3 VACUUM TANK VT0385Z0002 1
MF-385G SS PEDESTAL ASSEMBLY

1 PEDESTAL 6A-01A 1
2 GREASE NIPPLE 5AA-07 3
3 PLUG 6A-12A 1
4 O'RING 6A-29 2
5 GLAND FOLLOWER 6A-32SS 1
6 STUD & NUT KIT 6A-34SS 1
7 STUFFING BOX 6A-30SS 1
8 PACKING KIT 6A-33 1
9 O'RING 6A-31 1
MF-385G SS BEARING ASSEMBLY

1 SHAFT 6A-02 1
2 END CAP 6A-14A 1
3 BEARING 6A-10A 2
4 BOLT 6A-03 12
5 BEARING 6A-13A 1
6 LIP SEAL 6A-11H 2
7 SEAL 6A-05 1
8 SHAFT LOCK NUT 6A-08 1
9 O'RING 6A-17 1
10 SLINGER C/W O'RING 6A-16 1
11 O'RING (BEARING CAP) 6A-06 2
12 SEAL 6A-15 1
13 BOLT LOCK TAB 6A-20 6
14 GASKET 6A-21 2
15 BEARING CAP 6A-04A 1
16 SHAFT SLEEVE 6A-28 1
16
MF-385G SS WETTED PARTS

1 VOLUTE 380-67SS 1
2 BOLT 6A-35 8
3 IMPELLER 385-69 1
4 WEAR PLATE 380-72SS 1
5 O'RING 380-73 1
6 SHIM (.55MM) 380-55 A/R
7 SHIM (1MM) 380-56 A/R
8 SUCTION COVER PLATE 380-70SS 1
9 O'RING 380-74 1
PRIMING ASSEMBLY

1 VACCUM TANK VT385Z0002
2 KRUNDIMENT VALVE VT2002-02 1
3 WATER TRAP 200-0345 1
4 O-RING 200-0345-V 1
5 SIGHT GLASS SGA-16 1
6 FILLER / BREATHER VT99-002 1
7 VALVE NEEDLE 200-0354-38 1
8 CHECK VALVE SS (NOT SHOWN) VT2004-03 1
9 PROBES VT2002-01 2
VACUUM PUMP MODEL 57

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

1 REAR BEARING CAP MVP150-242 1
3 BEARING SUPPORTER MVP150-245 2
4 BOLT BLTM06020 12
5 DIPSTICK COVER PLATE MVP150-254DA 1
6 CRANK CASE MVP150-220 1
7 STUD MVP150-265 6
9 INSPECTION PLATE MVP150-219 1
10 DIPSTICK c/w O'RING MVP150-252 1
12 CRANKSHAFT MVP150-247 1
13 BEARING MVP150-239 2
14 SHAFT KEY MVP150-235 1
15 BOLT BLTM10025 4
16 FRONT BEARING CAP MVP150-240 1
17 OIL SEAL MVP150-238 2
18 BOLT BLTM10025 16
19 O'RING MVP150-253 1
VACCUM PUMP-CYLINDER BLOCK GROUP

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

1 DISCHARGE VALVE MVP150-213 2
2 DISCHARGE CAGE MVP150-212 2
3 DISCHARGE TRIANGLE MVP150-210 2
5 PUSH BOLT MVP150-208 2
6 CAP NUT MVP150-207 2
7 BLIND NUT MVP150-277 2
9 HEAD MVP150-214 1
10 BOLT BLTM10030 12
11 BOLT BLTM08035 4
12 PLUG BSPP 1-8GM 2
13 DIAMOND MVP150-201 2
15 INLET TRIANGLE MVP150-204 2
16 O'RING (NOT SHOWN) MVP150-203 2
17 INLET VALVE MVP150-205 2
VACUUM PUMP CLUTCH

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

1 MOUNTING PLATE MVP150-288 1
2 ADJUSTING BOLT MVP150-283 1
3 NUT MVP150-284 1
DRIVE ASSEMMBLY

1 STUBSHAFT SS-SAE14-2.75 1
2 KEY (STUBSHAFT) KS1/2x3/4-150 1
3 DRIVER PULLEY P2SPZ112-2.75 1
4 DRIVEN PULLEY P3SPZ300-110 1
5 ROBATIC CLUTCH ASSEMBLY 540-140-700-24 1
6 BELTS VB1800SPZ 2
7 FENAFLEX COUPLING F F140F 1
8 ELEMENT TYRE F140ST 1
9 FENAFLEX COUPLING H F140H 1
10 TAPERLOCK BUSH TL3525-2 3/4 2
11 COUPLING GUARD (5 PIECE) MCD385A003 1
12 KEY (BARE SHAFT PUMP) 6A-18 1
VACUUM PRESSURE GAUGE

1 VACUUM PRESSURE GAUGE 200-0365PM 1
BATTERY BOX

1 BATTERY BOX BB24V6B-01 1
2 BATTERY BATCENTN200 2
3 BATTERY HOLD DOWN BRACKET MSE000N004 1
4 BATTERY BOX STRUT (NOT SHOWN) BB24V6B-03 1
5 BATTERY MAT BM1 2
6 BATTERY HOLD DOWN TIE MGBHD 2
BATTERY ISOLATORS

1 BATTERY LOCKOUT LS11003-01 1
2 STARTER LOCKOUT (IF FITTED) LS11003-02 1
3 ISOLATOR 341003004 A/R
CONTROL BOX OUTSIDE

1 CONTROL BOX (BARE) EL0000Z0002 1
2 'FIRST OUT PANEL' EL0000Z0005 1
3 KEYED CHROME T HANDLE 2535000 1
4 SWITCH 8D-2676 2
5 CONTROL BOX MOUNTING BOLT BLTM08050G4.6 4
6 MOUNT PART A CBM-01-01 4
7 MOUNT PART B CBM-01-02 4
8 WASHER CBM-01-04 8
9 NUT BLTMNN08G 4
10 SLEEVE CBM-01-03-30 4
11 LOCKING KIT (NOT SHOWN) 10009989 1
12 ROTATIONAL SWITCH EL0000Z0023 1
CONTROL BOX INSIDE

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

1 FUSE HOLDER 5442BL A/R
2 FUSE (1AMP) 302-9219-01AMP A/R
3 FUSE (2AMP) 302-9219-02AMP A/R
4 FUSE (4AMP) 302-9219-04AMP A/R
5 FUSE (5AMP) 302-9219-05AMP A/R
6 FUSE (10AMP) 302-9219-10AMP A/R
7 FUSE (15AMP) 302-9219-15AMP A/R

1 CIRCUIT BREAKER (2AMP) CB-02K A/R

1 RELAY CHANGEOVER R24VCOAS-01 A/R
2 RELAY BLOCK H4973 A/R

1 C.B. BOX RS282-1152M 1
EMERGENCY STOP AND FIRE EXTINGUISHER

1 EMERGENCY STOP ES-03-01 1
NC CONTACT (IF REQUIRED) ES-03-02 1
2 MOUNTING PLATE FEP-1 1
3 FIRE EXTINGUISHER FEQ9KGC-70 1
4 MOUNTING BRACKET FEHDVMBC9KG 1
HYDRAU-FLO

1 WIGGINS RECEIVER + CAP ZNC2A 1
2 VALVE ASSEMBLY HF1105Z0001 1
3 ELBOW HFS20-090904 2
4 HOSE HH1J061062J06-3500 1
5 HOSE HH1J061062J06-1410 1
6 MOUNTING PLATE HF1012Z0003 2
7 ELBOW HFS8-0409 2
8 FLOAT ASSEMBLY HF1007Z0001 2
HIGH WALL FUEL FILLER

1 ELBOW HFS49-0804 1
2 NIPPLE HFS27-1208 1
3 HOSE (INCLUDE CRIMP-ON FITTINGS) 102822 1
4 MOUNTING PLATE HF1012Z0003 1
5 O'RING HF1012Z0004 1
6 FLOAT LOCK NUT HF1014Z0003 1
7 FLOAT HF1007Z0003 1
8 PLUG HFS64-12 1
FUEL FLOAT SWITCH ASSEMBLY

1 LOW FUEL FLOAT SWITCH ASSEMBLY EL0420Z0003 1
FUEL FILLERS

1 VALVE ASSEMBLY BLACK HF1105Z0001 1
2 RECEIVER FUEL BANLAW HF1113Z0003 1
3 ALUMINIUM CAP (NOT SHOWN) AUS23C-R 1
4 FUEL GAUGE 62200-A-250 1
5 KAMLOCK DUST CAP KL50-DC 1
6 KANLOCK PART A KL50-A 1
FUEL FILTERS / WATER SEPARATOR

1 RACOR 1000 FUEL FILTER 1000FH2 1
2 REPLACEMENT ELEMENTS 2020SM-OR A/R
FUEL BREATHER

1 BREATHER FUEL CELL UCSAB7101 1
AUTO-GREASING UNIT

1 GREASING PUMP ( SUIT 6A FRAME) MFAGU-01-0124V-6A 1
COMPLETE KIT MFAGU-01-6A-24K
AUTO-GREASING UNIT (CONTINUED)

1 DIVIDER BLOCK MFAGU-01-02-6A 1
2 HOSE END SLEEVE MFAGU-01-07 1
3 GREASE FILLED HOSE MFAGU-01-03 1
4 HOSE END STUD MFAGU-01-08 1
5 ELBOW MFAGU-01-06 1
6 TUBE MFAGU-01-04 A/R
SUCTION ASSEMBLY

1 BOOM C/W PULLEY MFB5.8 1
2 BOOM CHAINS CHB80ZP13-05000 1
3 WINCH (INCLUDES GUARD) F11620C 1
4 SPREADER BAR H200JSB-4000 1
5 SUCTION HOSE H20002205.8JL 1
6 STRAINER MFS200-40SS 1
7 WIRE ROPE WR10-16SASA 1
8 HAMMERLOK HL13 1
9 D SHACKLE DS-S-13 4
DISCHARGE ASSEMBLY (OPTION 1 – IF FITTED)

1 ONYX RING MSF150-K04 1
SPACER ONYX RING 205973 1
2 PIPE ASSEMBLY D200623 1
3 GASKET GTE150C3BA 1
4 NON RETURN VALVE NRV150-01SS 1
5 GASKET GTE150C3BA 1
6 PLUG BSPP1-0SS 1
7 PIPE ASSEMBLY D207241 1
8 LOW FLOW SWITCH TWS26SS-100 1
9 DISCHARGE PIPE BRACKET 102239 1
10 SPOOL D200990 1
11 VALVE 200358 1
12 ELBOW NRV150-23SS 1
13 GATE VALVE NRV150-22SS 1
14 NIPPLE NRV150-21SS 1
DISCHARGE ASSEMBLY (OPTION 2 – IF FITTED)

1 DISCHARGE ASSEMBLY A D209751 1
2 DISCHARGE ASSEMBLY B D207929 1
3 DISCHARGE ASSEMBLY C D200623 1
4 NON RETURN VALVE 150NB 316SS NRV150-01SS 1
5 GASKET 150NB TABLE E GTE150C3BA 3
6 PIPE SUPPORT D202055 2
7 PLUG BSPP1-0SS 1
8 ONYX RING SPACER 150mm 205973 1
9 PLUG BSPP-0SS 1
10 ELBOW NRV150-23SS 1
11 GATE VALVE NRV150-22SS 1
12 NIPPLE NRV150-21SS 1
NON- RETURN VALVE (STAINLESS STEEL)

COMPLETE VALVE NRV150-01SS 1
1 BODY NRV150-02SS 1
2 O'RING NRV150-03 1
3 DOWEL PIN NRV150-24 1
4 STUD NRV150-17 8
5 GASKET NRV150-20 1
6 INSPECTION LID NRV150-13 1
7 BAR, FIXING NRV150-07 1
8 STUD NRV150-19 3
9 STUD NRV150-18 16
10 FLAP NRV150-06HT 1
11 SEAT NRV150-04SS 1
12 NYLOC NUT NRV150-08 3
13 WASHER NRV150-14 8
14 NUT NRV150-15 8
Accompanying Manual MF-385G SS – Jan 2011 ©Copyright Weir Minerals Multiflo 141
WORK LIGHT AND STROBE LIGHT

1 AMBER STROBE LIGHT (OPTIONAL) PRE3414SL 1
2 BLUE STROBE LIGHT (OPTIONAL) BR95QBS 1
3 LIGHT BODY 9150901 6
4 LIGHT BEAM (24 VOLTS) 1096 6
HIGH LIFT SKID (OPTIONAL)

1 HI-LIFT SKID CHASSIS MSK000N001-16 1
2 MESH WA0000Z0001 1
TOW CHAINS (OPTIONAL)

1 HAMMERLOCK HL16 4
2 TOW CHAINS SAC16-3 2
3 LARGE MULTIHEAD LINK LMHL16 (NOT SHOWN) 1
BACKSAVER CRANE (OPTIONAL)

1 BACKSAVER CRANE S350-F19001 1
PONTOON (OPTIONAL)

1 PONTOON MF-P18T-SA 1
PART 5. ACCOMPANYING MANUALS
Accompanying Manual MF-385G SS – Jan 2011 ©Copyright Weir Minerals Multiflo 147
APPENDIX 1
WEIR MINERALS MULTIFLO

BARE SHAFT PUMP AUTO GREASING
OPERATING & MAINTENANCE INSTRUCTIONS

OUTLET CONNECTIONS & TIMER SETTINGS
TO SUIT PUMP UNIT MODELS
360, 380 & 385
(6A PEDESTAL)
PICO AUTO GREASE UNIT

OUTLET CONNECTIONS AND TIMER SETTINGS FOR
MULTIFLO MODELS 360, 380 AND 385 PUMPS
Outlet Connections
Connect the distributor block outlets to the ports on the Multiflo pumps as follows:-
• Outlet stamped with '45' to pump labyrinth
• Outlets stamped with '25' to pump bearings
Timer Settings
Ensure unit is set to the following time settings:-
• Lubrication Time – 18 seconds
• Cycle time – 8 hours
(1/2 gram)
25
(1/2 gram)
25
(1 gram)
45
Revision 2 - April 2002
(Always quote Model and Serial Number of Unit when Ordering Parts)
Central Lubrication System for
Commercial Vehicles
Operating instructions
for the central lubrication pump
PICO with integral controller S-EP 4
BAL2185.X.X.X.200 0201GB
Page
List of contents 2
1. System`s assembly groups, pump sizes 3

2. Technical data 4
3. Adjusting the integral controller 4-5
4. How the system functions 6-7
5. Lubricants 7
6. Filling the pump 8-9
7. Bleeding the system 10
8. Pump order codes 11
9. Installation instructions for the pump elements 12
10. Description of the PE-120F / PE-120FV pump elements 13-15
2 11. Description of the PE-5 / 10/15/25/50 pump elements 16-17

12. Order codes of the PE-5 / 10/15/25/50 pump elements 18
13. Function check 19
14. System maintenance and care 19
15. Warranty 19
16. Spare parts and Spare parts list 20-21
17. Troubleshooting 22-23
18. For your notes 23
1. System`s assembly groups:
1. BEKA-MAX - Grease-lubrication pump typ PICO with 1,2 kg grease container.
2. BEKA-MAX - progressive distributors MX-F
3. Main and secondary tubes
4. Installation materials and fixings
5. Pump integral controller S-EP 4
Scale drawing:
Top view
Front view rotated by 90°
3
ø 128 ±1
ca. 148
4
35
40
80 ±1
ca. 135
ca.
2 3
1
5
6
185 ±2
7
ca.259
150 ±0,5
171 ±1,5
9
35 ±0,5
10
76 ±1
157± 2
39 ±2
9,5 ± 0,4
242 ±2 Pressure
111 ±1
connection Ø6
124 ±1
Nr. 1 to 10 = outletposition
2. Technical data:
Operating temperature: -25°C to +70°C
Lubricant: Consistency class 2 greases
Number of outlets: Pump elements PE-120F + PE-120 VF:max. 2
Pump elements PE-5 / 10/15/25/50:max. 8
Output outlet max.:
pump elements PE 120F PE 120FV PE 5 PE 10 PE 15 PE 25 PE 50
cm³ / stroke 0,12 max. 0,12 0,005 0,01 0,015 0,025 0,05
cm³ / min. 1,8 max. 1,8 0,075 0,15 0,225 0,375 0,75
Direction of rotation: clockwise

Installation location: Normal type: container vertical
(See conversion instruction No.: 2158....0999D)
Protective class: IP 65
Drive type: 12 V or 24 V DC n = 15 rpm
Power consuption at 280 bar counter pressure: 3,8 A
Container size: 1,2 kg
4
3. Integral Controller
Technical data:
Supply voltage: 10 - 30 V
Max power load: I = 6,0 A
Signal lamp output: I = 0,4 A
Temperature range: -25°C to +75°C
Protection rating: IP 65
Setting the delay and lubrication times:

1. Remove red frame on pump`s motor housing, using a flat screwdriver, unscrew 4 Phillips
screws and remove transparent cover.
2. Set the delay (off) and lubrication (on) times to required periods with the two catch switches.
3. Ensure that transparent cover and red frame ae replaced to avoid water ingress. Failure to do
so will invalidate warranty.
Setting the cycle / lubrication time:
Red Button for additional lubrication on

the motor housing
PICO-Controller S-EP 4
Time of Lubrication (1-16 min)
Cycletime (0,5-8 h)
1 0,5
LED red
LED green
16 8
Standby1.5 sec. 1,5 sec.

Standby (green)
Until lubricant container
is refilled
Lubricant level error (red)
During whole lubrication
Lubricating active (green) 5

0,5 1
Cycletime:
0,5 h to 8 h
1 min.to 30 min. 8 30
Time of Lubrication:
1 2
1 min. to 16 min.
2 sec. to 32 sec.
16 32
Terminal diagram: lamp

- Lamp malfunction (for example grease level) colour of cable
red (No. 4)
- +
lamp
- lamp lubrication colour of cable green (No. 3) -
2
+
3
- Mass, terminal 31, colour of cable brown (No. 2) button

7
Intermediate Lubrication, colour of cable orange (yellow/green)

4
+
6
5
+ Ub ignition, terminal15, colour of cable black (1)
(...) = Cable No. for single-coloured cables
Connecting the illuminated button:

4
Pin 6: ZS, orange (yellow/green)
N P
PIN 5: +Ub terminal 15, black (cable 1)
3
PIN 1: ->, green (cable 3)
(...) = Cable No. for single-coloured cables

4. How the system functions:
The PICO central lubricating pump is a combination of progressive system and multi-routing
system, which can supply NLG class 2 grease. Progressive means that the lubrication points in the
central system are lubricated in sequence. The sequential lubrication means that a pressure relief
valve can easily monitor the progressive central lubrication system. If a lubrication point were to
take no grease from the distributor, the progressive distributor would block and a pressure of 280
bars would build up in the central lubrication system. If the system blocks in spite of the fact that the
electric pump is working properly, the lubricant will be discharged through the pressure relief valve
on the PE-120F/PE-120 VF pump element. This is to make the system safe and for monitoring
purposes.On deployment of the multi-routing system, the pump elements PE 5 to 50 supply directly
to the point of lubrication or serve as an extension.
6
The design of the BEKA-MAX grease-lubrication
system:
The PICO electric piston pump can be fitted with two types of pump element. The pump conveys the
lubricant via the PE-120 F and the PE-120 VF pump elements to the main progressive distributor.
The distributor is responsible for distributin the grease to the progressive sub-distributors at the
correct ratio. The lower progressive distributor then releases the grease to the individual points of
lubrication. The PE-5 /10/15/25/50 pump elements deliver the grease to the individual lubrication
points. The cycle (interruption) and lubricating duration of the pump is controlled by the S-EP 4
integrated automatic controller. (See pages 4 and 5).
Installation example:
Pump element
PE-5 bzw. 10/15/25/50
Centralised lubrication direct to the lubrication
pump PICO points
Pump
element
PE-120F
direct to the lubrication

points
to the to the
lubrication lubrication
points points
Secondary
distributor 7
Main
distributor
to the to the
lubrication lubrication
points points
to the
lubrication Secondary
points distributor
5. Lubricants:
The system has been designed to use commercially available multi-purpose NLGI-Cl.2 greases for
summer and winter use.
- Greases with high-pressure additives (EP greases)
- Preferably use lithium-based greases.
- Only use greases with the same base soap
- Lubricants with solids may not be used. (Lubricants such as graphite or MoS2 in inquiry.)
- Also refer to the vehicle manufacturer`s instructions when selecting the type of grease to be
used.
6. Filling the pump:
The PICO central lubrication pump is filled with a normal grease gun (lever-type hand gun) connec-
ted to the filling nipple on the pump housing.A rapid filling coupling with barrel pump is also optional-
ly available.
Attention: It is important to keep everything clean when filling! Do not fill the pump above the max.
Grease level as otherwise the overfilling protection device will trigger and discharge grease.
a) Standard filling through the conical lubricant nipple with a

8 manual or pneumatic grease gun.
Refill lubricant nipple

b) Refilling through refill coupling
Remove lubricant nipple replace

grease, Computer No. 2159 0061
012, via coupling holes
c) Filling via fill gun

For simple and safe filling of the grease container, we have developed the PICO FILL filling
set. On the PICO FILL the filling connection and the fill gun are enclosed together. Computer
No. 208103027 9
Fill connection level with non-return valve Detach fastening screw

Computer No. 21520152 and screw on fill connection
Fill gun
Computer No. 208103026
To refill: unscrew the dust cap from the fill connection and fully attach the fill gun port to the
filling connection. Squeeze grease until maximum fill level attained.
7. Ventilating the System
Should the grease level switch not be functioning and the pump
has been running completely empty, it may be necessary to
ventilate the system. This is done as follows:
1. Refill the pump via the lubricating nipple until the grease piston
is about 4cm above the support.
2. Unscrew main pipe to pump outlet.
3. Remove pump elements PE-120F/PE-120VF or fastening

screw (M20x1.5) and leave open until grease flows out without
bubbles.
4. Replace pump element or fastening screw.
10 5. Initiate additional lubricating impulse until lubricant flows from

pump outlet without bubbles.
6. Re-attach main pipe.
7. Initiate additional lubricating process..

8. Order Code:
Order example:
Type No.: 2185 . 1 . 1 . 1 . 2 . Z . 0000
Motor voltage 12 V 24 V
Code 1 2
Pump Outlet position

element 1 2 4+10 without
PE-120 F 1 2 3
PE-120 FV 4 5 6
PE-120 F + X 7 0
PE-120 FV X 11
PE-120 F + X 8
PE-120 FV X
Container size 1,2 kg

Code 1
Control with
Code 2
Cycle time 0,5 h - 8 h 0,5 h - 8 h

Lubrication time 1 min. - 16 min. 2 sec. - 32 sec.
Code Z W
Special design 0000

Attention: PE-5/10/15/25/50 pump elements must be ordered separately
(see Page 16).
9. Installation of Pump Elements
Pump elements PE-120F or PE-120VF can be mounted in outlet positions 4 and 10. Pump
elements PE-5 or 10/15/ 25/50 can be attached in outlet positions 1 to 3 and 5 to 9. A
maximum of 10 pump elements can be installed. The choice of installation position is fully
optional.
- The pump should not be running during mounting and demounting of pump elements.
- Remove the fastening screw from the desired threaded hole. Ensure washer is present.
- Screw in pump element.
- Tighten pump element.
- Proceed in reverse order when demounting pump elements.
- Once a pump element is attached, start test run to check if pump turns and supplies
grease.
- Grease without bubbles should flow from the pump outlet at each evolution
(See also “ventilating the system” on page 8).
12
blanking screw M14x1

blanking screw
M20x1,5
(PE 120F already attached)
(PE 5 already attached)

10. Description of the PE-120F und PE-120FV
Pump Elements:
Pump element PE-120 F
Set excess pressure valve to 280 bar
13
M 20 x 1,5
SW 24
6 mm diameter
tube connection
Technical Data:
Supply quantity: 0,12 cm³ /stroke
Order- / EDV-No.: 2185.99061.0000

Pump element PE-120 FV
(adjustable output)
Set excess pressure valve to 280 bar
SW 24
2
M 20 x 1,5
3
14 6 mm diameter
tube connection
1. On the pump element PE-120FV the quantity supplied is adjustable and comes into use
with trailers and appendages, since the pumping duration is the breaking duration, the
amount of lubricant can be re.duced in cases of excess lubricating.
2. This permits one pump unit to feed lubrication systems of different sizes, by virtue of its
adjustability
Specification:
- All pump elements are pre-set in the factory to maximum stroke capacity
- Element with 6 mm piston diameter
- Maximum output 0,12 cm³ with full stroke
- Reduction in output 0,013 cc per set position (180°)
Regulation of output:
- Remove plug (2) using an allen key ( 5 mm).
- Use a screwdriver to adjust set screw (3).
- Clockwise rotation will reduce the output.
- Anti-clockwise rotation will increase the output
- The maximum travel of the set screw is 2,4 mm = 6 set positions
- One rotation of the set screw 0,8 mm = 2 set positions
- Replace and tighten blanking plug (2) including the washer.
Technical data:
Supply quantity: from 0.04 to 0.12 cm³ / stroke
Regulating supply quantity: 6 fold grating every ½
Revolution reduction: 0.013 cm³ per grate
Medium supplied:
Order/Computer No.:
grease up to NLGI class 2
2185.99063.0000
15
Supply quantity: (cm³)

0,12
0,11
0,10
0,09
0,08
0,07
0,06
0,05
0,04
0,03
0,02
0,01
0
0 1 2 3 4 5 6 set positions
0 0,5 1 1,5 2,0 2,5 3,0 rotations
11. Description of the PE - 5/10/15/25/50
Pump Elements:
Up to eight PE-5/10/15/25/50 pump elements can be fitted to the PICO electric pump. These are
connected directly to the lubrication points with a polyamide tube (four millimetres in diameter x
0.85 semi-rigid, or six millimetres in diameter x 1.5, semi-rigid). The pump should be fitted in
such a way that the individual tubes are no longer than eight metres.
The PE-5/10/15/25/50 pump elements are available with five different outputs per stroke:
PE- 5 = 5 mm³/stroke;
PE-10 = 10 mm³/stroke;
The PE-5/10/15/25/50 pump elements are also available with five different connectors:
16
With 6 mm diamter tube connector

with union screw and double conical ring:
tube connection
6 mm diamter
22
With M10x1 thread:
M10x1
With straigt plug connector for
6 mm diameter tube:
Plug connector Ø6
16,7
Plug connector Ø6
17
25,2
With 90° plug connector
for 6 mm diameter tube:
17
With 4 mm diameter tube connctor with union

screw and double conical ring.
tube connection
4 mm diameter
21
12. Order code:
for pump elements PE-5/10/15/25/50:
Type No.: 2154 . 9000 . 01
Conveyed
Designation quantity/stroke
PE-5 5 mm³ 9001
PE-10 10 mm³ 9002
PE-15 15 mm³ 9003
18 PE-25 25 mm³ 9000
PE-50 50 mm³ 9010
Connection description
Thread connection M10x1 00

Tube connection,6 mm diameter
with ÜS6 and DKR6
01
Straight plug connector for 6 mm tube 02

90° connector for 6 mm tube 03
Tube connector, 4 mm diameter with 04
ÜS4 and DKR4
Attention: The PE-5 /10/15/25/50 pump elements must be ordered separately!

13. Function check:
To check the function, trigger as many lubrication pulses as necessary until lubricant is discharged
from all connected lubricationpoints.
When the system is blocked, but according to the functions of the PICO central lubricating pump,
the lubricant escapes from the upper pressure valve on pump elements PE-120F or PE-120 VF.
This serves as a safety and regulation mechanism
14. System maintenance and care:

In the first weeks after commissioning, the system should be checked frequently at the following points::
- Check for sufficient lubricant at the bearings - grease collar (depending

on the type of bearing and application condidtions)
- Check tubes (lubrication points, loose tubes, leaks) 19

- All BEKA-MAX - components are maintenance-free.
- Cleaning with HP washers and steam cleaners is permitted.
15. Warranty:
One year without kilometre limit for the entire system. The warranty becomes
void in the event of incorrect procedures.
16. Spare parts:
20
Spare parts list:
1 1 Pump housing incl. 12V motor mounted finished (2185-010) 2185G0010
Pump housing incl. 24V motor mounted finished (2185-011) 2185G0011
2 1 Tank cover FMZ00478-00
3 1 Bleeding tube FMZ00486-00
4 1 Pressure compensation element 100150140145
5 1 Surface sealing between tank and cover 080100171
6 1 Tank sealing below 100150020167
7 1 Clear view tank 1,2kg FMZ00479-01
8 1 Cone bolt spring 080150571
9 1 Follow piston mounted finished (FAZ03150-00) 2185G0005
10 1 Exzenter unit mounted finished (FAZ03151-00) 2185G0006
11 1 Savety device for to muck filling complete (FAZ03152-00) 2185G0007
12 1 Motor cover incl. citcuit board (FAZ03153-01) 2185G0008
Motor cover incl. control unit S-EP 4 (FAZ03153-02)
Time of lubrication: 2 sec. 32 sec. / cycle time 0,5 h -8 h 2185G0003W
Number of cycles: 1 cycle 16 cycles / cyc le time 0,5 h -8 h 2185G0003X
Time of lubrication: 2 sec. 32 sec. / cycle time 1min. - 30 min.
Time of lubrication: 1 min. 16 min. / cycle time 0,5 h - 8 h
2185G0003Y
2185G0003Z
21
13 1 Sealing for motor cover 080100170
14 0 to 8 Blanking screw M14x1 DIN 908 090090801450
15 9 USIT-ring U dia.18,7x14x1,5 100150010148
16 0 to 2 Blanking screw M20x1,5 DIN 908 090090800850
17 2 USIT-ring U dia.28x20,70x1,5 100150010149
18 3 Hex. socket screw M4x20 090091201423
19 3 Lock washer A4 DIN 127 0900127008131
20 1 Towbar 0802000565
21 1 Hex. hat nut M8 0802000582
22 1 USIT-ring U dia.8,5x13,4x1 100150010146
23 1 Cap for form grease nipple 1004010021
24 1 Form grease nipple R1/4” H1 DIN 71412 097141201111
25 1 Socket set with cable FAZ02977-00
26 0 to 2 Pump element PE-120F 2185.99061.0000
Pump element PE-120FV ( adjustable ) 2185.99063.0000
17. Troubleshooting:
Malfunction Origin Remedies
Pump not working Fuse blown Replace fuse

Controller defective Change controller
Electrical connection broken Renew electrical
connection
Pump defective Replace pump
Pump works, but not Air pocket in the Bleed pump

delivering lubricant delivery piston
Grease-level switch Replace switch
defective
Pump element defective Replace pump element
22 No grease collar at all Pump not working See “Pump not working””
lubrication points
Delay time too long Reduce delay time
Pump`s running time too Increase pump running time
short
System blocked See”Grease Escaping from
pressure relief valve”
No grease collar at all Pipe to secondary distributor Replace pipe

lubrication points burst or leaking
Union leaking Tighten union or replace
No grease collar at a Corresponding pipe Replace pipe

single location burst or leaking
Union leakin Tighten union or replace
Malfunction Origin Remedies
Pump speed low High system pressure Check system/bearings
Low ambient temperature Initiate one or two additional

lubrication cycles
Greae escapes from System pressure too high Check system

pressure relief valve
Progressive distributor Change distributor
blocked
System blocked Repair blocked / frozen
bearings
Ventilfeder defekt Change pressure relief
valve
18. For your notes: 23

BEKA
BAIER + KÖPPEL
BEETHOVENSTR: 14
D- 91257 PEGNITZ / GERMANY
TEL. +49(0)9241 / 729-0
FAX +49(0)9241 / 729-50
P.O.BOX 1320
D- 91253 PEGNITZ
http://www.beka-lube.de
E-Mail: [email protected]
[email protected]
Also available:
Gear pumps
Multi-line pumps for oil
Multi-line pumps for grease
Single-line central lubrication systems
Double-line central lubrication systems
Oil-circulation central lubrication systems
Oil/air and spray lubrication
Wheel-flange lubrication
Central lubrication systems for commercial vehicles
Central lubrication systems for rolling mills
Progressive distributors
Control and monitoring equipment
Subject to change!
APPENDIX 2

MODEL 57 PISTON VACUUM PUMP
ASSEMBLY PROCEDURE
UPDATED OCTOBER 2008

CYLINDER BLOCK GROUP
Item Description Qty

9 Cylinder Block 1
10 Stud 2
11 Nut and Washer 6
12 Cylinder Head Gasket 1
44 Conrod 2
45 Slipper Bearing Set 2
46 Conrod Bolt 4
47 Oil Splasher 2
48 Small Ends Bush 2
49 Piston 2
50 Pin 2
51 Circlip 4
52 Ring Set 2
Page 1 of Vacuum Pump Assembly Procedure

Revision 2 – October 08
CRANK CASE GROUP
Item Description Qty Item Description Qty
1 Crank Case 1 38 Bearing 2

2 Gasket Inspection Plate 2 39 Crank Shaft 1
3 Inspection Plate 1 40 Balance Weight 2
4 Inspection Plate with Dipstick 1 41 Lock Tab 2
5 Bolt 12 42 Bolt 4
6 Dipstick 1 43 Key 1
7 ‘O’ Ring 1 53 Front Bearing Cap 1
8 Gasket 1 54 Oil Seal 1
10 Stud 6 55 Washer 1
32 Rear Bearing Cap 1 56 Bolt 1
33 Gasket 2 57 ‘O’ Ring 1
34 Bearing Support 1 58 Oil Drain Plug 1
35 Screw 1 59 Plug 1
36 Cap Nut 1 62 Reducing Bush 1
37 Bolt 12 63 Hose
Revision 2 – October 08 Page 2 of Vacuum Pump Assembly Procedure

CYLINDER HEAD GROUP
Item Description Qty Item Description Qty

13 Head 1 24 Discharge Triangle 2
14 Bolt 6 25 Gasket 2
15 Blind Nut 2 26 Discharge Cage 2
16 Gasket 4 27 Discharge Valve Assembly 2
17 Inlet Triangle 2 28 Push Bolt 2
18 ‘O’ Ring 2 29 Gasket 2
19 Inlet Valve Assembly 2 30 Cap Nut 2
20 Gasket 2 31 Bolt 12
21 Diamond 2 60 Gasket 1
22 Bolt 4 61 Exhaust Pipe 1
23 Plug 2 64 Cover Guard 1

Revisin 12––March
Revision October
02 08
Bolt the vacuum pump crank case to a

Secure work bench as shown.
Fit the oil drain and plug (58) as shown.
Fit the outer bearing race (38) into the

front bearing cover (53), using an
Hydraulic press or similar.
The bearing race should fit level with the

spigot
After fitting the outer bearing race, turn the

end cover over and install the lip seal (54).
NOTE: The lip of the seal faces to the out

side of the end cover. Use a press and
drift to install the seal into the cover.

Apply a thin layer of grease to gasket (33)

and fit to the front bearing cover.
Fit the cover onto the crank case housing

(1). Apply Loctite 567 or thread sealant to
bolts (37).
Install the bolts and tension to 25 ft lbs.
Assemble the rear bearing cover (32) with

bearing supporter (34) and outer bearing
race (38)
Bearing supported (34) is a loose fit into

the bearing cap.
NOTE: Install the bearing supporter with

The concave centre facing into the
bearing cover.
Now install the outer bearing race into the

rear bearing cover using an hydraulic
press or similar.
The bearing race should fit below the level

of the spigot and tight against the bearing
supporter.
The narrow edge of the race taper faces to

the inside of the crank case.

Crankshaft (39) assembly is next.
Both bearings (38) are the same size.
The narrow edge of the taper faces to the

ends of the shaft.
Use an hydraulic press or similar device to

fit the bearings. A sleeve made to suit the
inner diameter of the bearing should be
used to ease the bearings onto the shaft.
The bearings must fit hard on the

shoulders of the crankshaft.
Apply a thin layer of grease to gasket (33)

and ready the shaft assembly for
installation into the vacuum pump crank
case.
Apply oil to the lip of the seal (54) in the

front bearing end cap and carefully install
the shaft.
Hold the shaft in place and fit the end

cover onto the crank case housing. Apply
Loctite 567 or thread sealant to bolts (37).
Install the bolts and tension to 25 ft lbs.

Install the grub screw (35) into the back of

the rear bearing cover.
The crank shaft will be loose in the

bearing.
To adjust the crank shaft end float, tighten

the adjusting screw until all end float is
Removed, then back off the grub screw
(35) a 1/4 to 1/2 a turn.
Tap the crankshaft with a rubber/soft ham-

mer. One sharp hit is all that is required.
The shaft should now rotate easily. If the
rotation is restricted, gradually increase
the adjustment by up to a 1/4 turn of the
grub screw and hit the shaft again. Don’t
let the shaft go loose in the bearings.
Once the end float is correct, lock the grub
screw with the locking cap (36)
Attach the two balance weights.
NOTE: The green arrows on the photo-

graph indicate the position in which the
balance weights are attached to the crank
shaft.
Use bolts (42) and lock tab (41) to secure

the balance weights to the crank shaft.

Once the balance weight is attached to the

crank shaft, tighten the counter weight
bolts to 25 ft lbs and bend the corner of
the lock tabs across the flat of the bolt
head as shown here.
Piston (49), piston rings (52), conrod (44),

gudgeon pin (50) and circlips (51) are
displayed.
The piston is fitted to the conrod first.
The gudgeon pin is a clearance fit into the

little end bearing.
NOTE: First, fit a circlip into the recess

provided. Ensure that the clip is correctly
located. Slide the gudgeon pin through
the piston and conrod little end.
Secure the pin with the second circlip as

shown.
Using “soft jaws”, the conrod should be

3
gently held in a vice so that the piston rings
may be installed easily.
2
The rings must be installed in the sequence
shown.
1

Use a piston ring expander to correctly fit

the piston rings into the piston ring
grooves.
Set the piston ring gaps at intervals of 120

degrees
Undo the big end cap bolts and fit the slip-
per bearings (45) as shown. The big end A
slipper bearings have bearing locator lugs
as per conventional conrods.
B
A. The conrod slipper bearing has an oil
groove in the centre of the inside of the
bearing.
B. The cap slipper bearing has no groove.
Using “soft jaws”, clamp the cylinder block

(9) into a vice. Fit a piston ring compressor
around the piston and compress the rings.
Prior to installation, the big end bolts (46)
should be fitted to the conrod.
Guide and support the conrod big end into
the bore of the cylinder block (9). Use a non
metallic device to push the piston into the
bore of the cylinder and out of the ring
compressor.
Fit gasket (8) to the crank case assembly.
Apply liberal amounts of oil to the conrod

journals on the crank shaft.

Lift the pre-assembled cylinder into position

over the crank case. Carefully lower the
assembly so that the conrod big end rests
on the crank shaft journals. Align the cylin-
der with the crank case studs. When the
cylinder is sitting in position, push the pis-
tons down so that the big ends are hard
onto the crank shaft journals. Check this
visually through the inspection port.
Fit the big end caps (44) and tension the

bolts to 25 ft lbs.
Apply a thin layer of grease to the cylinder

head gasket (12).
Fit the cylinder head (13).
Tension the block nuts (11) to approximately

20 ft lbs.
(Access with a conventional tension wrench

is not possible on these nuts).

Install head bolts (14) and blind bolts (15)

into the head (13).
Tension to 25 ft lbs in the tensioning 5 1 3

sequence shown here. 8 7
4 2 6
Fit gasket ring (16) to the two inlet and two

exhaust ports as shown here.
These rings locate into stepped recesses in

the head.
Insert the discharge valve assembly (27) as

shown in this illustration.
The valve seats in the same recess as the

gasket ring (16). Make sure that the valve
assembly sits square in the recess.
Install the discharge valve cage (26).
The valve cage fits into the shoulder on the

back of the discharge valve assembly (27).
Check the parts diagram on page 4

Gasket (25) fits into a recess under

discharge triangle (24) which creates a seal
between the discharge triangle and the
head.
After installing both discharge triangles, ten-

sion the securing bolts (31) to 25 ft lbs.
Do not over tension, as the triangle may

crack.
Copper gasket (29) fits into a recess on top

of the discharge triangle (24).
Push bolt (28) screws into the top of the

discharge triangle.
The push bolt is tensioned to positively lock

the valve down

Install cap nut (30) and tighten firmly.
Install the inlet valve assembly (19) into the

cylinder head in the same manor as shown
here.
Again, the valve seats on the same recess

as the gasket ring.
Fit ‘O’ ring (18) to the inlet triangle (17) and

fit into the cylinder head.
The assembly fits into a recess in the back

of the inlet valve assembly
Tension the hold down bolts (31) to 25 ft lbs.
Do not over tension as the triangle may

crack.

The illustration here shows the inspection

plate (4), inspection gasket (2) and the oil
level dip stick (6).
Apply a thin layer of grease to gasket (2) to

hold it in place on the crank case flange.
Fit the inspection plate (4) and tension the
bolts (5). Fit the dipstick (6) into the port pro-
vided. The opposite side inspection plate (3)
and gasket (2) are fitted in the same manner,
however, the plate has no dipstick. During
rebuild operations, only one inspection plate
needs to be removed unless the situation re-
quires that the plate be removed.
Install the vacuum pump balance hose (63)

and reducing bush (62) to the vacuum pump
as shown here.

APPENDIX 3

ELECTRO-MAGNETIC (ROBATIC) CLUTCH
DISASSEMBLY
AND
ASSEMBLY PROCEDURE
UPDATED OCTOBER 2008

ELECTRO-MAGNETIC CLUTCH
PART LIST
Item Part No Description Qty
1 540-140-701 Inner Circlip (Mounting Flange End) 1
2 540-140-702 Outer Circlip (Mounting Flange End) 1

3 540-140-703 Shim A/R
4 540-140-704 Shim A/R
5 540-140-705 Bearing, Mounting Flange 2
6 540-140-706 Shim A/R

7 540-140-708 Mounting Flange 1
8 540-140-709 Transmission Flange 1
9 540-140-710 Cap Head Screw 3
10 540-140-711 Rotor 1
11 540-140-712-12 Coil Carrier (12 Volt) 1
540-140-712-24 Coil Carrier (24 Volt) 1
12 540-140-713 Bearing, Coil Carrier 1
13 540-140-714 Shim A/R
14 540-140-715 Shim A/R
15 540-140-716 Outer Circlip (Coil Carrier End) 1
16 540-140-717 Inner Circlip 1
Part Number 540-140-700/12V = Complete Clutch Assembly 12 Volt

Part Number 540-140-700/24V = Complete Clutch Assembly 24 Volt
Part Number 540-140-719 = Complete Shim Kit (including Bearings).
**Shims are available in kit form only and not available individually**
Page 1 of Robatic Clutch Procedure

ELECTROMAGNETIC CLUTCH
PARTS ASSEMBLY

DISASSEMBLY PROCEDURE
Before working on the Electro-Magnetic Clutch,
the Clutch must first be removed from the
CAUTION! Vacuum Pump.
To Remove the Clutch from the Vacuum Pump: -
1. Referring to the diagram below, remove Circlip (8) and pulley (7) from the clutch
making sure to retain the key.
2. Remove bolt (10) and Washer (9) and replace with Clutch removal tool as out-
lined in drawing below (Figure 1)
3. Before removing Clutch, loosen Clutch Bracket Bolts (4) to ensure Clutch doesn’t
fowl on the Bracket as it’s being removed.
4. After Clutch has been removed ensure that Vacuum Pump Key (2) is retained.
Figure 1

Before disassembling the Electromagnetic

Clutch it must be determined whether it is
INFORMATION ! viable or cost effective to service the Clutch or
not. Following is a Check List that should help
determine whether a Clutch should be serviced
or replaced.
CLUTCH CHECK LIST

1. Using an ohmmeter set on RX10 check the resistance of the Coil Carrier.
For a 12 Volt Coil the resistance should be between 0.6 – 0.8 W.
For a 24 Volt Coil the resistance should be between 1.3 – 1.5 W.
If the resistance of the Coil is not sufficient the Coil Carrier will need to
be replaced.
2. Check the Clutch Housings for signs of wear, especially around the keyways
and bearing areas. If either Housing shows sign of excessive wear it would be
better to replace the whole Clutch assembly.
3. With a 0.3mm Feeler Gauge check the tolerance between the Rotor and the
Transmission Flange. If the tolerance is greater than 0.3mm check the Trans-
mission Flange for signs of wear, if the tolerance is less then 0.3mm it maybe
because of worn or insufficient Shims. Both the Shims and Transmission Flange
can be replaced. However if the wear is on the face of the Rotor, the whole
Clutch assembly should be replaced.
4. Clutch Bearings should also be checked. These Bearings are sealed Bearings
and come complete with Shims as part of the Shim Kit. Both the Shims and
Bearings are generally replaced when servicing a Clutch.
5. The Pulley and Keys should also be checked for signs of wear.
If wear is excessive, then these items should be replaced.

When assembling and disassembling an

Electromagnetic Clutch it is important that any
force applied to the Clutch is only applied to the
ATTENTION ! faces outlined in Figure 2 below.
This is achieved by using Shaft Clamps and Press

Tools outlined in the following procedures.
Figure 2
Page 5 of Clutch Procedure

STEP #1
Fix Shaft Clamp as shown in Figure 3 to the Coil Car- Press Tool
rier making sure that the cut out section of the clamp is
positioned over the coil wires, so not to damage them.
Remove inner circlip and any shims, making note of
number and size of shims to take out the guesswork
when re-assembling. Using the press tool shown in
Figure 3 press off the Coil Carrier.
Figure 3
Press Tool
STEP #2
Remove outer circlip, turn the Coil Carrier over and with
the press tool shown in Figure 4 press out the bearing.
Check Bearing and bearing housing area for signs of

wear.
If bearing area is worn, the Coil Carrier will need to be
replaced.
Figure 4
STEP #3
Fix Shaft Clamp as shown in Figure 5 to the Mounting
Press Tool
Flange. Remove inner circlip and any shims, making
note of number and size of shims to take out the guess-
work when re-assembling.
Using the press tool shown, press off the Mounting

Flange.
Figure 5

STEP #4
Remove shims, making note of number and size of
shims to take out the guesswork when re-assembling.
Check Rotor for signs of wear especially around the
face that opposes the Transmission Flange.
If the Rotor or Rotor Drive Face shows signs of exces-

sive wear, the whole Clutch assembly should be re-
placed.
Figure 6
Press Tool
STEP #5
Remove outer circlip, turn the Mounting Flange over
and with the press tool shown in Figure 7 press out the
bearings.
Check for any shims between bearings, note number
and size of shims to take out the guesswork when re-
assembling.
Check Transmission Flange for signs of wear, if worn

the Transmission Flange should be replaced. How-
ever ,if the Mounting Flange shows signs of excessive
wear the whole Clutch assembly should be replaced.
Figure 7
After the Electromagnetic Clutch has been

disassembled, assess what parts need to be
INFORMATION ! replaced, clean all components and then
re-assemble the Clutch following the steps
outlined in the following assembly procedure.

ASSEMBLY PROCEDURE
STEP #1
Press the bearing into the Coil Carrier as shown in
Figure 8. Insert outer circlip to prevent the bearing from
moving.
If this is a rebuild, the old bearing should be replaced.
Figure 8
STEP #2
– Using the same press tool as the one used to press
the bearing into the Coil Carrier, press the Coil Carrier
onto the Rotor and then insert inner circlip as shown
here in Figure 9. The circlip should be hard up against
the bearing. If the circlip is not hard up against the
bearing, shims may need to be added between the
bearing and the circlip.
Note the top of the Rotor should protrude no more then

0.5mm past the Coil Carrier.
Figure 9
STEP #3
– If the Transmission Flange is to be replaced, using
Loctite and the cap screws provided, fix the new
Transmission Flange to the Mount Flange as shown in
Figure 10.
Note the Transmission Flange will only need to be

replaced if it is worn or damaged, it is not generally
replaced when servicing a Clutch.
Figure 10

STEP #4
– As shown in Figure 11,Individually press both bear-
ings into the Mounting Flange, making sure to replace
the shims between the bearings, then insert the outer
circlip. The circlip should be hard up against the bear-
ing.
If the circlip is not hard up against the bearing, extra
shims may need to be added between the bearing and
the circlip.
If this is a rebuild, the old bearings and shims should be

replaced. Figure 11
STEP #5
– Replace the shims on the Rotor, then with the same
press tool used to press the bearings into the Mounting
Flange, press the Mounting Flange onto the Rotor.
Shown in Figure 12.
With a 0.3mm Feeler Gauge check the tolerance be-
tween the Transmission Flange and the Rotor. If the tol-
erance is greater then 0.3mm remove some of the Ro-
tor Shims. If the tolerance is smaller then 0.3mm more
Rotor Shims will need to be added.
Figure 12
STEP #6
– When the 0.3mm tolerance between the Transmis-
sion Flange and the Rotor has been achieved, insert
the inner circlip. Figure 13. The circlip should be hard
up against the bearing. If the circlip is not hard up
against the bearing, shims may need to be added be-
tween the bearing and the circlip.
Figure 13
Page 9 of Clutch Procedure

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Weir Minerals Multiflo

INSTALLATION, OPERATION, MAINTENANCE

DIESEL POWERED PUMP UNIT

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo i

Table of Figures ..........................................................................................................................................................vi

Copyright © 2011 Weir Minerals Multiflo................................................................................................................. viii

Contact Us: ..................................................................................................................................................................x

Pump performance curve ......................................................................................................................................... xiv

Electrical wiring diagrams .......................................................................................................................................... xv

PART 1. INSTALLATION ........................................................................................................................... 1

1.1 Pump Unit Delivery .......................................................................................................................................... 2

1.2 Storage Procedures ........................................................................................................................................ 2

1.3 General Safety of Major Equipments ............................................................................................................. 3

1.4 Unit Lifting Points ............................................................................................................................................ 4

1.5 Assembly Instructions ...................................................................................................................................... 5

1.6 Installation of Suction Assembly ...................................................................................................................16

1.7 Installation of Discharge Pipe work.................................................................................................................19

1.8 Fitting Pontoon Handrail (If Fitted) .................................................................................................................20

1.9 Moving and Locating the Pump unit ...............................................................................................................21

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo ii

Correct Pump Unit Positioning .................................................................................................................................... 26

PART 2. OPERATION .............................................................................................................................. 28

2.1 General Function of the Pump Unit.................................................................................................................29

2.2 Pump unit Orientation ....................................................................................................................................29

2.3 Daily Pre-Start Checks .....................................................................................................................................30

2.4 Starting procedure ..........................................................................................................................................32

2.5 Operating Speed .............................................................................................................................................32

2.6 Cavitation .......................................................................................................................................................32

2.7 Shutdown Procedure ......................................................................................................................................33

2.8 Description of Major Components ..................................................................................................................34

2.9 Electrical .........................................................................................................................................................53

PART 3. MAINTENANCE ........................................................................................................................ 56

3.1 General Safety ................................................................................................................................................57

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo iii

3.2 Bare Shaft Pump Assembly and Disassembly Procedure .................................................................................57

3.3 Bare Shaft Pump Maintenance .......................................................................................................................68

3.4 Model 57 Piston Vacuum Pump Maintenance ...............................................................................................73

3.5 Drive Components Maintenance ....................................................................................................................79

3.6 1000FH Series Fuel Filter Instructions (If Fitted) ..............................................................................................88

3.7 Routine General Maintenance Frequency .......................................................................................................93

3.8 Pump Unit Troubleshooting ............................................................................................................................96

3.9 Lubricants ................................................................................................................................................106

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo iv

PART 4. SPARE PARTS ....................................................................................................................... 107

MF-385G SS MAJOR COMPONENTS........................................................................................................................... 108

PART 5. ACCOMPANYING MANUALS ................................................................................................ 147

Appendix 1 / WMM Pico Auto Greaser Manual

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo v

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo vi

-Packing Removal Tool.................................................................................................................................... 69

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo vii

COPYRIGHT © 2011 WEIR MINERALS MULTIFLO

Weir Minerals Multiflo

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo viii

WEIR MINERALS MULTIFLO PUMPS

Introduction – Jan 2011 ©Copyright Weir Minerals Multiflo ix

Head Office Kimberley, Pilbara, Mid-West, Hunter Valley Authorised Service

Bowen Basin South West Region

Rockhampton Kalgoorlie & Goldfields Authorised