Part Book Pompa

MF-385-183-09.
25
ASSEMBLY, OPERATION, MAINTENANCE MANUAL & SPARE

PARTS LIST FOR MULTIFLO® MODEL MF - 385GSS
DIESEL ENGINE POWERED, BASE MOUNTED PUMP UNIT
©2014, Weir Minerals Australia Ltd., trading as Weir Minerals Multiflo®. All rights reserved. MULTIFLO®, VACTRONIC® and HYDRAU-FLO® are
registered trademarks of Weir Minerals Australia, Ltd. The document and its text, images, diagrams, data and information it contains must not
be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals Multiflo Ltd. Due
to continuous product development, the information contained herein may change.
Office of Origin: Head Office, Weir Minerals Multiflo, Coolum Beach, QLD, Australia
Date: 05/09/2014
MF-385-183-09.25
DO NOT CONVERT OR USE VACUUM PRIMED PUMP

UNITS AS BOOSTER PUMPS, PRIOR TO OPERATION
WITHOUT CONTACTING WEIR MINERALS MULTIFLO.
REMOVE SHAFT LOCKS (IF FITTED) FROM BARE SHAFT
PUMP BEFORE START-UP. BATTERY ISOLATOR LOCK
CODE IS 123.
Date: 05/09/2014
MF-385-183-09.25
PROJECT DETAILS:
Project Name MF-385 Base Mounted Pump Unit
Customer Name PT Weir Minerals Indonesia (PT Sukses Inti Solusindo)
WMM Job Numbers 20250001
Multiflo model MF - 385GSS, Base Mounted, Vacuum Primed

Equipment Description Pump Unit.
DOCUMENT HISTORY:
Version Date Author Description
1.0 5th September 2014 Shivakumar.S Release to Multiflo
Date: 05/09/2014
MF-385-183-09.25
2.4.2 Caterpillar Diesel Engine ................................... 23
Table of Contents 2.4.3 Model 57 Piston Type Vacuum Pump ............... 23
2.4.4 Vacuum Gauge ................................................. 23
No. Description Page No. 2.4.5 Vacuum Tank .................................................... 24
2.4.6 Vacuum Prime System ...................................... 24
O.E.M CERTIFICATES .............................................. .I 2.4.7 Non Return Valve .............................................. 25
2.4.8 Hydrau-Flo® Fuel Filling Valve........................... 25
AS/NZS 4801: 2001……………………………………..……......ii
2.4.9 Turbine Series 1000FH Fuel Filter/Water
AS/NZS 14001: 2004……………………………………….…….iii
Separators ........................................................ 26
OHSAS 18001: 2007..................................................iv
2.4.10 Engine Monitoring System .............................. 26
AS/NZS 9001: 2008...................................................v
2.5 NORMAL OPERATING PROCEDURES...................................... 27
General conditions of sale........................................vi
2.5.1 Pumping Operation Observations ..................... 27
Contact Details of O.E.M.........................................xiii 2.5.2 Daily Start Pre Checks ....................................... 28
Introduction & Safety 2.5.3 Starting Procedure ............................................ 28
O.E.M. Introduction.................................................xv
2.5.4 Operating Speed ............................................... 28
Safety…………………………...........................................xvi
2.5.5 Normal Operation ............................................. 30
Safety Symbols……………………..................................xvii
2.5.6 Shutdown Procedures ....................................... 30
Risks……………………………………………………………........xviii
2.5.7 Shutdown Protection ........................................ 30
1 ASSEMBLY & INSTALLATION .................................. 1 2.5.7.1 Vismode Control Panel .................................. 30
2.5.8 Low Flow Switch ............................................... 31
1.1 PUMP UNIT PACKING, TRANSPORT & HANDLING .................... 2
2.5.9 Taperlock Bushes .............................................. 31
1.1.1 Packing ............................................................. 2
2.5.10 Diesel Engine Operation Procedures, Start-
1.1.2 Loading & Unloading ........................................ 3
Up Procedures and Shutdown Procedures ....... 31
1.1.3 Receipt and Shipping - General Notes ............... 4
2.5.11 Pump Unit Greasing System ........................... 31
1.1.4 Reporting Shipping Shortage ............................ 4
2.5.12 Low-fuel Shutdown System ............................. 31
1.1.5 Storage Procedures ........................................... 5
2.6 EMERGENCY AND ABNORMAL CONDITIONS ............................ 32
1.1.5.1 Storage Recommendations after the pump
2.6.1 Cavitation ......................................................... 32
unit is Assembled ........................................... 5
2.6.2 Recirculation ..................................................... 32
1.1.5.2 Repacking....................................................... 5
2.6.3 Vibration ........................................................... 32
1.1.6 Environment Conditions .................................... 5
2.6.4 Maintenance Procedures .................................. 32
1.1.7 Fire Suppression and Fire Extinguishers ............ 5
2.6.5 Fire .................................................................... 32
1.2 SAFETY NOTES - PRE-OPERATIONAL & ASSEMBLY ................... 6
2.6.6 Oil Leak, Spill ..................................................... 32
1.2.1 Bare Shaft Pump Safety .................................... 6
1.2.2 Manual Shaft Rotation...................................... 6 3 MAINTENANCE ...................................................... 33
1.3 PUMP UNIT DESCRIPTION .................................................. 7
3.1 NORMAL MAINTENANCE PROCEDURE - SAFETY NOTES ............. 34
1.3.1 Major Components ........................................... 7
3.1.1 General Maintenance Notes - Bare Shaft
1.3.2 Unit Major Components.................................... 7
Pump ................................................................ 35
1.3.3 Unit Lifting Points ............................................. 9
3.1.1.1 Safety Awareness .......................................... 36
1.3.4 Discharge Assembly .......................................... 9
3.1.1.2 Personnel Qualification and Training............. 36
1.4 SAFETY NOTES – ASSEMBLY AND MOVING ............................. 10
3.1.1.3 General Notes - Pump Unit Lockout and
1.5 ASSEMBLY INSTRUCTIONS................................................... 11
Training .......................................................... 36
1.5.1 Pre - Assembly Checks ....................................... 11
3.1.1.4 Operational and Safety Observations -
1.5.2 Assembly Procedures ........................................ 12
Maintenance ................................................. 36
1.5.3 Assembly of Discharge Pipework ...................... 13
3.2 BARE SHAFT PUMP MAINTENANCE ...................................... 37
1.5.4 Pump Unit Mass ................................................ 16 3.2.1 Gland Packing ................................................... 37
1.5.5 Correct Position of Suction Boom ...................... 16 3.2.1.1 Gland Packing Removal ................................. 37
2 OPERATION ........................................................... 17 3.2.1.2 Gland Packing Adjustment............................. 38
3.2.1.3 Standard Procedure for Gland Adjustment ... 38
2.1 SAFETY NOTES – OPERATION .............................................. 18
3.2.2 Lubrication ........................................................ 38
2.1.1 Safety Awareness .............................................. 18
3.2.3 CATERPILLAR Diesel Engine............................... 39
2.1.2 Personnel Qualification and Training ................ 18
3.2.4 ‘V’ Belts Tensioning ........................................... 39
2.1.3 General Notes - Pump Unit Lockout and
3.3 GRADES AND FREQUENCY OF LUBRICATION ............................ 39
Tagging ............................................................ 19
3.3.1 Bare Shaft Pump Lubrication ............................ 39
2.1.4 Operational and Safety Observations -
3.3.1.1 Bare Shaft Pump Auto Greasing Unit............. 39
General ............................................................. 19
3.3.2 Diesel Engine Lubrication .................................. 41
2.2 BARE SHAFT PUMP SAFETY NOTES ....................................... 20
3.3.3 Coupling ............................................................ 41
2.3 GENERAL DESCRIPTION & FUNCTION OF THE EQUIPMENT ......... 21
3.3.4 Flow Switch ....................................................... 41
2.3.1 Principle of Operation ....................................... 21
3.3.5 Hydrau - Flo ...................................................... 41
2.3.2 Pump Unit Orientation ...................................... 21
3.3.6 Vacuum Pump................................................... 41
2.4 DESCRIPTION OF MAJOR COMPONENTS ................................ 22
3.3.7 Pump Greasing Unit .......................................... 41
2.4.1 Bare Shaft Pump ............................................... 22
3.3.8 Diesel Engine Procedures and Data .................. 41
Version 1.0 © Copyright Weir Minerals Australia Ltd

MF-385-183-09.25
3.4 ROUTINE GENERAL MAINTENANCE FREQUENCY ...................... 42 6.5 MF - 385 SERVICE POINT ................................................ 97
3.4.1 Every 10 Operating Hours or Daily .................... 42 6.6 MF - 385 FUEL BREATHER ............................................... 98
3.4.2 Every 250 Operating Hours (Perform in 6.7 MF - 385 FUEL FILTERS/WATER SEPARATOR ....................... 99
addition to daily checks) ................................... 42 7 DISCHARGE SECTION ............................................... 100
3.4.3 Every 500 Operation Hours (Perform in 7.1 MF - 385 DISCHARGE ASSEMBLY ...................................... 101
addition to 250 hours of maintenance items) .. 42 7.2 MF - 385 NON-RETURN VALVE STAINLESS STEEL.................. 102
3.4.4 Every 1000 Operating Hours (Perform in 7.3 MF - 385 ONYX PRESSURE GAUGE .................................... 103
addition to 500 hours of maintenance items) .. 42
3.4.5 Every 2000 Operating Hours (Perform in
addition to 1000 hours of maintenance
5 Appendices
items) ............................................................... 43 Tightening Torque Values…………………………………………105
3.5 PUMP UNIT TROUBLESHOOTING .......................................... 43 Performance Curve…………………………………….………......107
4 Parts List Wiring Diagrams..........................................................109
MF - 385 MAJOR COMPONENTS ....................................... 51

6 Accompanying Manuals
1 DRIVE SECTION ....................................................... 53
1.1 MF - 385 DRIVE MAIN COMPONENTS................................. 54 Y MF - 385 Bare Shaft Pump Disassembly & Assembly
1.2 MF - 385 DRIVE MAIN COMPONENTS................................. 55 Instructions Manual
1.3 MF - 385 VACUUM PUMP MODEL 57 ................................ 56
Y TW Series Heavy Duty Trailing Wire Flow Switch
1.4 MF - 385 VACUUM PUMP - CYLINDER HEAD GROUP ............. 57
1.5 MF - 385 VACUUM PUMP - CRANK CASE GROUP .................. 58 Y Fenner-Fenaflex Tyre Coupling Manual
1.6 MF - 385 VACUUM PUMP - CYLINDER BLOCK GROUP ............ 59
1.7 MF - 385 VACUUM PUMP CLUTCH .................................... 60 Y PICO - Auto Greaser Manual
1.8 MF - 385 VACUUM PUMP MOUNTING PLATE ...................... 61
Y Robatic Clutch - Disassembly & Assembly Procedure
2 PUMP SECTION ....................................................... 62 Manual
2.1 MF - 385 COMPLETE BARE SHAFT PUMP ............................. 63
2.2 MF - 385 GLAND GUARD ASSEMBLY ................................... 64 Y Vacuum Pump Model 57 Assembly Procedure Manual
2.3 MF - 385 COVER PLATE ASSEMBLY .................................... 65
Y Installation, Operation, Maintenance Manual for Hydrau-
2.4 MF - 385 WEAR PLATE ASSEMBLY ..................................... 66
Flo® valves
2.5 MF - 385 SHIMS ............................................................ 67
2.6 MF - 385 IMPELLER ........................................................ 68 Y Operation & Maintenance Manual Vismode® Controller
2.7 MF - 385 VOLUTE FASTENERS ........................................... 69 V4
2.8 MF - 385 GLAND ASSEMBLY ............................................. 70
2.9 MF - 385 STUFFING BOX ASSEMBLY ................................... 71
2.10 MF - 385 O-RINGS AND SLINGER ASSEMBLY ..................... 72
2.11 MF - 385 FRONT BEARING CAP ASSEMBLY ....................... 73
2.12 MF - 385 FRONT BEARING ............................................ 74
2.13 MF - 385 REAR BEARING CAP ASSEMBLY ......................... 75
2.14 MF - 385 REAR BEARING ASSEMBLY ............................... 76
2.15 MF - 385 PEDESTAL SEALS AND FITTINGS ......................... 77
2.16 MF - 385 MAINTENANCE PLATFORM .............................. 78
3 SUCTION SECTION .................................................. 79
3.1 MF - 385 SUCTION COMPONENTS.................................... 80
4 PRIMING SECTION .................................................. 81
4.1 MF - 385 PRIMING ASSEMBLY......................................... 82
4.2 MF - 385 Check Valve ............................................... 83
5 ELECTRICAL SECTION .............................................. 84
5.1 MF - 385 VACUUM PRESSURE GAUGE .............................. 85
5.2 MF - 385 BATTERY BOX................................................. 86
5.3 MF - 385 BATTERY ISOLATORS ........................................ 87
5.4 MF - 385 VISMODE CONTROL BOX ................................... 88
5.5 MF - 385 WORK LIGHT AND STROBE LIGHT ........................ 89
5.6 MF - 385 LOW FLOW SWITCH ......................................... 90
5.7 MF - 385 EMERGENCY STOP ........................................... 91
6 SERVICE/LUBRICATION ........................................... 92
6.1 MF - 385 HYDRAU - FLO ................................................. 93
6.2 MF - 385 FUEL FILLER .................................................... 94
6.3 MF - 385 FUEL FLOAT SWITCH ASSEMBLY ........................... 95
6.4 MF - 385 PICO AUTO - LUBER GREASER ............................. 96

MF-385-183-09.25

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Fig. No. Description Page No.
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Part I Assembly & Installation
FIG.1.1 MF-385GSS UNIT MAJOR COMPONENTS ......................................................................................................................................... 8

FIG.1.2 MF-385GSS SUCTION COMPONENTS .............................................................................................................................................. 8
FIG.1.3 MF - 385GSS PUMP UNIT LIFTING POINTS ....................................................................................................................................... 9
FIG.1.4 MF - 385GSS DISCHARGE ASSEMBLY.............................................................................................................................................. 9
FIG.1.5 ASSEMBLING DISCHARGE ASSEMBLY ............................................................................................................................................... 13
FIG.1.6 ASSEMBLING SUCTION ASSEMBLY COMPONENTS ............................................................................................................................... 14
FIG.1.7 FITTING BOOM CHAINS, SUCTION STRAINER AND ATTACHING WINCH ROPE ............................................................................................... 15
FIG.1.8 CORRECT POSITION OF SUCTION BOOM ........................................................................................................................................... 16
Part II Operation
FIG.2.1 PUMP UNIT ORIENTATION ............................................................................................................................................................ 21

FIG.2.2 BARE SHAFT PUMP - 385GSS ...................................................................................................................................................... 22
FIG.2.3 BARE SHAFT PUMP WET END PARTS ................................................................................................................................................ 22
FIG.2.4 BEARING ASSEMBLY PARTS ........................................................................................................................................................... 23
FIG.2.5 VACUUM GAUGE ....................................................................................................................................................................... 23
FIG.2.6 VACUUM TANK ......................................................................................................................................................................... 24
FIG.2.7 NRV OPERATION ...................................................................................................................................................................... 25
FIG.2.8 FUEL FILTER/WATER SEPARATOR .................................................................................................................................................. 26
FIG.2.9 CONTROL STATION ..................................................................................................................................................................... 29
FIG.2.10 VISMODE FRONT PANEL............................................................................................................................................................. 30
FIG.2.11 LOW-FUEL SHUTDOWN SETUP .................................................................................................................................................... 31
FIG.2.12 RESULT OF RECIRCULATION ON FRONT DOOR/THROAT BUSH............................................................................................................. 32
FIG.2.13 RESULT OF CAVITATION ON IMPELLER ........................................................................................................................................... 32
Part III Maintenance
FIG.3.1 GLAND PACKING REMOVAL TOOL ................................................................................................................................................... 38

FIG.3.2 AUTOMATIC GREASING GUIDE FOR BARE SHAFT PUMP. ....................................................................................................................... 40

MF-385-183-09.25
O.E.M CERTIFICATES
Version 1.0 © Copyright Weir Minerals Australia Ltd Page i

MF-385-183-09.25
Version 1.0 © Copyright Weir Minerals Australia Ltd Page ii

MF-385-183-09.25
Version 1.0 © Copyright Weir Minerals Australia Ltd Page iii

MF-385-183-09.25
Version 1.0 © Copyright Weir Minerals Australia Ltd Page iv

MF-385-183-09.25
Version 1.0 © Copyright Weir Minerals Australia Ltd Page v

MF-385-183-09.25
O.E.M GENERAL SALES CONDITIONS
Version 1.0 © Copyright Weir Minerals Australia Ltd Page vi

MF-385-183-09.25
1. APPLICATION Australia Foreign Exchange Rates, published on the date of
References to “Weir” in these General Conditions of Sale the quotation; and
shall mean Weir Minerals Australia Ltd ABN 69 009 701 802 (b) unless otherwise specified in writing by Weir, the quoted
acting in its own capacity and/or acting as agent for Linatex prices shall be adjusted upwards or downwards as the case
Australia Pty Ltd ABN 84 004 506 129, or a related company may be to reflect the difference between the base rate of
of Weir minerals Australia Ltd as applicable. exchange referred to in clause 5.3(a) and the actual rate of
Until such time as Weir notifies a customer (“Purchaser”) of exchange prevailing on the day Weir remits the foreign
replacement General Conditions of Sale, these General currency amount for the Goods or raw materials or
Conditions of Sale shall form part of any contract for the components, or if Weir hedges the order for the Goods or
sale of goods (“Goods”) or supply of services (“Services”) by raw materials or components, the rate hedged by Weir and
Weir to Purchaser, except as varied by written agreement advised to Purchaser in writing prior to Weir’s remitting the
between Weir and Purchaser. Conditions or terms of foreign exchange currency amount.
contract submitted by Purchaser in or with a purchase order 5.4 Any increases in the rate of GST, any increases in customs
or request for quotation or other document or duty on imported Goods or raw materials or components for
communication do not form part of any contract with Weir Goods (whether because of a change in the Customs Tariff
unless and to the extent agreed to by Weir in writing. Classification and/or rate), and any new carbon trading or
2. QUOTATIONS emissions trading or other levies, imposts, duties or taxes,
A quotation by Weir may be withdrawn or varied at any applicable to or impacting on the cost to Weir of the Goods
time, prior to acceptance by Weir of an order, and ceases to or Services, between the date of Weir’s tender or quotation
have any effect after 30 days from the date of the quotation and the date of invoice, will be to Purchaser’s account, and
unless extended in writing by Weir. Prices quoted are will be payable by Purchaser within 30 days from the date of
subject to variation in accordance with clause 5. Weir’s invoice.
3. ACCEPTANCE OF ORDERS 6. DELIVERY & STORAGE
Weir is not bound by any order from Purchaser until and 6.1 Delivery shall be deemed to occur when Purchaser is
unless Weir notifies Purchaser in writing of its acceptance of informed by Weir that the Goods are ready for collection at
that order. the works of Weir or Linatex, as applicable.
4. TERMS OF PAYMENT 6.2 Any times quoted for delivery are to be treated as best
4.1 Unless other terms of payment are expressly provided estimates only, not involving any contractual obligation,
for by Weir, invoices are payable strictly net within 30 days unless Weir has specifically agreed in writing to negate this
from the invoice date or the date on which Purchaser is clause 6.2 and to give a contractually binding commitment
notified that the Goods are ready for dispatch, whichever is that dispatch or delivery will be within a specified time or on
the earlier. or by a specified date.
4.2 The due date for payment shall not be postponed on 6.3 Any contractually binding commitment by Weir to deliver
account of damage, non-delivery or additions, alterations, on or by a specific date is subject to the provisions of clause
minor omissions or defects to, from or in the Goods which 18.4 below and also subject to Weir not being delayed by
do not substantially affect the commercial use of the Goods. instructions or lack of instructions from Purchaser. The times
Payments must be made without setoffs, counter-claim or quoted shall be increased by the duration of any event of
deduction. force majeure and by the period or periods of any such delay
5. PRICES & TAXES and any consequences of the delay.
5.1 GST All prices quoted are exclusive of GST. In addition to 6.4 Weir may make delivery of and invoice any order either
the payment of the prices quoted, Purchaser must pay to as a whole or progressively and effect delivery at any time
Weir an amount equal to any GST imposed on Taxable within the period advised by it for delivery of the order. If
Supplies made by Weir to Purchaser. Weir must give Purchaser requests Weir to delay delivery or fails to give
Purchaser a Tax Invoice in respect of each such Taxable Weir adequate delivery instructions, Weir may invoice
Supply. “Taxable Supply”, “GST” and “Tax Invoice” have the Purchaser and store the goods at Purchaser’s expense.
same meanings as in the A New Tax System (Goods and 7. RISK & INSURANCE
Services Tax) Act 1999. If Purchaser intends to export the Insurance cover is the responsibility of Purchaser and all
Goods, so that Weir will be exempt from GST in respect of Goods will be at Purchaser’s risk from the point of delivery as
its supply of the Goods, it must provide Weir with copies of defined in clause 6. Weir will not be responsible for any loss
the shipping documents, and such other documentation as or damage occurring after the time of delivery or deemed
Weir may reasonably require, within 60 days after the date delivery and will only arrange insurance upon written
of Weir’s invoice, otherwise an amount equal to the GST instructions from Purchaser and at the cost of Purchaser.
will be payable by Purchaser to Weir. 8. AMENDMENT AND CANCELLATION
5.2 Unless otherwise specified in writing by Weir, all prices Purchaser shall not, after acceptance of order, cancel or
quoted are ex works (the location specified by Weir in its amend it in any way without the written approval of Weir.
tender or quotation), unpacked, and all costs of freight and Weir may, on consenting to an amendment, revise its price
delivery from the works, and packing, will be to Purchaser’s and delivery schedule and amend the terms and conditions
account. to reflect such change. In the event of an amendment or
5.3 Where Goods or raw materials or components for cancellation, Purchaser shall reimburse Weir for all costs and
Goods are to be imported :(a) the quoted prices for those expenses already incurred by Weir or for which Weir has or
Goods are based on the foreign currency rate of exchange will become liable, and for any additional costs and expenses
disclosed in Weir’s quotation and if no rate of exchange is resulting from the amendment or cancellation.
disclosed, are based on the Commonwealth Bank of
Version 1.0 © Copyright Weir Minerals Australia Ltd Page vii

MF-385-183-09.25
The specification by Weir of any particular personnel, in any replaced by Weir. This warranty does not apply to repair of
quotation or tender, is subject to availability of those rubber.
personnel and Weir reserves the right to substitute any 11.3 Rubber Lining For rubber lining services the warranty
nominated personnel at any time. period is 12 months from the date of application if the
9. DEFAULT application is performed in accordance with Weir Minerals
If Purchaser makes default in payment or fails to carry out Standards RL101 Linatex Adhesives & Bonding and RL120
any part of any contract of which these General Conditions Lining Equipment & Vessels. Copies of these standards will be
of Sale form part or shall become bankrupt or commit any provided on request.
act of bankruptcy or compound with its creditors or have 11.4 Exceptions The warranties given by Weir in clauses 11.1,
judgment entered against it in any court or, being a 11.2 and 11.3 above do not cover:
company, have a provisional liquidator, receiver or manager (a) Fair “wear and tear”, or failures or damage not reported
appointed or enter into any other form of insolvency to Weir within the warranty period;
administration, Weir may at its option and without (b) Failures or damage due to misapplication, abuse,
prejudice to any of its rights and remedies under the improper installation or abnormal conditions of operation;
contract, suspend or terminate the contract or require (c) Failures or damage due to operation, either intentional or
payment in cash before or on delivery notwithstanding any otherwise, above or below rated capacities or in an
other terms of payment specified in the contract. If Weir otherwise improper manner;
terminates the contract pursuant to this clause, all amounts (d) Failures or damage resulting from Goods which have been
payable for work performed up to the date of termination, in any way tampered with or altered by anyone other than
whether or not otherwise then due for payment, will an authorised representative of Weir;
become immediately due and payable. Weir will not be (e) Goods damaged in shipment or without the fault of Weir;
liable to Purchaser for any loss or damage Purchaser suffers (f) Failures or damage resulting from the incorporation of, or
because Weir has exercised its rights under this clause. failure of, non-Weir manufactured or supplied parts in the
10. RETURN OF GOODS Goods; or
Weir may, at its absolute discretion, agree to accept the (g) Repairs to rubber lining.
return of any of Goods which have not been made or 11.5 Purchased Equipment Weir does not warrant any
purchased specifically for Purchaser and credit Purchaser equipment or other goods of other manufacturers which is
with the invoice value of the Goods provided the Goods is designated by Purchaser or purchased by Weir for resale to
returned in “as purchased” condition and the prior written Purchaser either separately or as a part of or operating in
approval of Weir has been obtained by Purchaser for the conjunction with equipment or other goods manufactured by
return of the Goods. Weir reserves the right to charge a Weir. For such equipment or other goods, Purchaser must
restocking fee for the return of Goods to stock. rely on the warranty given by the manufacturer of the
11. WARRANTIES equipment or other goods.
11.1 New Goods If within a period of 12 months from the 11.6 Supply of Services When Weir supplies Services to
date of delivery (“warranty period”) any new Goods sold by Purchaser including laboratory testing, process development,
Weir (other than purchased equipment as referred to in equipment selection, design (as part of design and
clause 11.4) are found to be defective in materials or manufacture), detail, contract supervision and contract
workmanship, or do not conform to any applicable drawings management, Weir shall exercise due care and skill in
and specifications approved in writing by Weir, or (in the undertaking such Services.
case of Goods which are Weir-manufactured pumps) do not 11.7 Limitation of Liability
perform in accordance with the current applicable water (a) Subject to clause 11.6(b), Weir’s total liability under any
performance curves supplied as part of the Weir quotation contract of which these General Conditions of Sale form part
or published by Weir as at the date of the quotation (within shall in no event exceed the total price of the Goods and/or
the tolerances specified in applicable Australian Standards), Services supplied.
then Weir will, at its option, either repair or provide (b) If any term, condition, guarantee or warranty is implied
replacement parts or Goods provided that: into these General Conditions of Sale by law, including the
(a) Purchaser has given written notice to Weir of any Australian Consumer Law, which cannot be excluded or
alleged defect within the warranty period; modified, then the term, condition, guarantee or warranty
(b) Purchaser has provided Weir a reasonable opportunity shall be deemed to be included in these General Conditions
to perform all appropriate tests on the Goods; of Sale, and the exceptions and limitations in clauses 11.1 to
(c) The defective Goods or parts are promptly returned to 11.5 do not apply to such term, condition, warranty or
a designated Weir service centre. Any defective Goods or guarantee, provided that Weir’s liability for a breach of or
parts replaced will become Weir property and the repaired failure to comply with any such term, condition, warranty, or
or new Goods or parts will be delivered free to Purchaser’s guarantee (other than a guarantee under sections 51, 52 or
site; and 53 of the Australian Consumer Law) including any
(d) No warranties are given by Weir as to the water consequential loss which Purchaser may sustain, shall be
performance of pumps other than in a test facility limited, at the option of Weir, to either replacing or
designated by Weir. Repairing the Goods or, in the case of Services, to supplying
11.2 Repaired Goods For repaired Goods, excluding rubber the Services again.
lining, the warranty period is 6 months from the date of (c) Subject to clause 11.6(b):
repair and shall only apply to Goods or parts repaired or (i) All conditions, warranties, terms, undertakings,
replaced by Weir. No separate warranty shall apply to representations, guarantees and obligations, not expressly
repaired Goods as a whole or to parts not repaired or
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MF-385-183-09.25
set out in these General Conditions of Sale or in any written 14. INSPECTION AND TESTING
contract of which these General Conditions of Sale form 14.1 Representatives of Purchaser approved by Weir will be
part, whether arising under statute, common law, equity, given access to Weir’s works or another site designated by
custom, trade usage or otherwise (including without Weir during normal office hours, for the inspection of the
limitation, any implied condition, warranty, term, Goods and (subject to clauses 14.2 and 14.3) for any testing
representation or guarantee as to the correspondence of of the Goods which is specified in the scope of works
the Goods or Services with any contract description or as to attached to or referred to in Weir’s quotation, in order to
merchantable quality, fitness for any purpose or safety of ensure compliance with specification. Purchaser must make
the Goods or Services, or operating performance where appointments for those inspections through Weir’s
such performance is conditional on empirical factors or on nominated representative, giving at least 5 days’ written
the whole installation or on the individual or overall notice (or such shorter period as may be agreed by Weir),
operation or on the skills of an operator), whether made and must be accompanied on such inspections by Weir
known or not and any liability of Weir to compensate or personnel or other persons designated by Weir.
indemnify any person or persons in respect of the 14.2 Where practicable, Weir will subject Goods to Weir’s
foregoing, are expressly negatived and excluded; standard tests before delivery. If tests other than Weir’s
(ii) In no event shall Weir be liable for any special, indirect, standard tests are required, these, unless otherwise agreed,
consequential, incidental or punitive losses or damages shall be conducted at Weir’s nominated place of works or at
whether in contract, tort (including without limitation some other place nominated by Weir in its sole discretion
negligence), equity, under statute or on any other basis, and and may at its option be charged for as extras. Any such
whether or not such loss or damage was foreseeable. The charges will be payable by Purchaser within 30 days from the
term "consequential damages" in these General Conditions date of Weir’s invoice.
of Sale shall include, but not be limited to, economic loss 14.3 If Purchaser or its representative fails or is unable to
including loss of actual or anticipated profits, business attend the tests after being given notice by Weir of not less
interruption, loss of use, revenue, reputation and/or data, than 7 days that it is ready to carry out the tests referred to
.increased cost of working, loss or damage to equipment or in clauses 14.1 and/or 14.2, the tests will proceed in the
other property, and liabilities of Purchaser to its customers absence of Purchaser or its representatives.
or third persons. 14.4 The water performance of Weir-manufactured pumps in
12. INDEMNITIES accordance with clause 11.1 above can be verified where
Subject to clause 11, Purchaser indemnifies and holds Weir required by Purchaser with water performance tests carried
harmless from and against all liabilities, losses, damages, out in a test facility designated by Weir. Additional charges
costs or expenses incurred or suffered by Weir and from and delivery extension apply if this verification is required.
and against all actions, proceedings, claims or demands 15. INTELLECTUAL PROPERTY RIGHTS
made against Weir, arising in either case as a result of: 15.1 Weir or Linatex, as applicable, is the owner of certain
(a) Purchaser’s failure to comply with any laws, rules, patents and registered designs as well as other intellectual
standards or regulations applicable in relation to the Goods property rights, including, but not limited to, copyright
or Services or the use of the Goods or Services; (together the “Intellectual Property Rights”), and Weir has
(b) Any use of the Goods or Services contrary to any also made certain applications for patents. Purchaser must
instructions or warnings given by Weir; not directly or indirectly manufacture or purchase from any
(c) Any other negligence or any breach of duty by Purchaser; third party the subject matter of the Intellectual Property
(d) Any compliance or adherence by Weir with any Rights or the patent applications, or in any way infringe the
instructions by Purchaser in relation to the Goods or Intellectual Property Rights or patent applications. The
Services or their manner of preparation or delivery; or Intellectual Property Rights remain at all times the exclusive
(e) Any failures resulting from the incorporation of, or property of Weir or Linatex, as applicable.
failure of, non-Weir manufactured or supplied parts in the 15.2 Weir or Linatex, as applicable, retains ownership of the
Goods. copyright and all other intellectual property rights in all
13. DRAWINGS AND SPECIFICATIONS drawings, manuals and other documents and materials
13.1 All descriptions, specifications, drawings and provided to Purchaser in connection with the Goods and/or
particulars of weights and dimensions attached to or Services. Purchaser may only use such documents and
submitted with any quotation or tender are approximate materials for its own internal business purposes and to the
only and the descriptions and illustrations contained in the extent necessary for it to enjoy the benefit of the Goods
catalogues, price-lists and other advertisement matter of and/or Services, and may not disclose any of them to any
Weir or Linatex, as applicable, are intended merely to third party without the prior written consent of Weir, which
present a general idea of the Goods or the Services may be granted or withheld in the absolute discretion of
described therein, and none of these shall form part of any Weir.
contract between Weir and Purchaser. 15.3 Purchaser must keep confidential all information
13.2 Only such descriptions, specifications, drawings and contained in all drawings, manuals and other documents and
particulars of weights and dimensions as are specifically materials provided by Weir to Purchaser in connection with
agreed by Weir in writing to form part of the contract shall the Goods and/or Services, except to the extent that such
do so. The designs and information concerning the Goods or information is in or comes into the public domain otherwise
the Services and as contained on any drawings which are than through any act or omission of Purchaser. It must only
supplied must not be disclosed to a third party without disclose such information to its employees, directors and
Weir’s prior written consent. advisers on a need-to-know basis.
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MF-385-183-09.25
15.4 Where and to the extent that the Goods or the are on sold by Purchaser to a third party prior to payment
Services ordered have been designed by Purchaser, by Purchaser in full for the Goods and all other goods
Purchaser is liable for and agrees to indemnify Weir supplied by Weir, Purchaser does so as agent for Weir and
against any and all costs, expenses, liabilities and losses Purchaser unconditionally agrees to keep the proceeds of
suffered or incurred by Weir arising from any claims of such on sale in a separate bank account on trust for Weir
infringement or alleged infringement of any third party’s and, at Weir’s request, to assign to Weir any debt owed to
intellectual property rights. Purchaser in respect of the on sale, until Weir has been
15.5 Where the Goods or the Services supplied are paid in full for the Goods and for all other goods supplied
designed by Weir and are found by a Court to have by Weir. Notwithstanding this paragraph, Purchaser shall
breached a third party’s intellectual property rights, Weir not represent to any third parties that it is in any way
shall have the right to do such things as are necessary to acting for Weir and Weir will not be bound by any
remedy that breach. contracts with third parties to which Purchaser is a party.
16. DISPUTE RESOLUTION 17.5 If any payment by Purchaser to Weir is overdue, in
16.1 If any dispute arises between Purchaser and Weir in whole or in part, or Purchaser is otherwise in default under
relation to or in connection with a sale or supply of Goods any contract with Weir, or Purchaser shall become bankrupt
or Services by Weir to Purchaser, they will use their best or commit any act of bankruptcy or compound with its
endeavours to resolve that dispute in a spirit of good faith creditors or have judgment entered against it in any court or,
and on a commercially realistic basis by mutual being a company, have a provisional liquidator, receiver or
negotiation or by mediation prior to commencing litigation manager appointed or enters into any other form of
proceedings. insolvency administration, all sums then owing by Purchaser
16.2 Any mediator shall be an independent person chosen to Weir in respect of the Goods or in respect of other goods
by the parties or, at their request, nominated by the supplied by Weir shall become immediately due and payable
Australian Commercial Disputes Centre. Each party shall and Weir may (without prejudice to any of its other rights)
bear its own costs. Any mediation shall take place in recover and resell the Goods and any other goods supplied
Sydney. The costs of the mediator shall be borne by the by Weir and may, for that purpose, enter upon Purchaser’s
parties equally. premises by its servants or agents, and Weir is irrevocably
16.3 If any dispute, controversy or claim has not been authorised to effect such entry, including the use of such
resolved within 30 days after written notice from one reasonable force as is necessary to effect such entry, and to
party to the other giving details of the dispute, controversy use the name of Purchaser and to act on behalf of Purchaser,
or claim, each party will be entitled to seek relief from an if necessary, to recover possession of the Goods and any
appropriate court. other goods supplied by Weir and to detach the Goods and
16.4 This Clause 16 does not prevent either party from any such other goods from any other object to which the
seeking or obtaining from a court any injunctive or other Goods have been attached or of which the Goods form a
interlocutory relief which it may urgently require. constituent part.
17. RETENTION OF TITLE, CHARGE & SECURITY 17.6 Weir is entitled to register its security interest in this
17.1 The Goods shall remain the sole and absolute Clause 17 under the Personal Properties Securities Act 2009
property of Weir or Linatex, as applicable, as legal and (‘PPSA’). Purchaser agrees to do all acts and things to assist in
equitable owner, and the property in and title to the such registration. Purchaser shall reimburse Weir for all
Goods shall not pass from Weir or Linatex, as applicable, costs, and expenses incurred in registering its security
to Purchaser until Purchaser has paid Weir in full for the interest under the PPSA. Purchaser acknowledges and
Goods and for all other goods supplied by Weir or Linatex, agrees, to the extent permitted by law, to waive each right to
as applicable. receive a notice which section 144 or 157(3) of the PPSA
17.2 Until title and property in the Goods passes, permits and to contract to exclude the operation of sections
Purchaser holds the Goods as bailee in the capacity of a 95, 121(4), 130, 132(3)(d), 135 and 143 of the PPSA.
fiduciary for Weir, and must mark the Goods or store them 17.7 Weir and Purchaser each agree to keep all information
separately and keep all necessary records, so that the of the type contemplated by section 275(1) of the PPSA
Goods can at all times be clearly identified and strictly confidential unless the other party provides prior
distinguished as the property of Weir. written consent to the disclosure or disclosure is required by
17.3 If the Goods in any way become attached to or a part law.
of another object before Purchaser has paid Weir in full for 18. GENERAL
the Goods and for all other goods supplied by Weir, 18.1 Compliance with Export Laws and Sanctions The
property in so much of the object as is comprised by the Customer shall comply with all applicable national and
Goods shall remain with Weir or Linatex, as applicable, and international export, re-export and/or economic sanctions
shall not pass to Purchaser until the Goods and all other laws and regulations, including obtaining any required
goods supplied by Weir have been paid for in full. Until authorizations or approvals, in relation to any export of the
Weir is paid in full for the Goods and all other goods Goods. Weir reserves the right to cancel or delay delivery of
supplied by Weir Purchaser holds any objects to which the the Goods if it becomes aware that Purchaser intends to
Goods are attached or of which the Goods form a unlawfully export the Goods to countries subject to
constituent part as bailee in the capacity of a fiduciary for economic sanctions laws or identified as “sensitive” by Weir
Weir and shall store such objects separately so as to be Group policy.
readily identifiable. 18.2 Non-waiver The fact that Weir fails to do, or delays in
17.4 If the Goods (or any objects to which the Goods are doing, something it is entitled to do under any contract of
attached or of which the Goods form a constituent part) which these General Conditions of Sale form part, does
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MF-385-183-09.25
not amount to a waiver of any right or remedy with
respect to any existing or subsequent breach or default.
18.3 Severability If any provision of any contract of which
these General Conditions of Sale form part is void,
voidable, illegal or unenforceable it shall be severed from
the contract but without in any way affecting the
effectiveness, validity, legality or enforceability of the
remaining provisions of the contract.
18.4 Force Majeure Weir shall not be considered in default
or liable if there is any failure to perform or delay in
performing any of its obligations under any contract of
which these General Conditions of Sale form part, to the
extent that such failure or delay is due to an event of force
majeure, but Weir shall use all reasonable endeavours to
cure such event (if curable) and to comply with its
obligations under that contract, and as soon as any such
event ceases to affect the performance of its obligations
under that contract Weir shall use all reasonable
endeavours to resume compliance with such obligations.
In these General Conditions of Sale, an “event of force
majeure” means any act of God or other occurrence
outside the reasonable control of Weir including, but not
limited to, war (whether declared or not), acts of public
enemies, industrial disputes, strikes, lock-outs, accidents,
hurricanes, fire and flood.
18.5 Interest Purchaser must pay Weir interest on all
overdue payments due to Weir under these General
Conditions of Sale at the Corporate Overdraft Interest rate
(monthly Charging Cycle) (or its successor) from time to
time charged by the Commonwealth Bank of Australia,
plus 2% per annum, calculated on daily rests from and
including the due date to and including the date of
payment.
18.6 Governing Law These General Conditions of Sale and
each contract of which they form part are governed by and
must be construed in accordance with the laws of New
South Wales.
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MF-385-183-09.25
O.E.M CONTACT DETAILS
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MF-385-183-09.25
In Australia
In Queensland: In Western Australia: In New South Wales:
Head Office Kimberly, Pilbara, Mid-West, Hunter Valley
Weir Minerals Multiflo Murchison Region Authorised Service 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
multifloparts@weirminerals.com Fax: 08 9366 2766 Fax: 02 4032 9497
Rockhampton Local contact details:

Authorised Service Provider South West Region
Weir Minerals Service Centre Authorised Service Provider
80 McLaughlin Street Weir Minerals Australia Ltd.
North Rockhampton QLD 4701 Bunbury Service Centre
Ph: 07 4924 7700 1 Shanahan Road
Fax: 07 4924 7799 Bunbury WA 6230
Email: Ph: 08 9726 2301
australiansales@weirminerals.com Fax: 08 9726 2303
Kalgoorlie & Goldfields

Authorized Service Provider
Weir Minerals Australia Ltd.
Kalgoorlie Service Centre
30 Atbara Street
Kalgoorlie WA 6430
Ph: 08 9021 1454
Fax: 08 9021 1468
Perth Metro
Authorized Service Provider
Weir Minerals Australia Ltd.
Henderson Service Centre
20 Stuart Drive
Henderson WA 6166
Ph: 08 9419 7500
Fax: 08 9410 7510
In Indonesia
PT Weir Minerals Multiflo Tanjung branch Office:
Jl Mulawarman No 29A RT Jl.Ahmad Yani Km 7.5 RT.01 Maburai.
003 Batakan Kecil Kelurahan Manggar Kecamatan Murung Pudak, Tanjung -
Balikpapan 76117 Tabalong, South Kalimantan.
East Kalimantan Phone: +62 526 - 2712267
Indonesia
Ph: 62 542 746098 Sangatta branch Office:
Fax: 62 542 746099 Jl.Yos sudarso iv rt.23 no.25
Desa Teluk Lingga, Kecamatan Sangatta
Utara.
Kabupaten Kutai Timur, Sangatta - East
Kalimantan.
Phone: +62 549 25584.
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MF-385-183-09.25
INTRODUCTION & SAFETY
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MF-385-183-09.25
INTRODUCTION
The purpose of this manual is to advise and instruct installers, operators and repairers of Weir Minerals
Multiflo® Pump Unit in the recommended installation, operation and maintenance of this equipment.
You have purchased a quality product which has been manufactured with utmost care and the ﬁnest
materials, reﬂecting many years of engineering knowledge and design.
The following information will aid you in the installation, operation and maintenance of your new Weir
Minerals Multiflo® pump unit. To ensure long life and trouble-free operation, you should read and
understand these instructions and provide regular, periodic maintenance.
The 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
correctly installed and operated as per IOM instructions, will give a long and trouble-free service with
minimum maintenance. To achieve the consistent high performance which Weir Minerals 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
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MF-385-183-09.25
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.
Good, robust Health, Safety and Environmental Systems, Process and Practices are undoubtedly an
important aspect of operating safely.
 Do not operate or perform any operation, installation, maintenance or repair on this product,
until you have read and understood the operation, installation, and maintenance and repair
information contained in the supplied documentation.
 Personal Protective Equipment (PPE) must be used when installing, operating, servicing,
maintaining and repairing this equipment.
 It is the user’s responsibility to be aware of and comply with all federal and state occupational
health and safety requirements.
 Use trained competent people to assess all site OHSE risks involved with the installation of this
equipment in accordance with the Installation and Operations Manual supplied by Weir Minerals
Multiflo®.
 Use correct, safe and appropriate equipment related to the site conditions.
SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THE SUPPLIED DOCUMENTATIONS. FAILURE
TO HEED THESE WARNINGS AND PRECAUTIONS MAY RESULT IN PERSONAL INJURY AND/OR DEATH TO
YOURSELF AND/OR OTHERS AND ALSO RESULT IN EQUIPMENT AND ENVIRONMENTAL DAMAGE.
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.
Any aspect of the installation, which the customer is unsure of, we advise the customer to discuss with a
Weir Minerals Multiflo® representative.
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MF-385-183-09.25
SAFETY SYMBOLS
The accompanying documentation supplied with the Weir Minerals Multiflo® pump unit utilises the
following safety symbols to highlight potentially harmful situations to personnel, equipments and the
environment, as per ISO 9001:2008.
SYMBOLS DEFINITIONS CONSEQUENCES
Imminent risk of fatal or Fatal or crippling injuries likely to result

crippling injuries. from any exposure.
Possibility of a harmful
Minor or slight injuries possible.
situation.
Failure to follow may lead to fatality,

Mandatory Instructions injuries or damage to property and
environment.
Possible damage to the product,

Prohibited activities.
equipments or property.
Fatal or crippling injuries likely to result

Warning of electrical shock.
from any exposure.
Mandatory Personal Fatal or crippling injuries likely to result if

Protective Equipments. not worn.
Possibility of explosion if instructions not

Explosion warning.
followed.
Application hints and other

useful Information.
User has to refer accompanying manuals

Refer other documents.
or other documents.
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MF-385-183-09.25
RISKS
It is the user’s responsibility to perform the risk analysis specific to the application of the pump unit and
the site conditions.
It is the user’s responsibility to understand all the inherent risks and consequences involved during
Moving, Locating, Positioning, Assembly, Installation, Operation & Maintenance procedures and take
necessary precautions against such risks.
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MF-385-183-09.25
PUMP UNIT DESIGN & TECHNICAL

DATA
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MF-385-183-09.25
PUMP UNIT DATA - 2025-0001

JOB NUMBER 2025-0001
OWNER PT Weir Minerals Indonesia (PT Sukses)
PURCHASE ORDER NUMBER 4500006380

UNIT MODEL MF - 385GSS
Multiflo® model MF-385, Base mounted,

UNIT TYPE
Vacuum primed unit
PUMP UNIT SERIAL NUMBER MF-385-183-09.25

ORIGINAL DISPATCH DATE September 2014
ENGINE MAKE Caterpillar
ENGINE MODEL C13
ENGINE SERIAL NUMBER RRA08169
ENGINE ARRANGEMENT NUMBER 360-5981
ENGINE OPERATING SPEED 1800 rpm
ENGINE VOLTS 24 V
POWER 310 kW @ 1800 rpm
BARE SHAFT PUMP MODEL Multiflo® 385GSS
BARE SHAFT PUMP SEALING Gland
BARE SHAFT PUMP BEARING LUBRICATION Grease Lubricated - Automatic
LABYRINTH LUBRICATION Grease Lubricated - Automatic
DRIVE COUPLING Fenner Tyre coupling - F140
NON RETURN VALVE TYPE 150 mm
NON RETURN VALVE MATERIAL Stainless Steel
TOTAL UNIT MASS 8,500 kg
SUCTION FLANGE TYPE 200 mm Table E
DISCHARGE FLANGE TYPE 200 mm ANSI class 150
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MF-385-183-09.25
BARE SHAFT PUMP DATA - 2025-0001

JOB NUMBER 2025-0001
PUMP DESIGNATION Multiflo® MF 385GSS
BARE SHAFT PUMP MATERIAL Standard
BARE SHAFT PUMP SERIAL NUMBER 6A-385GSS-289
IMPELLER MATERIAL 316 stainless - (AS 2704)
SUCTION 200 mm
DISCHARGE 150 mm
IMPELLER TYPE Open
IMPELLER DIAMETER 500 mm
IMPELLER VANES 4
MIN. PASSAGE SIZE 45 mm
H (m) 105 m
MAXIMUM RPM 1800 rpm
EFFICIENCY 65%
DUTY 150 l/s
NPSHr 8m
POWER 271 kW
SHAFT SLEEVE MATERIAL Standard
VOLUTE POSITION A
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MF-385-183-09.25
PART I
ASSEMBLY INSTRUCTIONS
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MF-385-183-09.25
1 ASSEMBLY
1.1 PUMP UNIT PACKING, TRANSPORT & HANDLING
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 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 THE DESTINATION IN THE SAME ORDER AS TENDERED BY THE
SHIPPER.
In the event of damage or shortage, have the transportation company note the same on the
freight bill.
A packing list is attached to all the shipment for the items contained. Check each item against
the list. Check by description, Item/Tag No., Document reference, quantity, etc. Must there
be any discrepancies, notify Weir Minerals Multiflo® immediately. Small parts and items such
as bolts, washers, bushings and keys are just as important to the assembly of the larger parts.
Ensure that these are located and checked before disposing of any containers or packing
equipment. Weir Minerals Multiflo® is not responsible for the loss of items that are listed and
included on our packing list.
1.1.1 PACKING
The MF - 385 pump unit is shipped through an approved transport company. The MF - 385
pump unit is disassembled to suit the transport requirements. The pump unit components
are packed and shipped separately and must be assembled onsite to form a complete pump
unit.
Refer to the packing list attached with the pump units for more details.

MF-385-183-09.25
1.1.2 LOADING & UNLOADING
Lifting, loading and unloading of the pump unit components must be undertaken
by experienced personnel only. Refer to the site procedures for lifting, personnel
and equipment requirements.
Keep all body parts clear of moving machine parts during lifting.
Do not stand under suspended load.
Be careful not to get fingers caught in and under the lift assembly.
 PPE must be worn all the time while moving, installing, operating or
overhauling the unit.
 Ensure correct PPE is available at the start of the job.
 Check all PPE for faults/damage, and correct fit for all personnel.
 Ensure correct manual handling techniques are identified and communicated
to all workers on task.
 PPE is to be worn in accordance with the specific job specifications.
 Ear muffs to be used in place of ear plugs, if the noise level exceeds legal
levels.
 Safety specs to be worn in areas of high risk to eyes.
 Hard hats to be worn in all designated areas (specifically when working
on/under or around loads).
 Safety boots to be worn in all work areas.
 Gloves & other safety equipment as and when needed.
Unload all the pump unit components using approved and appropriate lifting and unloading
techniques. Consideration must be given to the mass and dimensions of individual
components while selecting the lifting equipments and procedures.
The user must unload the components using appropriate lifting & unloading procedures and
equipment.
Assembly and Operational Observations
 Ensure all equipment required to lift items for assembly are available and in good
serviceable condition. This will include forklifts, overhead gantry cranes, slew crane and
all the lifting equipment necessary to lift the pump unit assemblies and parts that is
Slings, chains etc.
 Ensure a specific SOP/risk assessment is compiled for any operation with consideration
to the specific steps associated with this assembly as detailed in this document.
 Use the correct tools and follow correct and recommended procedures. Personnel must
not work under suspended loads.
 Always check centre of gravity. Use appropriate supports or cradles that extend in front
of the component past the centre of gravity.
 Ensure that personnel have access to manuals and understand the various risks involved.
Always operate in accordance with manuals and remain within the allowable
recommended maximum operating limits.
 A specific SOP/risk analysis must be completed for all hazardous lifting operations.
Crane/Plant operators, dog-man, and field service personnel to be aware of specific risks
associated with the lifting/moving operation, and follow the SOP and risk analysis
closely.
MF-385-183-09.25
 Rigger/dogger to access work task prior to proceeding. Access and use correct manual
handling techniques, ask for assistance if required.
 Open communication/line of sight with crane driver whilst performing the task.
 Crane operator to exercise caution, and utilize communication with rigger/dogger as
required.
 If the crane is deemed to be unsuitable for operation, cease process and shut down the
crane. Re-communicate with site management regarding crane layout/type of crane to
be used for job.
 Vehicle movement to be constantly supervised whilst on site by supervisor.
 Ensure loads are secure and weight is distributed evenly.
 Keep unnecessary personnel away from area. Barricade the area and erect warning signs
where required.
 External weather conditions, fatigue of employees, inadequate training of personnel to
carry out the required procedures, lack of safety equipments, lack of PPE and risk
analysis, incorrect lifting equipment and techniques, not providing due diligence to
weights, dimensions and safe operating procedures will result in serious and fatal
injuries to the personnel and cause equipment/ property damage. Ensure all risks are
analyzed and all on site safety procedures are adhered while performing any operation.
Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, onsite
health and safety regulations and the operators own internal work, operation and safety
regulations.
Personnel Qualification and Training
All personnel involved in the operation, inspection and maintenance of the unit must be
qualified to carry out the work involved. If the personnel in question do not already possess
the necessary knowledge and skill, appropriate training and instruction must be provided.
1.1.3 RECEIPT AND SHIPPING - GENERAL NOTES
Upon receiving the pump unit, check for any damage as follows:
 Inspect all the components for shipping damage.
 In case of any damage, immediately alert the shipping company to the nature of the
damage.
 Contact Weir Minerals Multiflo® for further queries.
Weir Minerals Multiflo® is not responsible for any damage that might have occurred
during shipping of components.
1.1.4 REPORTING SHIPPING SHORTAGE

If you did not receive all the goods that you ordered and present on the packing list, do the
following:
 Check the number of items listed on the packing list. If the number of pieces listed is
greater than the number of pieces received, contact the carrier concerning the missing
piece.
 Carefully check the packing material and container to ensure that you did not overlook
the missing item.
 If you cannot find the item, please notify Weir Minerals Multiflo® immediately.

MF-385-183-09.25
Weir Minerals Multiflo® contact details are provided at the beginning of this manual for
any queries.
.
Refer to the packing list attached with the pump unit for more details.
1.1.5 STORAGE PROCEDURES

Upon the receipt of all goods, the next step is the proper storage of the components prior to
use. 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.
Upon receipt of the pump unit, components must be stored in a dry, vibration, shock and
dust free environment. Humidity must also be avoided.
All electrical components must be stored in a dry, damp - free and dust free environment.
All electrical components must be properly enclosed in a crate or any suitable packing
material.
Ensure adequate ventilation is provided when electrical components are stored and
ventilation openings are not obstructed.
THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP UNIT AND ANY
ASSOCIATED EQUIPMENT WHEN STORED, HANDLED AND TRANSPORTED ON-SITE.
1.1.5.1 STORAGE RECOMMENDATIONS AFTER THE PUMP UNIT IS ASSEMBLED
If the assembled pump unit is to be stored prior to use it must be stored in vibration and
shock free conditions.
1.1.5.2 REPACKING
If the pump unit components have to be transported again, the user must repack the unit
in a similar manner as it was received.
Appropriate packing, loading, lifting and transport procedures must be followed so as to
not damage the integrity of the components.
Weir Minerals Multiflo® does not bear any responsibility if any pump unit components are
damaged during repacking and transport.
1.1.6 ENVIRONMENT CONDITIONS
The Weir Minerals Multiflo® MF - 385 models are of a robust construction and are designed
to operate in harsh weather conditions. Rain will not affect the operation of the pump units.
However, it is necessary to take caution when the weather takes turn for worse, say, flash
floods in case of dam, pit dewatering operations, etc.
1.1.7 FIRE SUPPRESSION AND FIRE EXTINGUISHERS
Fire suppression systems are tested and certified during OEM product on, it is a
maintenance requirement for the system to be inspected every6months. Current
certification of the fire system needs to be checked during assembly and commissioning. If
the system certification is out of date, Inspect on and re certification must be completed
before the unit is put into service.
Fire extinguishers are supplied without current certification and need to be tested and
tagged prior to the machine being operated.
MF-385-183-09.25
1.2 SAFETY NOTES - PRE-OPERATIONAL & ASSEMBLY
1.2.1 BARE SHAFT PUMP SAFETY
THE PUMP IS BOTH A PRESSURISED COMPONENT AND A PIECE OF ROTATING
EQUIPMENT. ALL STANDARD SAFETY PRECAUTIONS FOR SUCH EQUIPMENT MUST BE
FOLLOWED BEFORE AND DURING OPERATION AND MAINTENANCE.
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 the 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 will cause the pump casing to crack.
Tapped holes (for eye bolts) and lugs (for shackles) on bare shaft pump parts are for
lifting individual parts only.
To eliminate the possibility of brinelling of the pump, shaft locking devices may be
employed. These must be removed and the free rotation at the pump and engine must be
checked before use.
The bare shaft pump rotation check must be carried out with the pump completely
disconnected from the engine. Rotating the pump in the reverse direction will unscrew
the impeller from the shaft causing serious damage to the pump.
The correct direction of pump rotation will be indicated on the volute of the pump.
1.2.2 MANUAL SHAFT ROTATION

It is also recommended that the shaft of the bare shaft pump be rotated a minimum of
three full rotations at least once in every seven days.
Method of Rotation:
a) Remove the coupling guard.
b) With shaft and coupling exposed, rotate the shafts three full turns.
c) Replace the coupling guard.

MF-385-183-09.25
1.3 PUMP UNIT DESCRIPTION
1.3.1 MAJOR COMPONENTS
The MF-385 centrifugal pump unit is vacuum primed, diesel engine driven and is base
mounted. A Caterpillar C13 diesel engine is the main drive unit and is protected by an all-
weather canopy.
Assembly, operation and maintenance of all the major components are explained in
subsequent sections. Appropriate safety, assembly and installation instructions and
references are provided throughout the manual. It is the user's responsibility to read and
follow these instructions before/during any assembly, installation, operation and
maintenance procedure.
Positive pump priming is critical to the reliability of a pump unit. Weir Minerals Multiflo®
pump units are designed to ensure that the pump is always able to self-prime within
moments of starting.
1.3.2 UNIT MAJOR COMPONENTS
Strobe Light
Lifting Point
Vacuum Tank
NRV
Diesel
Engine
Battery
Vacuum Box
Pump
Winch Discharge
Bare Shaft Assembly
Pump

MF-385-183-09.25
Vismode Control Box

Coupling Guard
Service
Point Fuel
Filter Pico Electro Fire Extinguisher
Luber Mount
Gauge Panel
Fig.1.1 MF-385GSS unit major components
Boom Chains
Suction Boom
Winch Rope
Spreader Bar
Strainer
Suction Pipe
Fig.1.2 MF-385GSS suction components

MF-385-183-09.25
1.3.3 UNIT LIFTING POINTS
Unit Lifting Points
Fig.1.3 MF - 385GSS Pump unit lifting points
Refer to "Part IV - Spare Parts List" of this manual for a complete list of parts.
Refer to “Part V - Appendices” of this manual for Torque Setting Values and Electrical
Data.
1.3.4 DISCHARGE ASSEMBLY
Isolation Valve
Discharge Pipe
Bleed-off Valve
Fig.1.4 MF - 385GSS Discharge assembly

MF-385-183-09.25
1.4 SAFETY NOTES – ASSEMBLY AND MOVING
Lifting of the pump unit components must be undertaken by experienced
personnel only. Refer to site procedures for lifting, personnel and equipment
requirements. Only use site approved lifting equipment.
IT IS THE USER’S RESPONSIBILTY TO ENSURE THAT NO COMPONENTS ARE
DAMAGED DURING ASSEMBLY PROCEDURES.
Only use designated crane lifting points to lift pump components.
Pump unit to be moved by experienced personnel only.
After unpacking, the components must be stored in a dry, dust-free, vibration-
free environment to avoid damage. Ensure that there is sufficient space
around the pump unit assembly to work around.
Pump unit to be tagged and locked out before performing any procedures.
Assembly to be carried out on level flat ground and by trained personnel only.
The following graphical descriptions are intended as a guide only. Some of the
instructions may contain information & illustrations which may not be specific
for this pump unit.
 Ensure correct manual handling techniques are identified and
communicated to all workers on task.
 PPE to be worn in accordance with the specific job specifications.
levels.
Do not stand under suspended load.
Do not place any part of body under suspended load.
Make sure to use anti-seize on all bolt threads before tightening the bolts.
When bolt holes are aligned, insert bolts and tension.

MF-385-183-09.25
1.5 ASSEMBLY INSTRUCTIONS
1.5.1 PRE - ASSEMBLY CHECKS
Before carrying out any assembly procedures, please check the following:
 No damage has occurred to the pump unit or any of its components during transport of
the unit or its handling.
 All the mechanical and electrical connections remain undamaged. Check for paint
damage and repair if any damage has been found.
 Please contact Weir Minerals Multiflo® customer services for any queries.
Pre - Assembly and Facility Observations:
 Ensure a specific SOP/risk assessment is compiled for any operation with consideration
to the specific steps associated with this assembly as detailed in this document.
 All assembly procedures to be carried out on level ground only.
 If ground is excessively rough, have it levelled first.
 Ensure that there is sufficient space around the pump unit to work around.
 Necessary arrangements to be made to provide safe working conditions as per on-site
laws.
 Close the assembly area to all traffic.
 Necessary movable road blocks, warning and information signs to be installed.
 Service vehicles for workers and staff to be facilitated while going inside the area.
 Keep the assembly work area as clean as possible.
 Ensure signage and barricading is appropriate near pump unit (if required) to prevent
serious to fatal injuries to employees working on the unit.
 All lifting operations must be undertaken only after giving consideration to the mass and
dimensions of the components.
 All safety equipment, tools and necessary accessories for performing assembly
procedures MUST be kept ready beforehand.
 All procedures must be carried out by trained personnel only. If necessary training must
be provided to person/persons handling the assembly procedures.
 All procedures MUST be carried out in accordance to local laws and local environmental
norms.
After unloading the pump unit components employ appropriate lifting techniques and
position the components at the appropriate site for assembly. Prior to assembly, remove
any surface rust or debris from all the threaded holes.

MF-385-183-09.25
1.5.2 ASSEMBLY PROCEDURES
The MF - 385GSS pump unit is shipped with the Suction Assembly and Discharge Assembly
disassembled. After positioning the pump unit at an appropriate location, the discharge and
suction assembly components must be assembled as explained below.
Refer to "Part IV Spare Parts List" a complete list of parts.
Use designated lifting eyes only.

Use appropriate lifting procedures and equipment to lift the components.
 Ensure that there is sufficient space around the pump unit assembly to work around.
 When bolt holes are aligned, insert bolts and tension.
 Assembly procedures to be carried out on level ground only.
 Assembly of the boom assembly components to be undertaken by experienced
requirements.
 Prepare ground level close to the positioning point. Ensure that there are no uneven
surfaces.
All assembly 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 assembly of items not
specifically used for this pump unit.

MF-385-183-09.25
1.5.3 ASSEMBLY OF DISCHARGE PIPEWORK
The Discharge Pipe assembly is fitted onto the base as shown in Fig.1.5.
Fig.1.5 Assembling discharge assembly

a) Installation of Discharge Assembly
Discharge assembly consists of two Discharge pipes, Isolation Valve and a Spool.
Installation to be done as explained below.
i. Assemble Discharge Pipe attached with Bleed-off Valve to NRV along with a
gasket.
ii. Attach the other Discharge Pipe to the already assembled Pipe along with the
gasket.
iii. Fit the Isolation Valve and the Spool to the Discharge Pipe.

MF-385-183-09.25
b) Assembly of Suction Components
i. With boom lying flat, insert boom locking bolts in boom and pump base.
Tighten bolts. (See Fig.1.6).
ii. If not already done so, attach winch to pump base winch mount.
iii. With boom lying flat, run winch rope through boom pulley. Removal of the
pulley may be necessary.
Boom
Fasteners
Fig.1.6 Assembling suction assembly components

MF-385-183-09.25
iv. 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 (See Fig.1.7) on the
canopy.
v. Attach winch rope to the spreader bar using the D-shackle (See Fig.1.7).
vi. Fit Suction Strainer to the Suction Hose.
Attaching Strainer
Attaching
Winch Rope
Fig.1.7 Fitting boom chains, suction strainer and attaching winch rope
MF-385-183-09.25
Refer to "Part IV Spare Parts List" a complete list of parts.
Use designated lifting eyes only.

Use appropriate lifting procedures and equipment to lift the components.
 Ensure that there is sufficient space around the pump unit assembly to work around.
 When bolt holes are aligned, insert bolts and tension.
 Assembly procedures to be carried out on level ground only.
 Assembly of the pump unit assembly components to be undertaken by experienced
requirements.
 Prepare ground level close to the positioning point. Ensure that there are no uneven
surfaces.
All assembly 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 assembly of items not
specifically used for this pump unit.
1.5.4 PUMP UNIT MASS
Consideration must be given to the pump unit components mass and dimensions while
transporting, moving, lifting.
Pump Unit Mass
Description Mass in kgs
Pump Unit Mass (dry) 6,500
Pump Unit Mass (wet) 8,500
1.5.5 CORRECT POSITION OF SUCTION BOOM
The suction boom supports the suction hose and allows it to be raised and lowered using a
winch. The boom is to be installed so that it sits at an angle of 45° to the deck of the pump
unit. It must be checked that the boom chains that run back to the canopy of the unit are of
equal length.
45°
Fig.1.8 Correct position of suction boom

MF-385-183-09.25
PART II
OPERATION

MF-385-183-09.25
2 OPERATION
2.1 SAFETY NOTES – OPERATION
Bare shaft pump, diesel engine parts and all the fluids may be at extremely
high temperatures when the pump unit is stopped and may cause serious
burns. Ensure pump unit is cooled before any checks or maintenance is carried
out.
Pump unit to be locked and tagged before any operation is carried out.
Do not wear loose clothes around rotating machines.
While working near electricity, DO NOT use metal rules, flashlights, metallic
pencils, or any other objects having exposed conducting material.
Make sure you are NOT grounded while adjusting electrical equipment or using
measuring equipment.
It is the user’s responsibility to ensure that appropriate pipes/hoses are
connected at the discharge and suction ends of the bare shaft pump.
Pump unit must be operated by trained personnel only.
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.
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.
levels.
2.1.1 SAFETY AWARENESS
health and safety regulations and the operator’s own internal work, operation and safety
regulations.
2.1.2 PERSONNEL QUALIFICATION AND TRAINING
All personnel involved in the operation, assembly, inspection and maintenance of the unit
must be qualified to carry out the work involved. If the personnel in question do not already
possess the necessary knowledge and skill, appropriate training and instruction must be
provided.

MF-385-183-09.25
2.1.3 GENERAL NOTES - PUMP UNIT LOCKOUT AND TAGGING
When operational work is carried out on plant and equipment, a lockout procedure is
required to safeguard the personnel carrying out this work.
All energy sources must be isolated and stored energy dissipated before carrying out any
work.
A procedure must be formulated and documented to provide plant specific instructions for
workers to follow in the Lockout/Tag-out out of equipment.
Personnel must be trained in the implementation of site Isolation procedures and the
correct use of tags and locks.
Hazardous Energy Sources
The hazardous energy sources must be identified and if a potential risk is apparent then
measures must be taken to eliminate, isolate or dissipate the energy.
There are four kinds of energy sources:
 Electrical energy (mains, battery/capacitor, static)
 Mechanical energy (transitional, rotational)
 Thermal energy (hot, cold)
 Potential energy (springs, gravity, hydraulic/pneumatic/vacuum pressure)
Isolating Hazardous Energy
 Isolate all forms of potentially hazardous energy.
 Ensure that an accidental release of hazardous energy does not occur.
 Make certain that entry to a restricted area is tightly controlled.
 Apply locks and tags to ensure that energy isolation devices remain in the “OFF” or
“SAFE” position. Tags applied must be easily read and identified.
2.1.4 OPERATIONAL AND SAFETY OBSERVATIONS - GENERAL
 Ensure a specific sop/risk assessment is compiled for any operational procedure.
 Ensure that personnel have access to manuals and understand the various risks involved.
Always operate in accordance with manuals and remain within the allowable
 Keep unnecessary personnel away from area. Barricade the area and erect warning signs
where required.
 External weather conditions, fatigue of personnel, inadequate training of personnel to
analysis, incorrect lifting equipment and techniques and not providing due diligence to
weights, dimensions, safe operating procedures may result in serious and fatal injuries to
the personnel and cause equipment and property damage. Ensure all risks are analyzed
and all on site safety procedures are adhered while performing any operation.
 Ensure signage and barricading is appropriate near pump unit to prevent serious to fatal
injuries to personnel working on the unit.

MF-385-183-09.25
2.2 BARE SHAFT PUMP SAFETY NOTES
THE PUMP IS BOTH A PRESSURISED COMPONENT AND A PIECE OF ROTATING
EQUIPMENT. ALL STANDARD SAFETY PRECAUTIONS FOR SUCH EQUIPMENT MUST BE
FOLLOWED BEFORE AND DURING INSTALLATION, OPERATION AND MAINTENANCE.
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 pump parts are for lifting
individual parts only.
To eliminate the possibility of brinelling of the pump bearings, shaft locking devices may
be employed. These must be removed and the free rotation at the pump must be checked
before use.
The pump rotation check must be carried out with the pump completely disconnected
from the engine. Rotating the pump in the reverse direction will unscrew the impeller
from the shaft causing serious damage to the pump.
It is also recommended that the shaft of the bare shaft pump be rotated a minimum of three
full rotations at least once in every seven days.
Method of rotation:
a) Remove the coupling guard.
b) With shaft and coupling exposed, rotate the shafts three full turns.
c) Replace the coupling guard.

MF-385-183-09.25
2.3 GENERAL DESCRIPTION & FUNCTION OF THE EQUIPMENT
2.3.1 PRINCIPLE OF OPERATION
The MF - 385 pump unit is designed to be used as a mine dewatering pump unit in
accordance with the pump performance data contained in this manual. The pump is driven
by directly coupled Caterpillar diesel engine. The vacuum pump is connected to the bare
shaft pump by a belt driven system.
This type of bare shaft pump used on Multiflo® pumps is of the centrifugal design and this
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 mounted on the gauge panel board 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 suction hoses, 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 uses vacuum to prime the bare shaft pump, it is necessary to ensure that the
hose couplings to the bare shaft pump, both suction and discharge, are completely sealed. It
will be necessary to use a “non-return valve” to prevent the vacuum pump sucking air back
through the discharge side of the pump which would cause the auto vacuum prime system
to malfunction.
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.
Use the correct size pipe on the discharge to obtain maximum performance from the unit.
2.3.2 PUMP UNIT ORIENTATION
Pump Unit Left Side

Pump Unit Front End
Pump Unit
Rear End
Pump Unit Right Side
Fig.2.1 Pump unit orientation

MF-385-183-09.25
2.4 DESCRIPTION OF MAJOR COMPONENTS
2.4.1 BARE SHAFT PUMP
The ‘MF’ range of Multiflo pumps are specifically designed for continuous running in slurry
and dirty water duties where ordinary water pumps are not suitable. Acidic water found in
many mine water runoff situations can also be handled.
The impellers are specially designed to obtain high efficiencies without requiring close
clearances between impeller and casing, and still maintain the ability to pass reasonable
sized solids.
The impeller is cast from 316 stainless - (AS 2704). This long wearing material has been
developed for abrasion and corrosion resistance and also to give a long life in slurry
pumping applications.
Fig.2.2 Bare shaft pump - 385GSS
Volute
Wear Plate
Stuffing Box
Impeller
Cover Plate
Gland Seal
Fig.2.3 Bare shaft pump wet end parts

MF-385-183-09.25
Roller Bearings Bearing Housing Pedestal
Gland Follower Shaft
Ball Bearings
Fig.2.4 Bearing assembly parts

2.4.2 CATERPILLAR DIESEL ENGINE
For further information, refer to “Caterpillar C13 Manual" supplied.
Refer to wiring diagram in the appendices section of this manual for electrical wiring
connections information of the unit.
2.4.3 MODEL 57 PISTON TYPE VACUUM PUMP
The vacuum pump is 38 C.F.M. air cooled twin reciprocating piston type fully sealed unit
with self-contained oil lubrication - 2.2 litres capacity. Operating at 700 rpm, it is driven by
two "SPZ" section vee belts from the pump input shaft.
Refer to “WMM Model 57 Vac Pump Manual” in the accompanying manuals section of
this manual for further information.
2.4.4 VACUUM GAUGE

A vacuum gauge which is mounted on the panel board indicates, while the pump unit is
operating, dynamic head loss in the suction system. The normal operating range depicted by
the gauge must be within -80 kPa to -20 kPa.
Fig.2.5 Vacuum gauge

MF-385-183-09.25
2.4.5 VACUUM TANK
The high lift vacuum tank is manufactured from 6 mm stainless 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.
Krundimendt Valve
Vacuum Tank
Water Separator
Probes
Fig.2.6 Vacuum tank

2.4.6 VACUUM PRIME SYSTEM
The vacuum prime system consists of two probes fitted into the vacuum tank, an electric
clutch fitted to the vacuum pump and the 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, if the discharge line 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.
Refer to “WMME Robatic Clutch Parts & Procedure” in the accompanying manuals
section for further details.

MF-385-183-09.25
2.4.7 NON RETURN 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:
 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.
 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®
Valve). The flap must 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.
Flap Closed Flap Open
Fig.2.7 NRV Operation

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.
2.4.8 HYDRAU-FLO® FUEL FILLING 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.
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.
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.
For further information on Hydrau-flo fuel filling valve components, refer to “Hydrau-flo®
IOM” in accompanying manual section.

MF-385-183-09.25
2.4.9 TURBINE SERIES 1000FH FUEL FILTER/WATER SEPARATORS
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.
Fig.2.8 Fuel Filter/Water Separator
Mount the filter assembly vertically. Do not exceed 10 from vertical or the assembly
may not function properly.
2.4.10 ENGINE MONITORING SYSTEM

Refer to Wiring Diagrams in the accompanying manual section for more details.

MF-385-183-09.25
2.5 NORMAL OPERATING PROCEDURES
Ensure that the Emergency Stop (Isolation Switch) is in the correct position to enable the
unit to be started. Re-set the emergency stop to start position by turning in clockwise
direction until the button releases. The code to unlock Battery Isolator key is ‘123’.
Pump unit to be locked and tagged before any maintenance or service is carried
out.
Engine and bare shaft pump parts and all fluids will 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.
Personal protective equipment must be worn when operating or servicing this

unit.
2.5.1 PUMPING OPERATION OBSERVATIONS

Ensure:
 The largest possible pipe diameter, both at suction and discharge, is being used.
 Ensure that a correct suction assembly is employed for the unit.
 The foot valve must be no less than one meter below the surface of the water.
 The hose couplings, both suction and discharge, are completely sealed.
 The bare shaft pump is operating without cavitation.
 There is a good and constant rate of liquid flow coming into the suction end of the bare
shaft pump.
 There is a good rate of liquid flow coming from the end of the discharge line.
 The unit as clean as possible.
 The gland packing is replaced 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.
 Maximum RPM must not be exceeded; vibration from impeller imbalance will lessen
bearing life.
 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 must be checked.
 The pump unit is situated in a safe position and not operating at an angle of more than
10°.

MF-385-183-09.25
2.5.2 DAILY START PRE CHECKS
Engine Oil Maintain oil level between ‘add’ and ‘full’ marks on the dipstick.
Check all diesel engine and bare shaft pump mounting bolts are
Mounting bolts
not loose or missing. Retighten or replace bolts as necessary.
Ensure the gland is adjusted to the correct position required to
Gland adjustment
pump.
Vacuum Pump Oil Maintain level between ‘high’ and ‘low’ mark on the dipstick.
Drive belts Check condition and re-tension if required or replace if
(Fan/generator/vacuum pump) necessary.
Probes Clean the probes.
Water trap Drain and clean the bowl.
Auto Greaser Check the grease level.
Fuel Tank Fill as required. Use dipstick.
Battery Maintain level in range above plates and filler bridge.
Make sure engine is stopped and cold. Maintain level in range
Coolant Level
above baffle plate and filler neck.
2.5.3 STARTING PROCEDURE
1. Complete the prestart checks.
2. Ensure that all applicable suction and discharge valves are open.
3. Ensure Emergency Stops are disengaged.
4. Turn starter motor and Battery Isolators to ‘ON’.
5. Turn start switch to start the engine and idle at 750-800 rpm for 2 minutes.
6. Increase the RPM to 1000 until the wet end primes (approximately -20 to -40) on the
vacuum gauge). When primed, set the rpm to achieve the desired duty point.
7. Check for Gland Packing leakage and adjust as required.
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.
It is recommended that the unit be monitored for at least six minutes to ensure it does
not shut down on prime or flow.
Do not run the pump in cavitation for extended periods.
2.5.4 OPERATING SPEED

Increase the engine RPM until the pump starts to cavitate. The pump will vibrate and a
crackling sound will be heard from the pump volute. Decrease the RPM slowly until the
pump stops the cavitation 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.

MF-385-183-09.25
It is recommended that the unit be monitored for at least six minutes to ensure it does
not shut down on prime or flow.
Do not run the pump in cavitation for extended periods.
1. Check all engine gauges.
2. Check for oil or water leaks etc around the engine.
3. Check that the engine protections system is set.
4. The vacuum prime light will go out when the vacuum pump starts pumping.
Even though the pump does not cavitate it could create imbalance in radial force inside
the pump casing. If this occurs, it puts more load on the bearings.
The code to unlock Battery Isolator key is 123.
Emergency Stop Discharge Pressure Vacuum Pressure

Gauge Gauge
Control Box
Fig.2.9 Control station
Refer to “Part V - Appendices” section of this manual for all electrical data.

MF-385-183-09.25
2.5.5 NORMAL OPERATION
Please refer to site procedures.
2.5.6 SHUTDOWN PROCEDURES
1. Decrease engine rpm slowly to idle.
2. Allow the engine to idle for 2 - 3 minutes before shutting down.
3. Stop the engine.
4. Turn the master switch key to ‘off’ position.
5. Drain down the pump if it has been used for pumping slurry.
2.5.7 SHUTDOWN PROTECTION
2.5.7.1 VISMODE CONTROL PANEL
Fig.2.10 Vismode front panel

The “Vismode” control panel is a tool to monitor the operating parameters of the electrical
system. When running, the Engine ‘Running’ Light will be lit for the entire time the engine
is running. The ‘Priming’ 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 ‘Priming
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
six minute cycle to shut down. If the prime is regained in this time the shutdown timer will
not continue & will reset.
If the unit has shut down by other means than by the operator tuning the key the cause
will be displayed on the Vismode panel and will remain there until the ignition has been
turned off (or if the Vismode is reset by pressing the Stop button). If the fault is shown as
engine shut down it is the Caterpillar system that has shut the unit down, consult the CAT
Manual for engine shutdown conditions.
MF-385-183-09.25
2.5.8 LOW FLOW SWITCH
The system is fitted with heavy duty wire low flow switch which senses low flow in the
suction and triggers a shutdown process.
Refer to "Wire Flow Switch" manual in the accompanying manual section for more
details.
2.5.9 TAPERLOCK BUSHES
Refer to "Taperlock Assembly & Installation" in the accompanying manuals section of

this manual for further information any taperlock bushes.
2.5.10 DIESEL ENGINE OPERATION PROCEDURES, START-UP PROCEDURES AND SHUTDOWN PROCEDURES
Refer to "Vismode Operation and Maintenance Manual" in the accompanying manuals

section for more details.
2.5.11 PUMP UNIT GREASING SYSTEM

Refer to “Operating instructions for the central lubrication pump PICO with integral
controller S-EP 4” in the accompanying manuals section of this manual for further
information on PICO BEKA MAX Auto Greaser Unit.
2.5.12 LOW-FUEL SHUTDOWN SYSTEM
The Fuel level Shutdown Switch monitors the Fuel Level in the Fuel Cell. When it determines
that the fuel capacity has decreased to a predetermined level, it will start a shutdown
procedure. The Engine will ramp down to idle, and after a cool off period will shut down.
The event will be monitored and displayed on the Vismode Panel.
Fuel Float
Switch Setup
Fig.2.11 Low-Fuel shutdown setup

MF-385-183-09.25
2.6 EMERGENCY AND ABNORMAL CONDITIONS
2.6.1 CAVITATION
Cavitation is vaporized 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:
 Pitting of material surfaces due to continual hammering action.
 Reduction in pump performance.
 Damage to impeller and casing, if cavitation is severe.
Fig.2.12 Result of recirculation on Front Door/Throat Bush Fig.2.13 Result of cavitation on impeller
2.6.2 RECIRCULATION
Recirculation in the pump can be identified by excessive wear around the eye of the
impeller and the throat bush of the front door. This is generally caused by excessive
clearance between the impeller and the front door, it will result in decreased performance
and in extreme circumstances component failure. Recirculation damage will look much like
cavitation damage but will be in the low pressure area of the pump.
2.6.3 VIBRATION
Vibration has several possible causes, most commonly debris has become lodged in the
impeller veins. However bearing wear and coupling element deterioration may be the cause
or a symptom of unsustainable operating conditions. Other causes can be but not limited to
engine balance, loose mounting or coupling bolts, cavitation and harmonics.
Operation of the unit with severe vibration for extended periods will result in reduced
service life or component failure.
2.6.4 MAINTENANCE PROCEDURES
The maintenance schedule detailed in section 3 of this IOM manual must be strictly adhered
to. Deviation from the procedure or service intervals without proper assessment or
consultation with WMM may result in catastrophic failure of components or the unit.
2.6.5 FIRE
Follow site specific procedures in the unlikely event of a fire. Two 9 kg fire extinguishers are
fitted to quick release brackets on either side of the pump unit for use on manageable fires.
The engine must be stopped using the emergency stop switches if it is safe to do so.
2.6.6 OIL LEAK, SPILL
Any oil leak from any part of the unit needs to be rectified immediately. Larger leaks or spills
need to be controlled, cleaned up and reported as per site requirements and government
regulations. Oil spill booms, where required, must be maintained as per the manufacturer’s
recommendations.
MF-385-183-09.25
PART III
MAINTENANCE

MF-385-183-09.25
3 MAINTENANCE
3.1 NORMAL MAINTENANCE PROCEDURE - SAFETY NOTES
Bare shaft pump, diesel engine parts and all fluids may be at extremely high
temperatures when the pump unit is stopped and will cause serious burns.
Ensure pump unit has cooled down before any checks or maintenance is carried
out.
It must be checked that the intake and discharge openings are totally isolated
from all potentially pressurised connections and that they are and can only be
exposed to atmospheric pressure.
Pump unit to be locked and tagged out before any maintenance or service is
performed.
Pump unit may start at any time by remote operation.
Appropriate lifting techniques and lifting equipment to be used while
performing any lifting operations. Lifting must be done by authorized personnel
only.
Observe for unusual gauge leaks and general condition of the unit. If condition
exists, determine the cause and have necessary repairs made.
levels.

MF-385-183-09.25
3.1.1 GENERAL MAINTENANCE NOTES - BARE SHAFT PUMP
The pump is both a pressurised component and a piece of rotating equipment.
All standard safety precautions for such equipment must be followed before
and during installation, operation and maintenance.
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 will 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 pump components are
for lifting individual parts only.
To eliminate the possibility of brinelling of the pump bearings, shaft locking
devices may be employed. These must be removed and the free rotation at the
pump must be checked before use.
Rotating the pump in the reverse direction will unscrew the impeller from the
shaft causing serious damage to the pump.
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.
When pumps are dismantled for complete overhaul, all parts must be closely
inspected and new parts checked for correct identification.
Used parts being replaced must be thoroughly cleaned and repainted where
required.
Mating faces and spigots must be free of rust, dirt and burrs and given a coat
of grease before they are fitted together to assist future overhaul.
Full part numbers are given in the spare parts section of this manual. Full part
numbers must be used upon ordering spare parts.
It is preferable to renew small bolts and set screws during overhaul and all
threads must be coated with graphite grease before assembly. It is also
recommended that all rubber seals must be replaced during major overhauls as
rubber tends to harden and seals lose their effectiveness.
Vibration from transport and operation can cause the loosening of some
fasteners. Check and tighten.
Procedure and diagrams provided for the bare shaft pump is a guide only and
must be followed in conjunction with the attached ‘MF - 385 Bare Shaft Pump
Disassembly & Assembly Instructions Manual Supplement’ in the
accompanying manuals section.
It is recommended that all Bearings, Gaskets, O-Rings, Bushes and Nyloc Nuts
be replaced when rebuilding pump bare shaft assembly.
Impeller adjustment is a key element in extending the wear life. Field tests on
certain pumps indicate if impellers are adjusted right forward when fitted and
again at regular intervals during the operation, then an increase of 40% - 50%
in life can be achieved over pumps which are not correctly adjusted forwards.
Further pumps which were regularly adjusted have shown a 20% increase in
their life over pumps which were adjusted only one at initial setup.

MF-385-183-09.25
3.1.1.1 Safety Awareness
health and safety regulations and the operator’s own internal work, operation and safety
regulations.
3.1.1.2 Personnel Qualification and Training
All personnel involved in the operation, installation, inspection and maintenance of the
unit must be qualified to carry out the work involved. If the personnel in question do not
already possess the necessary knowledge and skill, appropriate training and instruction
must be provided.
3.1.1.3 General Notes - Pump Unit Lockout and Training
When operational work is carried out on a plant and equipment, a lockout procedure is
required to safeguard the employees carrying out this work. All energy sources must be
isolated and stored energy dissipated before carrying out any work. A procedure must be
formulated and documented to provide plant specific instructions for workers to follow in
the Lockout/Tag-out out of equipment. Employees must be trained in the implementation
of site Isolation procedures and the correct use of tags and locks.
Hazardous Energy Sources
The hazardous energy sources must be identified and if a potential risk is apparent then
measures must be taken to eliminate, isolate or dissipate the energy.
There are four kinds of energy sources:
 Electrical energy (mains, battery / capacitor, static)
 Mechanical energy (transitional, rotational)
 Thermal energy (hot, cold)
 Potential energy (springs, gravity, hydraulic / pneumatic / vacuum pressure)
Isolating Hazardous Energy
 Isolate all forms of potentially hazardous energy.
 Ensure that an accidental release of hazardous energy does not occur.
 Make certain that entry to a restricted area is tightly controlled.
 Apply locks and tags to ensure that energy isolation devices remain in the “OFF” or
“SAFE” position. Tags applied must be easily read and identified.
3.1.1.4 Operational and Safety Observations - Maintenance
 Ensure a specific sop/risk assessment is compiled for any maintenance or service
procedure.
 Ensure that personnel have access to manuals and understand the various risks
involved. Always operate in accordance with manuals and remain within the allowable
 Keep unnecessary personnel away from area. Barricade area and erect warning signs
where required.
 Ensure signage and barricading is appropriate near pump unit to prevent serious to
fatal injuries to employees working on the unit.
 External weather conditions, fatigue of employees, inadequate training of personnel to
analysis, incorrect lifting equipment and techniques and not providing due diligence to
weights, dimensions, safe operating procedures may result in serious and fatal injuries
to the personnel and cause equipment and property damage. Ensure all risks are
analysed and all on site safety procedures are adhered while performing any
maintenance or service procedures.

MF-385-183-09.25
3.2 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 Packing
 Impeller
 Lubrication
3.2.1 GLAND PACKING
The Multiflo Pump’s oil feed system provides lubrication and sealing of the gland packing
under snore and high vacuum conditions. This system uses "Flurograph 193" or equivalent
packing, which is capable of providing excellent service under the harsh conditions. All these
pumps utilize five rows of ¾ gland packing.
The gland should be adjusted regularly to prevent excess leakage. The gland must not be
over tightened as this will lead to overheating 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.
Always replace the whole set.
Each ring of packing must 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.
3.2.1.1 Gland Packing Removal
 The gland packing must be replaced when packing has deteriorated to a 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 are not sufficient to provide a proper seal.
 Remove the gland guard.
 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 remove all packing rings from stuffing box
and clean out any remaining residue.
 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 must 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.

MF-385-183-09.25
Fig.3.1 Gland packing removal tool

3.2.1.2 Gland Packing Adjustment
After pump has started, the gland 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 applies, air may be induced into the pump through the
gland. This may prevent the pump “picking up” its prime or cause it to lose its prime during
operation.
 Packing has insufficient tension.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
3.2.1.3 Standard Procedure for Gland Adjustment
1. Release gland nuts by one full turn.
2. Start the unit as per site procedures. Once unit has started, allow to prime. Once
primed, check for water moving past the gland and gland follower. A constant drip is
ideal. This will reduce friction and prevent over heating of the gland.
3. If there is no flow of water past the gland or gland follower.
4. Loosen the gland nuts by one more turn. Repeat steps 2 through to 4 until a constant
drip is achieved.
5. If the flow of water is too great past the gland follower, tighten the gland nuts by one
turn at a time to ensure that only a constant drip is achieved.
3.2.2 LUBRICATION
Refer “Section 3.3 for further details on lubrication”.

MF-385-183-09.25
3.2.3 CATERPILLAR DIESEL ENGINE
For further information, refer to “Caterpillar Engine Manual" supplied.

Refer to wiring diagram in the appendices section of this manual for electrical wiring
connections information of the unit.
3.2.4 ‘V’ BELTS TENSIONING
Refer to “Part VI - Link V-belts Installation Instructions” of this manual for installation
instructions on V-Belts.
3.3 GRADES AND FREQUENCY OF LUBRICATION

3.3.1 BARE SHAFT PUMP LUBRICATION
A correctly assembled and pre-lubricated 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 must be opened at regular intervals (no
longer than 12 months) to inspect the bearings.
The MF-385 bearing assembly and labyrinth are grease lubricated.
Weir Minerals Multiflo® recommends the use of PICO-BEKA MAX lubrication system to
ensure the correct amount of grease is supplied to the bearings and labyrinths. Please refer
to the information that follows for correct settings for the auto greasing unit fitted to the
MF-385 pump unit.
3.3.1.1 Bare Shaft Pump Auto Greasing Unit
PICO AUTO GREASE UNIT OUTLET CONNECTIONS AND TIMER SETTINGS FOR BARE SHAFT
PUMP LUBRICATION
Recommended Grease:
 Lithium base (not containing Molybdenum or EP additives)
 Base oil Viscosity of 75 cSt to 120 cSt @ 40 degree 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:
 SHELL ALVANIA RL2 Grease
 SKF LGMT 2
For further information on pump bearing lubrication, refer to “Pico Beka Max S-EP4 Auto
Lube Instructions for Multiflo 5AA” in accompanying manual section.
The greasing unit will be filled with grease before shipping.
The grease will dry out if left unprotected. Direct sunlight on the grease must be avoided.
Do not mix different types of grease/oil. Incompatible lubricants may cause bearing
damage.

MF-385-183-09.25
a. Outlet Connections
Connect the distributor block outlets to the ports on the Multiflo pumps as follows:
o Bottom outlet stamped with ‘45’ to Pump Labyrinth
o Top and Middle outlets stamped with ‘25’ to Pump Bearings.
b. Timer Settings
Ensure unit is set to the following time settings:
o Lubrication Time – 18 seconds
o Cycle time – 8 hour
Front bearing
½ gram
Rear bearing
½ gram
Labyrinth 1 gram
Fig.3.2 Automatic greasing guide for bare shaft pump
For further information, refer to “Spare Parts Section" of this manual for more details on
spare parts.

MF-385-183-09.25
3.3.2 DIESEL ENGINE LUBRICATION
3.3.3 COUPLING
Refer to "Fenner Coupling" in the accompanying manuals section of this manual for
further information on Coupling.
3.3.4 FLOW SWITCH
Refer to “Wire Flow Switches” in the accompanying manuals section for further
information.
3.3.5 HYDRAU - FLO
Refer to “Hydrau-flo IOM” in the accompanying manuals section for further information.
3.3.6 VACUUM PUMP
Refer to “WMM Model 57 Vac Pump Manual” in the accompanying manuals section of
this manual for further information.
3.3.7 PUMP GREASING UNIT

Refer to “Operating instructions for the central lubrication pump PICO with integral
controller S-EP 4” in the accompanying manuals section of this manual for further
information on PICO BEKA MAX Auto Greaser Unit.
3.3.8 DIESEL ENGINE PROCEDURES AND DATA

MF-385-183-09.25
3.4 ROUTINE GENERAL MAINTENANCE FREQUENCY
If the pump is operating continually, it must be checked about twice a day (Every 10
hours).
3.4.1 EVERY 10 OPERATING HOURS OR DAILY

SCHEDULE MAINTENANCE
Inspect the bare shaft pump gland. Check gland leakage. Adjust if
Bare shaft pump
required.
Belts and pulleys Check condition and tension if required.
Discharge assembly Check discharge pipe work for leaks. Repair if necessary.
Gland packing Check gland leakage and adjust if required.
Check the grease level in the Automatic Greasing Unit. It must not be
Bare shaft pump
allowed to be completely empty. Use Multiflo Pump Grease or refer to
lubrication system
Lube List.
Vacuum Trap/Water Trap Check and drain if required.
Diesel Engine Check oil & water levels, check and drain fuel filter if required.
3.4.2 EVERY 250 OPERATING HOURS (PERFORM IN ADDITION TO DAILY CHECKS)
Inspect the bare shaft pump gland. Adjust if required.
Bare shaft pump Change the bare shaft pump lubricants. Check gland packing condition
and repair/replace if necessary.
Inspect mounting bolts of the engine and bare shaft pump. Re-tension if
Mounting bolts
required.
Belts and pulleys Inspect condition of belts and pulleys. Re - tension belts if required.
Non return/Check valve Check condition. Repair if necessary.
3.4.3 EVERY 500 OPERATION HOURS (PERFORM IN ADDITION TO 250 HOURS OF MAINTENANCE ITEMS)
Impeller clearance to be adjusted when pumping slurry.
Inspect the bare shaft pump gland seal, adjust if required, and
Bare shaft pump
repair/replace the gland if necessary. Change the bare shaft pump
lubricants. Refer section 3.3.
Diesel Engine Service as prescribed in CATERPILLAR engine manual.
3.4.4 EVERY 1000 OPERATING HOURS (PERFORM IN ADDITION TO 500 HOURS OF MAINTENANCE ITEMS)
Impeller clearance to be adjusted when pumping dirty water.
Inspect the bare shaft pump condition. Make any adjustments required.
Bare shaft pump
Inspect the impeller, wear plate(s) and volute. Inspect the bare shaft
pump gland seal. Adjust/Replace if required. Refer section 3.3.
Non return/Check valve Check condition. Replace flap if required.

MF-385-183-09.25
3.4.5 EVERY 2000 OPERATING HOURS (PERFORM IN ADDITION TO 1000 HOURS OF MAINTENANCE ITEMS)
Inspect the bare shaft pump bearings for moisture inclusion. Inspect the
Bare shaft pump bare shaft pump gland. Adjust/Replace if required. Change the bare
shaft pump lubrications.
Non return/Check valve Check condition. Repair if necessary. Replace valve seat if required.
3.5 PUMP UNIT TROUBLESHOOTING

SYMPTOMS POSSIBLE CAUSES REMEDIES
VACUUM GAUGE READINGS – BASIC FAULTS
Emergency stop switch
Pump unit not starting Reset emergency stop switch.
activated.
High Vacuum Gauge reading Static suction lift too high. Lower suction lift.
(-80 and above) Obstruction in suction hose Remove obstruction from hose
or foot valve. and/or foot valve.
Suction hose kinked or
Unkink suction hose.
collapsed.
Suction hose collapsed
Replace suction hose.
internally.
Suction hose stuck low into Remove suction hose from
the mud. mud.
Low or No reading Air leak in the suction line. Repair suction line.
(-20 and below), If Vacuum Pump Discharge reflux valve not
is operating with air being Replace seat.
sealing.
exhausted Air leak in vacuum line from
Repair vacuum line.
tank.
Leaking gland packing. Adjust gland packing.
Foreign materials lodged in Check and clear foreign

the impeller. materials in the Impeller.
Low bare shaft pump rpm Increase rpm (1800 rpm
(700 rpm minimum). maximum).
Obstruction in discharge
Check and clean obstructions.
hose.
Partial obstruction in suction
Check and clean obstructions.
hose.
Pump fails to deliver water or
Obstruction in non-return
delivers at a reduced rate Check and clean obstructions.
valve.
Air leak in suction system. Repair leak.
Identify and replace
components. To avoid
Worn pump components.
premature wear, follow
maintenance procedure as per
the manual.
Collapsed suction hose. Check and clean obstructions.

MF-385-183-09.25
Pump located too high Reduce the height of the
above water being pumped. location of the pump.
Check gland packing Change gland packing if worn
condition. or hard.
Check the gland follower is Tighten if required to show
not loose. small visual leak.
Check suction side of the
Pump won’t prime Repair if required.
pump for vacuum leaks.
NRV seat or flap may be
damaged (if the discharge is Replace seat and/or flap if
still primed the flap and seat damaged.
are ok).
Check and run the engine at
Speed too high.
recommended speed.
Specific gravity and viscosity
of pump fluid different from Check application.
Pump overloads engine
pump rating.
Mechanical defects. Replace defective parts.
Total dynamic head lower
than pump rating – pumping Lower engine speed.
too much water.
Check the probe condition. Replace if damaged.
Check the suction foot valve
Pump keeps shutting down on Remove from mud if required.
is not in the mud.
water loss
Ensure continuity between
Check the operation of the
common and normally closed
flow switch.
terminals.
Check the suction line for
Clear blockage if required.
blockage.
Prime light won’t go out
Check the float in the
Krundimendt valve is not Replace valve if required.
shut.
Check the hydraulic oil tank Fill hydraulic oil tank if

level. required.
Replace hydraulic filter if

Check and replace the filter.
required.
Check the switch for
Check switch.
operation.
Pump oil pressure light is on with
the engine shut down Remove filter from the tank
Blocked suction filter. and inspect. Fill reservoir with
Delvac 1330 Oil.
Remove pump from the engine
remove the back plate and
Low oil.
inspect pump components for
wear.
Check drive rotation in the
Pump failure.
engine.

MF-385-183-09.25
Check the plug at the switch Check plug is correctly inserted
under the vacuum tank. in switch.
Low fuel light is on with the Remove the float from the
engine shut down (presuming tank and see if the float Replace float if damaged.
there is enough fuel) floats.
Check the switch for
Check switch.
operation.
Lower the discharge, increase
Dynamic head is too high for
the pipe diameter, and lower the
the pump.
NPSH.
Pump primes but has no flow at Check impeller wear and
Pump condition.
discharge of pipe adjustment.
Leaks in discharge pipe. Find and repair leaks.
Check engine load at Vismode
Low engine power.
control panel.
Dynamic head is too high for Lower the discharge height,
the pump. increase pipe diameter.
Check impeller wear and
Pump primes but has low flow Pump condition.
adjustment.
Check engine load at Vismode
Low engine power.
control panel.
Check the flow rate is enough to
Low flow.
operate the flow switch.
Check flow switch operation and
Flow switch faulty.
condition.
Pump primes, has flow but shuts
If the flow switch is ok check the
down after six minutes Flow switch timer faulty.
timer operation.
Check the Vismode control panel
Engine fault. (where fitted) for fault codes
and warnings.
Vacuum leaks. Find and repair leaks.
Pump has difficulty maintaining
Insufficient water supply. Increase the water supply.
prime
Failing vacuum pump. Service or replace the pump.
Empty water trap more
Water temperature.
frequently.
Check that the Krundimendt
Failed Krundimendt float ball.
float ball isn’t full of water.
The water trap fills with water
Atmosphere valve stuck shut Inspect the valve and seat clean,
or blocked. readjust or replace as required.
Inspect valve and seat for
Vacuum valve leaking.
damage or obstruction.
Pump running on the left hand
side of the curve, reduce the
total head. (Pump volute will be
Pump primes, pumps then shuts hot).
Low flow.
down after six minutes
Increase the pump speed.
Refer to the pump performance
curve for maximum head and
MF-385-183-09.25
flow information.
Refer to the electrical trouble
Faulty flow switch.
shooting guide.
Refer to the electrical trouble
Engine Fault.
shooting guide.
Increase the water supply.
Low water supply.
Pump regularly shuts down after Slow the pump speed down.
a few hours Refer to the electrical trouble
Engine fault.
shooting guide.
Lower the head height.
Total head too high (hot Increase the pipe size.
volute). Increase the pump speed
within recommended limits.
Low or no discharge flow Check for damaged or flattened
Blocked discharge (hot
pipes under haul roads and
volute).
culverts.
Excessive leakage along pipe
Inspect and repair the discharge
route (ambient water
pipe for leakage.
temperature volute).
Decrease the engine speed
Pump is operating on the within recommended limits.
Pump cavitates excessively
right hand side of the curve. Fit an orifice plate or throttle
valve to the discharge.
Excessive head pressure (may
Excessive leakage occur when the pump has Lower the total head.
dead headed).
Check the gauge for accuracy. Replace gauge if faulty.
Check gaskets at the vacuum
tank inlet pump suction and
pump discharge.
Check the Krundimendt float
Vacuum leaks. ball lid gasket, check the lid for
flatness.
Check the vacuum hose
between the vacuum tank and
Pump takes excessive amounts of the vacuum pump.
time to prime, vacuum gauge
reading low If belts are excessively worn,
replace them. Check the
Loose belts. alignment if the wear is uneven.
Re-tension the belts.
Remove the Krundimendt float
Atmosphere valve on the ball lid and inspect the
Krundimendt float ball lid is atmosphere valve, readjust or
damaged or incorrectly replace as required. (If the finish
adjusted. on either valve is not smooth the
operation will be compromised).

MF-385-183-09.25
Dilute the slurry.
Specific gravity of slurry too Put the pump closer to the
thick. water.
Select another pump.
Consult the pump performance
Pump too far from the water. curve for recommended NPSH
requirements.
Blocked foot valve. Unblock the foot valve.
Remove the suction hose,

Blocked or delaminated
inspect, clean or replace as
suction hose.
required.
Pump takes excessive amounts of Remove the tank lid and suction
time to prime, vacuum gauge Vacuum tank full of hose and clean the tank. May
reading high contamination. require for the volute to be
cleaned as well.
Remove the Krundimendt float

ball lid, inspect the valves, clean
Vacuum valve in the if blocked, replace if damaged,
Krundimendt float ball lid and readjust if out of tolerance.
faulty, stuck or blocked. (If the finish on either valve is
not smooth the operation will be
compromised).
Check operation service or

Vacuum pump failed.
replace as required.
Lower the foot valve low enough
so there is no visible vortex on
Foot valve not submerged far
Pump wont prime vacuum gauge the water. If the water source is
enough into the water.
reading low too shallow, dig a sump or wait
until there is enough water.
Water trap seal worn or
Replace the seal.
missing.
Vacuum pump exhaust Check the exhaust for
blocked. obstructions.
Note:
1) When replacing gland packing replace all rows with fresh packing, refer to the manual for
instructions.
2) Running pumps in cavitation for excessive periods will cause damage to impellers and volute
casings.
ENGINE - BASIC FAULTS
Ensure emergency stop is in out
Engine won’t crank Emergency stop may be pushed.
position.
Refer the Caterpillar manual or
Engine shuts down with no Check power supplies and earths
contact a Caterpillar
diagnostic lights on in Kensho engine safeguard.
representative.

MF-385-183-09.25
‘V’ BELT TROUBLESHOOTING
SYMPTOMS POSSIBLE CAUSES REMEDIES
Generally caused by shortage of
Small cracks on ‘V’ Belt side belt tension but excessive heat Small cracks on ‘V’ Belt side and
and base and/or chemical fumes can also base.
give same failure.
Caused by excessive
‘V’ Belt swelling or softening contamination by oil, certain ‘V’ Belt swelling or softening
cutting fluids or rubber solvent.
Usually caused by incorrect
tensioning, principally on long
centre drives. If a slightly higher
(or lower) tension does not cure
Whipping during running Whipping during running
the problem there may be a
critical vibration frequency in
the system which requires re-
design or a banded belt.
HYDRAU-FLO VALVE TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES REMEDY
Nozzle or receiver spring setting Check condition and rating of
too low. spring, replace if necessary.
Ensure there is not excessive
Back pressure in filler pipe too
restriction in the flow of fuel
Fuel nozzle shutting off high. from the Hydrau-Flo to the tank.
prematurely
Breather blocked. Clean or replace if necessary.
Float valve set too low in tank. Adjust to desired fill height.
Check line for damage, kinks, or
Restriction in capillary line.
crushing. Replace if necessary.
Check operation of float
Float valve not closing capillary ensuring it does not hit internal
line. walls of fuel tank. Check valve
seat for damage or obstruction.
Check piston operation is
Fuel nozzle not shutting off Piston stuck open.
smooth and unrestricted.
Check line and fittings for leaks
Leakage in capillary line.
or damage.
Float lever set above breather Lower float lever below height of
height. breather.
Float level set too high, not
Fuel weeping from breather allowing enough air space for
Lower float level setting.
after tank has been filled fuel expansion due to rise in
temperature.

MF-385-183-09.25
PART IV
PARTS LIST

MF-385-183-09.25
MAJOR COMPONENTS
(Always quote model and serial number of pump when ordering spare parts)
MF-385-183-09.25
MF - 385 MAJOR COMPONENTS
5 4
..
NO. DESCRIPTION SECTION

1 VACUUM TANK PRIMING
2 STROBE LIGHT ELECTRICAL
3 DIESEL ENGINE DRIVE
4 DISCHARGE COMPONENTS DISCHARGE
5 MAINTENANCE PLATFORM PUMP
6 SUCTION COMPONENTS SUCTION
MF-385-183-09.25
MF - 385 MAJOR COMPONENTS
3
2
1
8
7 6 5
NO. DESCRIPTION SECTION

1 COUPLING DRIVE
2 VACUUM PUMP PUMP
3 BOOM CHAINS SUCTION
4 BOOM SUCTION
5 BARE SHAFT PUMP PUMP
6 AUTO-LUBRICATION SERVICE/LUBRICATION
7 VISMODE PANEL ELECTRICAL
8 SERVICE POINT SERVICE/LUBRICATION
MF-385-183-09.25
1 DRIVE SECTION
MF-385-183-09.25
1.1 MF - 385 DRIVE MAIN COMPONENTS
4 2
NO. DESCRIPTION PART NUMBER QTY

1 COUPLING GUARD MCD385A003 1
2 ENGINE DIESEL CATERPILLAR 104824 1
3 VACUUM PUMP GUARD GU0057Z0001 1
4 BARE SHAFT PUMP 385GSS 1
MF-385-183-09.25
1.2 MF - 385 DRIVE MAIN COMPONENTS

5
3
2
1 6
7
8
9
10
11
12

1 TAPERLOCK BUSH TL3525-2 ¾ 2
2 FENAFLEX COUPLING F F140F 1
3 DRIVER PULLEY P2SPZ112-2.75 1
4 KEY (STUB SHAFT) KS1/2x3/4-150 1
5 COUPLING GUARD (5 PIECE) MCD385A003 1
6 STUB SHAFT SS-SAE14-2.75 1
7 BELTS VB1800SPZ 2
8 DRIVEN PULLEY P3SPZ300-110 1
9 ROBATIC CLUTCH ASSEMBLY 540-140-700-24 1
10 ELEMENT TYRE F140ST 1
11 FENAFLEX COUPLING H F140H 1
12 KEY (BARE SHAFT PUMP) 6A-18 1
MF-385-183-09.25
1.3 MF - 385 VACUUM PUMP MODEL 57
2
1
7
3

1 COVER MVP150-282 1
2 GASKET MVP150-215 1
3 COMPLETE VACUUM PUMP MVP150-200-24V-300 1
4 EXHAUST PIPE MVP150-254 1
5 OIL DRAIN PLUG C/W O-RING MVP150-223 1
6 REDUCING BUSH MVP150-278 1
7 HOSE MVP250-279 1
MF-385-183-09.25
1.4 MF - 385 VACUUM PUMP - CYLINDER HEAD GROUP

1
2
3
16
15 4
14
5
6
13
7 8
12
11
10

1 BOLT BLTM08035 4
2 PLUG BSPP 1-8GM 2
3 DIAMOND MVP150-201 2
5 INLET TRIANGLE MVP150-204 2
6 INLET VALVE MVP150-205 2
7 BLIND NUT MVP150-277 2
9 HEAD MVP150-214 1
10 DISCHARGE VALVE MVP150-213 2
11 DISCHARGE CAGE MVP150-212 2
12 DISCHARGE TRIANGLE MVP150-210 2
14 PUSH BOLT MVP150-208 2
15 CAP NUT MVP150-207 2
16 BOLT BLTM10030 12
MF-385-183-09.25
1.5 MF - 385 VACUUM PUMP - CRANK CASE GROUP

4 5
3 6
1 2
7
8
9
10 11
10
10
19
15
5
18
15 14
16
17 13 12

1 REAR BEARING CAP MVP150-242 1
3 CRANK CASE MVP150-220 1
6 INSPECTION PLATE MVP150-219 1
7 STUD MVP150-265 6
8 BOLT BLTM10025 4
9 CRANKSHAFT MVP150-247 1
10 BEARING SUPPORTER MVP150-245 2
12 OIL SEAL MVP150-238 2
13 FRONT BEARING CAP MVP150-240 1
14 SHAFT KEY MVP150-235 1
15 BEARING MVP150-239 2
16 DIPSTICK COVER PLATE MVP150-254DA 1
17 O-RING MVP150-253 1
19 DIPSTICK C/W O-RING MVP150-252 1
MF-385-183-09.25
1.6 MF - 385 VACUUM PUMP - CYLINDER BLOCK GROUP

1
13 3
5
12
7
11
10
8

2 STUD MVP150-265 2
3 CYLINDER BLOCK MVP150-217 1
4 RING SET (BOTH PISTONS) MVP150-261 1
5 CIRCLIP MVP150-228 4
6 PIN MVP150-229 2
7 CONNECTING ROD MVP150-232 2
8 SLIPPER SET (PAIR) MVP150-233 2
9 SPLASHER MVP150-248 2
10 NUT MVP150-276 4
11 BIG END BOLT MVP150-275 4
12 PISTON MVP150-231A 2
13 NUT BLTMCN10 6
MF-385-183-09.25
1.7 MF - 385 VACUUM PUMP CLUTCH

2
1 3 4
5
6
7
6
8
12
9
11
10

COMPLETE CLUTCH 540-140-700-24 1
1 CIRCLIP 540-140-717 1
2 CIRCLIP 540-140-716 1
3 BEARING 540-140-713 1
4 COIL CARRIER 540-140-712-24 1
5 WAVE WASHER 540-140-722 1
6 SHIM KIT 540-140-719 1
7 BEARING 540-140-705 2
8 CIRCLIP 540-140-702 1
9 CIRCLIP 540-140-701 1
10 MOUNTING FLANGE 540-140-708 1
11 TRANSMISSION FLANGE 540-140-709 1
12 ROTOR 540-140-711 1
MF-385-183-09.25
1.8 MF - 385 VACUUM PUMP MOUNTING PLATE

1 NUT MVP150-284 1
2 ADJUSTING BOLT MVP150-283 1
3 MOUNTING PLATE MVP150-288 1
MF-385-183-09.25
2 PUMP SECTION
MF-385-183-09.25
2.1 MF - 385 COMPLETE BARE SHAFT PUMP

1 COMPLETE BARE SHAFT PUMP 385GSS 1
MF-385-183-09.25
2.2 MF - 385 GLAND GUARD ASSEMBLY

1 GLAND GUARD LH MSA000N001A 1
2 BOLT BLTC20050 2
3 GLAND GUARD RH MSA000N001B 1
MF-385-183-09.25
2.3 MF - 385 COVER PLATE ASSEMBLY
2
3
4
1

1 STUDS 380-75 8
2 COVER PLATE 380-70SS 1
3 NUT BLTMN20G 8
4 WASHERS BLTMW20G 8
MF-385-183-09.25
2.4 MF - 385 WEAR PLATE ASSEMBLY
3
1 2

1 O-RING 380-74 1
2 WEAR PLATE 380-72SS 1
3 O-RING 380-73 1
MF-385-183-09.25
2.5 MF - 385 SHIMS
2
1

1 SHIM 380-55 A/R
2 SHIM 380-56 A/R
MF-385-183-09.25
2.6 MF - 385 IMPELLER

1 IMPELLER 380-69 1
MF-385-183-09.25
2.7 MF - 385 VOLUTE FASTENERS
3
2

1 BOLTS BLTC20050 1
2 WASHERS BLTMW20G 1
3 VOLUTE 380-67SS 1
MF-385-183-09.25
2.8 MF - 385 GLAND ASSEMBLY
1
2

1 GLAND FOLLOWER - 2 PIECE 6A-32SS 1
2 GLAND NUT 6A-34NSS 2
MF-385-183-09.25
2.9 MF - 385 STUFFING BOX ASSEMBLY

1 STUFFING BOX 6A-30SS 1
2 STUD 6A-34ST 2
3 PACKING RINGS 64-33 1 set
4 O-RING 6A-31 1
MF-385-183-09.25
2.10 MF - 385 O-RINGS AND SLINGER ASSEMBLY

1 SLINGER 6A-16SS 1
2 SHAFT SLEEVE 6A-28 1
MF-385-183-09.25
2.11 MF - 385 FRONT BEARING CAP ASSEMBLY
1 2
5
6

1 BEARING CAP 6A-14A 1
2 O-RING 6A-06 1
3 SEAL 6A-15 1
4 ELBOW MFAGU-01-05 1
5 BOLT LOCK TAB 6A-20 3
6 BOLTS BLTC20050 6
MF-385-183-09.25
2.12 MF - 385 FRONT BEARING

1 FRONT BEARING 6A-13A 1
MF-385-183-09.25
2.13 MF - 385 REAR BEARING CAP ASSEMBLY
1
2
4
3

1 O-RING 6A-06 1
2 SEAL 6A-05 2
3 BOLTS BLTC16042 6
4 BOLT LOCK TAB 6A-20 3
5 BEARING CAP 6A-04A 1
MF-385-183-09.25
2.14 MF - 385 REAR BEARING ASSEMBLY
2
2
1

1 LOCK NUT 6A-08 1
2 BEARING 6A-10A 2
3 SHAFT 6A-02 1
MF-385-183-09.25
2.15 MF - 385 PEDESTAL SEALS AND FITTINGS
1
2
2 3

1 PLUG BP-14 1
2 PEDESTAL SEAL 6A-11H 2
3 ELBOW MFAGU-01-05 2
MF-385-183-09.25
2.16 MF - 385 MAINTENANCE PLATFORM

1 GRATE 103997 2
MF-385-183-09.25
3 SUCTION SECTION
MF-385-183-09.25
3.1 MF - 385 SUCTION COMPONENTS
5
3
1
2
7
3

1 STRAINER MFS200-40SS 1
2 SPREADER BAR 209693 1
3 WIRE ROPE WR10-16SASA 1
4 BOOM C/W PULLEY MFB5.8 1
5 HAMMERLOCK HL13 4
6 BOOM CHAINS 101148 1
7 WINCH (INCLUDES GUARD) F11620C 1
8 SUCTION HOSE 103239 1
9 D SHACKLE DS-S-13 1
MF-385-183-09.25
4 PRIMING SECTION
MF-385-183-09.25
4.1 MF - 385 PRIMING ASSEMBLY

1 2

1 FILLER / BREATHER VT99-002 1
2 KRUNDIMENDT VALVE VT2002-02 1
3 O-RING 200-0345-V 1
4 WATER TRAP 200-0345 1
5 PROBES VT2002-01 2
6 VACUUM TANK 208816 1
7 VALVE NEEDLE 200-0354-38 1
8 SIGHT GLASS SGA-16 1
MF-385-183-09.25
4.2 MF - 385 CHECK VALVE

1 CHECK VALVE VT84-015 1
MF-385-183-09.25
5 ELECTRICAL SECTION
MF-385-183-09.25
5.1 MF - 385 VACUUM PRESSURE GAUGE

1 VACUUM PRESSURE GAUGE 200-0365PM 1
MF-385-183-09.25
5.2 MF - 385 BATTERY BOX
5
3
4 4
2
4

1 BATTERY BOX BMS-BB-2 1
2 BATTERY BATCENTN200 2
3 BATTERY HOLD DOWN BRACKET MSE000N004 1
4 BATTERY MAT MAT BM1 2
5 BATTERY HOLD DOWN TIE MGBHD 2
6 STRUT BB24V6B-03 1
MF-385-183-09.25
5.3 MF - 385 BATTERY ISOLATORS

1 STARTER LOCKOUT LS11003-02 1
2 BATTERY LOCKOUT LS11003-01 1
3 ISOLATOR 341003004 1
MF-385-183-09.25
5.4 MF - 385 VISMODE CONTROL BOX

1

1 VISMODE CONTROL UNIT 104881 1
MF-385-183-09.25
5.5 MF - 385 WORK LIGHT AND STROBE LIGHT

1

1 LED BEACON 105571 1
2 LED WORK LIGHT 105076 6
MF-385-183-09.25
5.6 MF - 385 LOW FLOW SWITCH

1 FLOW SWITCH TWS26SS-100 1
MF-385-183-09.25
5.7 MF - 385 EMERGENCY STOP

1 EMERGENCY STOP ES-03-01 1
MF-385-183-09.25
6 SERVICE/LUBRICATION
MF-385-183-09.25
6.1 MF - 385 HYDRAU-FLO

3
2
1
4

1 RECEIVER HF1113Z0003 1
2 VALVE ASSEMBLY HF1105Z0001 1
3 MOUNTING PLATE HF1012Z0003 2
4 FLOAT ASSEMBLY HF1007Z0001 2
MF-385-183-09.25
6.2 MF - 385 FUEL FILLER

1 HOSE HH1081081B08-00223 1
2 PLUG HFS64-12 1
3 FLOAT ASSEMBLY HF1007Z0003 1
4 FLOAT LOCK NUT HF1014Z0003 1
5 O-RING HF1012Z0004 1
6 MOUNTING PLATE HF1012Z0003 1
MF-385-183-09.25
6.3 MF - 385 FUEL FLOAT SWITCH ASSEMBLY

1 LOW FUEL FLOAT SWITCH ASSEMBLY 100376 1
MF-385-183-09.25
6.4 MF - 385 PICO AUTO - LUBER GREASER

1 PICO AUTO GREASER MFAGU-01-0124V-6A 1
2 DISTRIBUTION BLOCK MFAGU-01-02-6A 1
MF-385-183-09.25
6.5 MF - 385 SERVICE POINT
1 2
6 5 4 3

1 DUST CAP KL50-DC 1
2 DUST CAP AUS23C-R 1
3 RECEIVER HF1113Z0003 1
4 VALVE HF1105Z0001 1
5 FUEL GAUGE 62200-A-250 1
6 RECEIVER KL50-A 1
MF-385-183-09.25
6.6 MF - 385 FUEL BREATHER

1 BREATHER FUEL CELL UCSAB7101 2
MF-385-183-09.25
6.7 MF - 385 FUEL FILTER/WATER SEPARATOR
1
2

1 RACOR 1000 FUEL FILTER 1000FH2 2
2 REPLACEMENT ELEMENTS 101135 A/R
MF-385-183-09.25
7 DISCHARGE SECTION
MF-385-183-09.25
7.1 MF - 385 DISCHARGE ASSEMBLY
1
2
11 3
9
10 5
8 4

1 NON RETURN VALVE 150NB NRV150-01SS 1
2 1" BSP STEEL PLUG BSPP1-0 1
3 DISCHARGE PIPE 207241 1
4 DISCHARGE PIPE CLAMP 206309 2
5 DISCHARGE PIPE 209753 1
6 ISOLATION VALVE MF150BFV-KG0 1
7 SPOOL 200990 1
8 VALVE NRV150-22SS 1
9 ONYX GAUGE MFS150-K04 1
10 GASKET GANSI300LB-200 6
11 ELBOW 200623 1
MF-385-183-09.25
7.2 MF - 385 NON-RETURN VALVE STAINLESS STEEL
1 3
4
14
6
13
12
11
5
7
8
9
10

COMPLETE VALVE NRV150-01SS 1
1 INSPECTION LID NRV150-13 1
2 NUT NRV150-15 8
3 WASHER NRV150-14 8
4 DOWEL PIN NRV150-24 1
5 SEAT NRV150-04SS 1
6 STUD NRV150-17 8
7 O-RING NRV150-03 1
8 BODY NRV150-02SS 1
9 STUD NRV150-18 16
10 STUD NRV150-19 3
11 NYLOC NUT NRV150-08 3
12 BAR, FIXING NRV150-07 1
13 FLAP NRV150-06HT 1
14 GASKET NRV150-20 1
MF-385-183-09.25
7.3 MF - 385 ONYX PRESSURE GAUGE

1 ONYX PRESSURE GAUGE 102993 1
MF-385-183-09.25
PART V
APPENDICES
MF-385-183-09.25
Tightening Torque Values
Metric Hexagon Bolts & Screws, Coarse Pitch Threads
Property Classes 4.6 & 8.8
Nominal Pitch Property Class 4.6 Property Class 8.8
Diameter Induced Bolt Tension Torque Induced Bolt Tension Torque Across
corresponding to 65% of (Nm) corresponding to 65% (Nm) Flats
Proof Load (kN) of Proof Load (kN) Wrench
Size
M6 1.00 2.94 3.5 7.54 9.0 10.00
M8 1.25 5.36 8.5 13.80 22.0 13.00
M10 1.50 8.45 17.0 21.90 44.0 16.00
M12 1.75 12.40 30.0 31.80 77.0 18.00
M16 2.00 22.90 73.0 59.20 190.0 27.00
M20 2.50 35.80 143.0 95.60 372.0 32.00
M24 3.00 51.60 248.0 138.00 640.0 41.00
M30 3.50 81.90 491.0 219.00 1314.0 46.00
M36 4.00 120.00 864.0 319.00 2297.0 55.00
Note: All Torque values are in Nm. Multiply by 0.738 for lbf.ft
Note: For Hot-Dip Galvanised product (plus no lubrication) a friction factor of 2.1 may be applied
(e.g.: for Hot-Dip Gal M12 Class 8.8, final torque required will be 77 x 2.1 Nm = 161.7 Nm, etc)
MF-385-183-09.25
PUMP PERFORMANCE CURVE
MF-385-183-09.25
MF-385-183-09.25
WIRING DIAGRAM
MF-385-183-09.25
MF-385-183-09.25
PART VI
ACCOMPANYING MANUALS
MF-385-183-09.25
1 BARE SHAFT PUMP DISASSEMBLY & ASSEMBLY PROCEDURES

1.1 385 DISASSEMBLY PROCEDURE - REVISION 8 - TO SUIT NEW BEARING ASSEMBLY
1. Securely mount PUMP UNIT to anchored work bench.
2. Remove SUCTION COVER PLATE (31).
3. Remove WEAR PLATE (32) from VOLUTE (29) & discard O-Rings (34) & (33).
4. Remove KEY (17) from SHAFT (2). Using Impeller Locking tool (Fig 3.6) to lock IMPELLER
(30), remove the IMPELLER by turning the SHAFT with the shaft spanner (Fig 3.5).
5. Remove BLANK DUST CAPS (38) from PEDESTAL (1) & use ¾ UNC BOLTS (28) through
DUST CAP holes to separate VOLUTE (29) from PEDESTAL (1). Remove VOLUTE (29) from
PEDESTAL (1).
6. Remove STUFFING BOX (20) from VOLUTE (29) & discard PACKING (23) & O-Ring (21).
7. Remove SHAFT SLEEVE (18) & discard O-Rings (19). Withdraw grub screws from
LABYRINTH SLINGER (15) & remove from SHAFT SLEEVE (18). Discard O-Ring (16).
8. Remove BEARING CAPS (13) & (4). Discard O-Ring (6) & SEALS (14) & (5).
9. Remove SHAFT LOCK NUT (8) from SHAFT (2).
10. Press SHAFT (2) from PEDESTAL (1) out through Impeller end.
11. Remove BEARINGS (9) from Coupling End of PEDESTAL (1) along with LIP SEAL GREASE
RETAINERS (10).
12. Remove CARB BEARING (12) from SHAFT (2).
13. Thoroughly clean & inspect all parts of pump. Pay particular attention to SHAFT &
IMPELLER. If there is any doubt about serviceability, replace suspect parts.
It is recommended that all bearings, gaskets O-Rings, bushes & nyloc nuts be replaced
when rebuilding pump bare shaft assembly.
1.2 385 ASSEMBLY PROCEDURE – 6A PEDESTAL
Fig.1.1 Pedestal Assembly

1. Fit BEARING (12) to SHAFT (2) Impeller end.
MF-385-183-09.25
Use an Induction Heater or similar to heat bearing (12) to 1200 C.

Bearing is an interference fit onto shaft & transitional fit into pedestal.
2. Fit LIP SEALS (10) inside PEDESTAL (1).

Lip seals have a 1/16’’ diameter hole in face to allow journal to breath & release
any pressure build up.
Use CRC 5.56 for ease of fitting the shaft assembly to pedestal.
3. Fit FRONT SEAL (10) (Impeller End) with lip facing outwards & with the 1/16’’
diameter hole to top. Fit REAR LIP SEAL (10) with lip facing outwards & with 1/16’’ hole
to top.
4. Fit SHAFT ASSEMBLY into PEDESTAL (1) from Impeller End, using Tool ‘A’ in front
of CARB BEARING (12) to keep it in line. PEDESTAL (1) must 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.
5. Once SHAFT ASSEMBLY is in place, remove TOOL ‘A’ & grease CARB BEARING (12)
30% to 50% full with ALVANIA RL2 grease. Fit END CAP TOOL, Tool ‘B’. Turn
PEDESTAL (1) 1800, pre-load BEARINGS (9) 30 % to 50% with ALVANIA RL2 grease.
Fit pre-greased BEARINGS (9). Press into place using Tools ‘C’ & ‘D’.
Tool ‘B’ acts as a press bed.

SHAFT is an interference fit & PEDESTAL is a transitional fit.
6. Once BEARINGS (9) are in place, fit SHAFT LOCK NUT (8) to SHAFT (2) with loctite 271
& tighten to torque specifications. Raised face against bearing.
Oil between BEARING (9) & SHAFT LOCK NUT (8).
7. Fit SEALS (5) & (14) to BEARING CAPS (4) & (13).
8. Fit CORK GASKET (37) to BEARING CAP (4). Using Tool ‘E’ to avoid damaging LIP SEAL
(10) fit BEARING CAP (4) to PEDESTAL (1).
9. Fit BOLT LOCK TABS (36) & BEARING CAP BOLTS (3) to BEARING CAP (4) &
torque BEARING CAP BOLTS (3) to 95 Nm (70 ft-lb). Lock BOLTS (3) with LOCK TABS (36).
Over torqueing of BOLTS (3) will cause a heat increase.
10. Rotate PEDESTAL 1800 & remove Tool ‘B’. Fit CORK GASKET (37) to BEARING CAP (13)
& fit BEARING CAP to PEDESTAL.
11. Fit BOLT LOCK TABS (36) & BEARING CAP BOLTS (3) to BEARING CAP (13). Fit
BEARING CAP to PEDESTAL & torque BEARING CAP BOLTS to 95 Nm (70 ft-lb).
12. Fit SHAFT SLEEVE (18) with O-Rings (19). Apply anti seize to inside of SHAFT SLEEVE
(18) & fit to SHAFT (2). Fit O-RING (16) to LABYRINTH SLINGER (15). Clearance between
LABYRINTH SLINGER (15) & BEARING CAP (13) is 1 +/- 0.5 mm.
MF-385-183-09.25
Over torqueing of BOLTS (3) will cause a heat increase.

Fit LABYRINTH SLINGER to BEARING CAP END of SLEEVE before assembly of SLEEVE as it is
much easier. Once assembled, set LABYRINTH SLINGER & fix with GRUB SCREWS.
13. 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 7000 C. Above 7000 C strip pedestal to find cause of overheating
then RE-RUN. TEMP RECOMMENDED front & back 600 C +/- 50 C.
Too much grease will cause the bearings to run hot, that is, above the
recommended temperature.
1.1 385 ASSEMBLY PROCEDURE – WETTED PARTS

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 1800 intervals. Then fit STUFFING BOX (20) with BOLTS (25) into VOLUTE (29)
with the GLAND OIL FEED HOLE to the top.
Use oil on shaft & packing to assist in assembly of stuffing box.
3. 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 & bolted surfaces for ease of future disassembly.
4. Apply anti-seize to shaft thread then fit IMPELLER (30) onto SHAFT (2) using Shaft
Spanner (Fig 1.4) to prevent shaft from turning. SPIN IMPELLER HARD HOME AND
ENSURE IT IS NOT FOULING.
5. Insert STUDS (35) using Loctite 620 into face of VOLUTE (29).
6. 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) & IMPELLER (30) when
SUCTION COVER PLATE (31) is installed (Fig 1.6). Fit O-Ring (34) to WEAR PLATE (32)
& install into VOLUTE (29).
7. Fit O-Ring (33) to recess in the back of WEAR PLATE (32) then fit SUCTION COVER
PLATE (31) & secure with VOLUTE NUTS (31). Grease all O-Rings for ease of fitting.
8. Install GLAND NUTS (24). DO NOT OVERTIGHTEN INITIALLY.
9. Install KEY (17) to SHAFT (2).
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.
MF-385-183-09.25
MF 385 Bolt Tension Settings
B - Bearing Cap 95 Nm (70 ft-lb)

D - Volute Mounting Bolts 270 Nm (200 ft-lb)
H - Volute Studs 270 Nm (200 ft-lb)
I - Wet End Mounting Bolts 750 Nm (550 ft-lb)
J - Shaft Lock Nut Tap up Tight – Use Loctite
Shaft lock Nut Grub Screws 15 Nm (11 ft-lb) – Use Loctite
K - Stuffing Box Bolts 270 Nm (200 ft-lb)
Fig.1.2 Model 385 gland packing bare shaft pump bolt tension settings
MF-385-183-09.25
Fig.1.3 Exploded view of 385 bare shaft pump

MF-385-183-09.25
Fig.1.4 Shaft spanner Fig.1.5 Impeller locking tool
Fig.1.6 Impeller clearance Fig.1.7 Angular contact ball bearing arrangement (Face to face)
MF-385-183-09.25
Fig.1.8 Tool ‘A’
Fig.1.9 Tool ‘B’

MF-385-183-09.25
Fig.1.10 Tool ‘C’
Fig.1.11 Tool ‘D’
Fig.1.12 Tool ‘E’

MF-385-183-09.25
MF-385-183-09.25
FENNER TYRE COUPLINGS
Fenner Tyre couplings provide all the desirable features of an ideal flexible coupling, including Taper Lock fixing. The
Fenner Tyre coupling is a "torsionally elastic" coupling offering versatility to designers and engineers with a choice of
flange combinations to suit most applications.
The flanges are available in either F or H version Taper Lock fitting or bored to size B.
With the addition of a spacer flange, the coupling can be used to accommodate standard distance between shaft ends
and facilitate pump maintenance.
Fenner Tyre couplings can accommodate simultaneous maximum misalignment in all planes without imposing undue
loads on adjacent bearings and the excellent shock-absorbing properties of the flexible tyre reduce vibrations and torsional
oscillations.
Fenner tyres are available in natural rubber compounds for use in ambient temperatures between -50OC to +50OC.
Neoprene rubber compounds are available for use in adverse operating conditions e.g. oil or grease contaminations and
O O
can be used in temperatures of - 15 C to + 70 C.
F.R.A.S. tyres are available for use when fire-resistance and antistatic (F.R.A.S.) properties are required.
TORQUE-BORE RANGE
The range includes couplings with torque capacity upto 12606 Nm. and bore diameters upto 190 mm.
MISALIGNMENT
Handles parallel, angular and axial displacements, either singly or in any combination. They can accommodate parallel
O
misalignment upto 6 mm, angular misalignment upto 4 and end float upto 8 mm.
TORSIONALLY SOFT
Cushions against destructive shock loads protecting the complete system, preventing expensive breakdowns and
lengthens machine life.
FREE OF BACKLASH
Does not create 'snatch' on take up of the drive.
INSTALLATION
Requires neither special tools nor skilled labour to assemble. Alignment is quickly checked by placing a straight edge
across outside diameter of flanges. The split flexible tyre is then positioned in the flanges and the screws tightened into
place.
DAMPING
Reduces vibration and torsional oscillations developed in internal combustion engines, the amplitude of which increases
greatly at critical points in the speed range. Fenner Tyre coupling dampens these destructive vibrations.
MAINTENANCE
Because there are no moving parts, no lubrication is required. Periodic visual inspection of the tyre is all that is necessary.
EASY ELEMENT REPLACEMENT

To replace flexible element simply loosen the clamping screws, remove the tyre and replace with a new one. It is not
necessary to move either driver or driven machine or coupling flanges.
ENVIRONMENT
Use of natural or Neoprene rubber compounds makes the Fenner Tyre coupling suitable for use in most conditions. For fire
hazard areas the F.R.A.S. tyre is recommended. This allows free flow of electricity between the two shafts to avoid static
electricity build up.
FENNER TYRE COUPLINGS - INSTALLATION
INSTALLATION INSTRUCTIONS
Note : Satisfactory performance depends on correct installation and maintenance. All instructions in this manual must
therefore be followed carefully.
1. Thoroughly clean all components, paying particular attention to the removal of the protective coating in the bore of the
flanges.
2. Fit flanges to the shafts placing the external clamp rings on the shafts. (Where Taperlock flanges are used, see separate
fitting instructions supplied with the Taper Lock Bushes). Locate flanges so that dimension M2 is obtained (see
paragraph 3). Flanges with internal clamping rings should then have the clamping rings fitted, engaging only two or
three of the threads of the screws at this time.
3. Bring shafts into line until dimension M2 is obtained (table 5). If shaft end float is to occur, locate the shafts at mid-
position of end float when checking dimension M2. 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 misalignment. 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 table 6.
TABLE 6
COUPLING F40 F70 F140 F160 F200

SIZE TO TO TO TO
F60 F120 F180 F250
Tyre
2 3 5 6.5 8
Gap in mm.
6. Tighten clamping ring screws alternately and evenly (half turn at a time) working round each flange untill the required
screw torque is achieved.
Seating Dia. Internal Seating Dia.

External M2 M2
for Tyre Clamping for Tyre
Clamping Ring
Ring
Flange
Flange
FENNER TAPERLOCK® BUSHES
CK
R LO
PE
TA
Using Fenner Taper Taperlock Bushes, it is possible for unskilled labour to achieve 'shrink fit' of pulleys, coupling etc., onto
shafts using only a hexagonal wrench.
The arrangement of half-threaded holes and longitudinally split tapered bushes ensures maximum grip and fast, easy
fitting. Tightening of the screws into the threaded holes in the hub forces the bush into the taper bored components, thereby
effectively contracting the bore of the Taperlock Bush until the equivalent of a 'shrink fit' is obtained.
Taperlock Bushes are suitable for metric as well as imperial shafts.
ADVANTAGES
• No reboring and keywaying costs.

• Saves time and cost in fitting.
• Eliminates precision taper fitting keys.
• 239 bush size/bore combinations are available.
• Interchangeable between many products.
• Taper bored components can be transferred to other diameter shafts by fitting alternative bore bushes.
• Convenience in dismantling for maintenance and component replacement.
• Accommodates shaft limits of +0.051 mm/-0.127mm.
The benefits of using Taperlock Bushes can be extended to include components which have a parallel bore by
incorporating Taperlock Adaptors, Taperlock Bolt-on Hubs or Taperlock weld-on Hubs.
FENNER TAPERLOCK® BUSHES
TABLE 8
METRIC BORES AND KEYWAYS
Keyway Shallow Catalogue Code Group 029 ...
Bore Keyway 1008 1108 1210 1215 1310 1610 1615 2012 2517 2525 3020 3030 3525 3535 4040 4545 5050
Dia. Width Depth Depth
AO BO CO DO EO GO HO KO MO NO PO QO JO RO SO TO UO
9 3 1.4 - …009 009
10 3 1.4 - …010 010
11 4 1.8 - …011 011 011 011
12 4 1.8 - …012 012 012 012
14 5 2.3 - …014 014 014 014 014 014 014 014
16 5 2.3 - …016 016 016 016 016 016 016 016 016
18 6 2.8 - …018 018 018 018 018 018 018 018 018
19 6 2.8 - …019 019 019 019 019 019 019 019 019 019
3 Hexagon Socket
20 6 2.8 - …020 020 020 020 020 020 020 020 020 020 Cap Screws Supplied
22 6 2.8 - …022 022 022 022 022 022 022 022 022 022
24 8 3.3 1.3 …024* 024 024 024 024 024 024 024 024 024
25 8 3.3 1.3 ...025* 025 025 025 025 025 025 025 025 025 025
28 8 3.3 1.3 028* 028 028 028 028 028 028 028 028 028
30 8 3.3 - 030 030 030 030 030 030 030 030 030
32 10 3.3 1.3 032* 032* 032 032 032 032 032 032 032
35 10 3.3 1.3 035* 035 035 035 035 035 035 035 035 035
38 10 3.3 - 038 038 038 038 038 038 038 038 038
40 12 3.3 1.3 040* 040* 040 040 040 040 040 040 040 040
42 12 3.3 1.3 042* 042* 042 042 042 042 042 042 042 042
45 14 3.8 - 045 045 045 045 045 045 045 045
48 14 3.8 - 048 048 048 048 048 048 048 048
50 14 3.8 2.8 050* 050 050 050 050 050 050 050
55 16 4.3 - 055 055 055 055 055 055 055 055
60 18 4.4 - 060 060 060 060 060 060 060 060
65 18 4.4 - 065 065 065 065 065 065
70 20 4.9 - 070 070 070 070 070 070 070
75 20 4.9 - 075 075 075 075 075 075 075
80 22 5.4 - 080 080 080 080 080
85 22 5.4 - 085 085 085 085 085
90 25 5.4 3.4 090* 090* 090 090 090
95 25 5.4 - 095 095 095
100 28 6.4 5.4 100* 100 100
105 28 6.4 - 2 Hexagon Grub 105 105
110 28 6.4 - Screws Supplied 110 110
115 32 7.4 - 115
120 32 7.4 - 120
125 32 7.4 - 125
Nominal dia
at large end of Taper 35.0 38.0 47.5 47.5 51.0 57.0 57.0 70.0 85.5 85.5 108.0 108.0 127.0 127.0 146.0 162.0 177.5
Approx. Mass of Bush (Kg) 0.1 0.1 0.2 0.3 0.3 0.3 0.5 0.7 1.5 1.9 2.7 3.6 3.8 5.0 7.7 10 14
Dimensions in millimeters
Keyways are British Standard Metric B.S. 4235: Part 1:1972 and conform to I.S.O. recommendations except for the bore sizes
marked * which are shallower.
Where a key is to be used it should be parallel and side fitting with top clearance. Depth of keyway is measured at CENTRE.
®
Note : Taper-Lock Bushes with imperial bores can also be supplied. Please consult Fenner.
Weir Minerals Multiflo
WEIR MINERALS MULTIFLO

BARE SHAFT PUMP AUTO GREASING
OPERATING & MAINTENANCE INSTRUCTIONS

OUTLET CONNECTIONS & TIMER SETTINGS
TO SUIT PUMP UNIT MODELS
WITH DOUBLE BEARINGS
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
135
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: beka@beka-lube.de
beka@beka-max.de
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!

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


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
Revision 2 – October 08 Page 1 of Vacuum Pump Assembly Procedure

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
Revision 1
2 – October
March 0208 Page 3 of Vacuum Pump Assembly Procedure
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.
Page 4 of Vacuum Pump Assembly Procedure

Revision 2 – October 08
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-
A
slipper bearings have bearing locator lugs
as per conventional conrods.
B
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 manner 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.
TORQUE SETTINGS
Cylinder Head 35 Nm + 3 25 ft lb + 2
Cylinder to Crankcase 30 Nm + 3 20 ft lb + 2
Bearing Cap 35 Nm+ 3 25 ft lb + 2
Conrod Big Cap 35 Nm + 3 25 ft lb + 2
Valve Retainer Cap 35 Nm + 3 25 ft lb + 2

Mechanical and Non-Pressurised
Fuel Filling Valves
Installation, Operation, Maintenance Manual for

Hydrau-Flo® valves
© 2011, Weir Minerals Australia Ltd., trading as Weir Minerals Multiflo. All rights reserved. MULTIFLO, VACTRONIC and HYDRAU-FLO are
registered trademarks of Weir Minerals Australia, Ltd. The document and its text, images, diagrams, data and information it contains must not
be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals Multiflo Ltd. Due
to continuous product development, the information contained herein may change.
Office of Origin: Head Office, WMMultiflo, Coolum Beach, QLD, Australia
Date: 30/05/2011

Mechanical and Non‐Pressurised
Fuel Filling Valves

Table of contents

1 INTRODUCTION........................................................................................................................................... 1
1.1 SAFETY ............................................................................................................................................................. 1
1.2 SAFETY SYMBOLS ............................................................................................................................................... 2
2 HYDRAU‐FLO® FUEL FILLING VALVE ............................................................................................................. 3
2.1 WORKING PRINCIPLE ........................................................................................................................................... 3
2.2 HYDRAU‐FLO® CONFIGURATIONS .......................................................................................................................... 5
2.2.1 Hydrau‐Flo® Fuel Filling Valves.............................................................................................................. 5
2.2.2 Hydrau‐Flo® Float Control Valves .......................................................................................................... 6
2.2.3 Pilot Line ................................................................................................................................................ 7
2.2.4 Optional Features .................................................................................................................................. 7
2.2.5 Roll – over Protection .......................................................................................................................... ..8
2.3 HYDRAU‐FLO® APPLICATIONS............................................................................................................................. ..8
3 HYDRAU‐FLO® INSTALLATION .................................................................................................................... 9
3.1 PREPARATION ................................................................................................................................................... 9
3.2 INSTALLATION TOOL KIT .................................................................................................................................... 10
4 HYDRAU‐FLO® MAINTENANCE .................................................................................................................. 11
4.1 MAINTENANCE INSTRUCTIONS ............................................................................................................................ 11
4.2 TROUBLE SHOOTING GUIDE ............................................................................................................................... 11

HYDRAU‐FlO®HARDWARE...............................................................................................................................................13

Fuel Filling Valves

1 Introduction
The purpose of this Manual is to advise and instruct installers, and operators of Weir Minerals
Hydrau‐Flo® fuel filling valve units about the recommended installation, operation and
maintenance of the equipment. The following information will aid you in the installation,
operation and maintenance of your new Weir Minerals Hydrau‐Flo® fuel filling valve. To ensure
long life and trouble‐free operation, it is imperative that the instructions contained in these
manuals are read understood and carried out by all users of this product.

The Weir Minerals Hydrau‐Flo® fuel filling valve is of robust construction and is used to prevent
build up of pressure and overfilling in the fuel tank. It has been designed to be used in
conjunction with the existing “fast fill” systems and also the traditional splash filling systems.

Please check our website www.weirminerals.com/hydrau‐flo or search youtube for ‘hydrau‐flo’
to view the 5 minute video on how the system works.
1.1 Safety
Weir Minerals Hydrau‐Flo® fuel filling valve unit has been designed to provide a safe
working environment for operators, maintenance personnel and to be used in
environmentally sensitive areas where “zero‐spill” is mandatory.

o Read the instruction manual prior to installing or operation.
o Personal Protective Equipment (PPE) must be used when installing, operating,
servicing, maintaining this equipment.
o It is the user’s responsibility to be aware of and comply with all federal and state
occupational health and safety requirements or the safety regulatory organisation
having jurisdiction. Use trained competent people to assess all site risks involved
with the installation of this equipment in accordance with the Installation and
Operations Manual.

Safety warnings and precautions are provided intermittently throughout this document.
Failure to heed these warnings and precautions may result in personal injury and/or death
to yourself and/or others and also result in equipment and environmental damage.

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:‐
o My colleagues and my own safety are paramount;
o No task is so important or urgent that it cannot be undertaken safely;
o I will only undertake tasks that I am trained, competent and properly prepared
for;
o I will never cut corners, nor take shortcuts at the expense of safety;
o I will stop the job if I believe it is unsafe to continue.
Any aspect of the installation, which the Customer is unsure of, we advise the customer
to discuss with a Weir Minerals Multiflo Representative or its authorised distributor.
© Copyright Weir Minerals Australia Ltd Page 1 of 13
Fuel Filling Valves
1.2 Safety Symbols

The accompanying documentation supplied with the Weir Minerals Hydrau-Flo Fuel Cell
pressure Control Valve utilizes the following safety symbols to highlight potentially harmful
situations to personnel, equipments and the environment, as per ISO 9001:2008.
Imminent risk of fatal or crippling Fatal or crippling injuries likely to

injuries result from any exposure.
Possibility of a harmful situation Minor or slight injuries possible.

environment.
Possible damage to the product,

Prohibited activities
equipments or property.
Fatal or crippling injuries likely to

Warning of Electrical shock
result from any exposure.
Mandatory Personal Protective Fatal or crippling injuries likely to

Equipments result if not worn.
Possibility of explosion if instructions

Explosion Warning
not followed.
Application Hints and other useful

Information
User has to refer accompanying

Refer other
manuals or other documents.

Fuel Filling Valves
2 Hydrau-Flo® Fuel Filling Valve

The Hydrau-Flo® valve system is a safer, cleaner and more reliable fuel filling valve arrangement
which removes the risk of overfilling, spillage and tank rupture while minimising safety and
environmental hazards associated with fuel transfer. With flow rates up to 1,000 litres/min (265
gallons/min) and pressures up to 100 kilopascals (20 psi), it is imperative to provide safer
solutions for fuel filling. Hydrau-Flo® fuel filling valve systems offer superior operator protection
and improved environmental outcomes.
The Hydrau-Flo® fuel filling valve system overcomes the traditional fuel transferring problems
without the need for electronics or complex arrangements prone to blockage and failure. It
incorporates robustly designed fuel filler safety valves and float control valves to provide a
reliable, hydraulically operated arrangement which depends on fluid level rather than pressure.
The system is designed to be used in conjunction with existing “fast fill” systems or traditional
“splash” filling.
Advantages of using Hydrau-Flo® Valve are

o Prevents overfilling, fuel spillage and wastage
o Removes the risk of tank rupture due to pressure build up during and after filling
o Minimises the risk of fire as a result of fuel spillage
o Reduces costs associated with fuel wastage and equipment damage
o Significantly improves safety and environmental outcomes
o Reduces fuel theft.
2.1 Working principle

The system consists of fuel filling valve, a float valve and a pilot line. The Hydrau-Flo® valve
is activated via fuel level, not the contained fuel pressure unlike traditional systems.
Open breather
Capillary Line
Hydrau-Flo® float valve Fuel Tank
Standard fast fill receiver
Hydrau-Flo® Fuel
“Filling” valve
Fig.1. Working principle of a stationary fuel filling set-up

Fuel Filling Valves
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.
Lever Float in Open Position Lever Float in Closed Position
Fig.2. Operation
When the fuel level in the tank rises and closes the float valve, thus stopping the bleed and
pressure leak, the fuel pressure is equalised on both sides of the piston. Spring pressure
will force the piston back to close the fuel ports, preventing any extra fuel from entering
the fuel tank.
The fuel nozzle cannot be overridden 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.
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.

Fuel Filling Valves
2.2 Hydrau-Flo® Configurations

Hydrau-Flo® fuel filling valves and float control valves are available in different
configurations, designed to suit various mobile and stationary applications, majority of
equipment types and filling requirements.
2.2.1 Hydrau-Flo® Fuel Filling Valves
Hydrau-Flo® fuel filling valves usually fitted on the fuel tank, in a location suitable for
attaching fuel filling systems. It has a piston backed by a spring which opens up and let the
fuel in and closes when the fuel is filled.
The standard Hydrau-Flo® fuel filling black valve is ideal for all new equipment applications
and existing equipment that has suitable fittings. The compact design delivers the highest
flow rate capacity in the range.
Fig.3. Hydrau-Flo® fuel filling black valve HF1105Z0001
The retro fit Hydrau-Flo® fuel filling red valve is designed to fit into tanks using the
Wiggins® ZNC3 recess. These are typically used on CAT® 776 and 773 trucks.
Fig.4. Hydrau-Flo® fuel filling red valve HF1105Z0002

Fuel Filling Valves
The most commonly used retro fit Hydrau-Flo® fuel filling valve is the blue valve
HF1105Z0003 which fits directly into truck and loader fuel tanks using the same thread (2”
NPT) as the conventionally used dry break fittings (which are screwed back into the
Hydrau-Flo® fuel filling valve). These valves fit into typical CAT® and Komatsu® fuel tank
recesses.
Fig.5. Hydrau-Flo® fuel filling blue valve HF1105Z0003
2.2.2 Hydrau-Flo® Float Control Valves

Hydrau-Flo® float control valves are connected to the fuel filling valve via a pilot line. It
contains a float which rises up and stops the bleed and thereby making the spring backed
piston in the filling valve to close and stop filling the tank. The valves are available for both
stationary and mobile applications. These floats and lever floats can be set at varying
heights, by simple extensions to control the level of fuel in the tank when it is full. This float
can purge 32cfm of air from the tank while refuelling at 1000 lpm (265 gpm).
The Hydrau-Flo® float control valve has a robust design for use on mobile equipment which
ensures reliable pilot operation of the Hydrau-Flo® fuel filling valve. It also incorporates roll
over shut off protection and an anti-surge fuel breather vent to prevent spillage that can
occur as a result of vehicle motion when using “conventional” valves.
HF1008Z0001 HF1007Z0001
Fig.6. Hydrau-Flo® float control valve & lever control valve
The lever control valve is typically used on stationary equipment including skid mounted
pump sets, generators and lighting plants. The simple and robust design provides a lower
cost option for stationary equipment and is available in two different lengths.

Fuel Filling Valves
2.2.3 Pilot Line
The pilot line can be connected to the fuel filling valve and the float control valve either
from outside or inside of the tank.
Float Control Valve
Breather Pilot Line

Hose
Fuel Filling Valve
Fig.7. Hydrau-Flo® float control valve & lever control valve

The standard pilot hose provided with Hydrau-Flo® kits is a marine grade push on hose
which is perfect for installation where the exact hose length is not pre-determined. The
pilot lines are available in 3/8” & 1/2” push on, single wire braid as well as stainless steel
wire braided reinforced hoses.
2.2.4 Optional Features

A. Internal Pilot lines
The pilot lines can be connected, if preferred, inside the tank with little modifications to
the valves. Both fuel filling & float valves are designed with 2 outlets with ¼” BSP threads,
with one of them plugged. Just by replacing the plug from one outlet to the other, the pilot
line can be run either internal or external to the tank.
Remove the ¼” BSP plug from here

and plug here
Fig.8. Converting external pilot line to an internal line.
While using internal pilot lines, single wire braided hose is used for abrasion
resistance. The hose lines have swivel fittings at their ends to facilitate the easy
assembly.

Fuel Filling Valves
Refer 5.1 ‘ Lever float dimension drawing’ for lever float dimensions

2.2.5 Roll – over Protection
In the normal vertical position, the weight of the vent float compresses the spring and the porting to
the atmosphere is un‐obstructed.

As the assembly starts to tilt, the effective weight of the vent float against the spring decreases and
the spring starts to raise the float and closes off the vent porting well before the diesel fuel reaches
the open vent porting. As the assembly continues to tilt, the weight of the diesel fuel too holds the
float to be closed against the vent port.

The positive sealing provided with an o‐ring ensures no leakage whatsoever.
Fig.12. Roll over Protection

2.3 Hydrau‐Flo® Applications
Hydrau‐Flo® fuel filling systems can fuel both stationary and mobile applications. It is
suitable for re‐fuelling trucks, loaders, excavators, gantries, dozers & graders, etc.

It can also be used to trickle feed multiple smaller stationary fuel tanks from a main fuel
storage tank. As the fuel is consumed from the smaller tanks and the fuel level in the tank
drops, the Hydrau‐Flo® fuel filling system will top up until the tank is full and ensures that
the tank is always full. The Hydrau‐Flo® lever float system is perfect for this type of
arrangements. See Fig.12 & 13 below.

Fuel Filling Valves
Remote fuel fill
point
Lever float
Anti ‐ Surge
Fig.12. Trickle feed system Breather

Fig.13. Trickle feed system with two floats

Anti‐surge breather is used for redundancy and for asset relocation in order to eliminate
fuel spill in transit
It can feed the tanks at the rate of 2.1 lpm (0.6 gpm) at atmospheric pressure and the shut‐
off can withstand up to 20 bar (290 psi).
3 Hydrau‐Flo® Installation
3.1 Preparation
Clean the area around the fuel receiver and adaptor on the fuel tank.
Drain the tank empty before installing.
Isolate, tag out and lock out the machine as per site requirements.
Ensure safe access to the areas to be work on as per site standards. Site specific
PPE must be worn for the areas where the work is to be performed. Provision
should be made for the catchment and disposal of excess fuel.
Ensure the right type of receiver is selected for the application.
Fuel Filling Valves
3.2 Installation Tool Kit

The Hydrau-Flo® valves are supplied with an Hydrau-Flo® Installation tool kit (103628)
which contains tools for installing all types of Hydrau-Flo® valves.
200629
Tool for installing Hydrau-Flo® float control valve – Side entry
201240
Tool for installing Hydrau-Flo® fuel filling valve (Blue & Black) –
Side entry
202125
Tool for installing Hydrau-Flo® fuel filling valve (Red)
101023
Tool for installing Hydrau-Flo® fuel filling valve (Blue & Black) –
Top entry

Fuel Filling Valves
4 Hydrau-Flo® Maintenance
4.1 Maintenance Instructions
Hydrau-Flo® system essentially is maintenance free and requires minimal attention
throughout it is life. However, the following points must be taken care of to ensure a
trouble free performance.
o Keep the fuel receiver & the fuel nozzle clean.

o Ensure integrity of the pilot line. Make sure no dents or kinks on the line.
o Clear any kind of debris from flow control valve’s vent port.
4.2 Trouble Shooting Guide
Symptoms Causes Remedies

Nozzle or receiver spring setting Check condition & rating of spring.
too low Relace if necessary
Back pressure in filler pipe too high Ensure no excessive restriction in flow
of fuel from the Hydrau-Flo® system to
Fuel nozzle shutting
the tank
off prematurely
Breather blocked Check & clean. Replace it necessary
Float valve set too low in tank Adjust to desired fill height
Restriction in pilot line Check line for damage, crushes or kinks.
Replace if necessary.
Float valve not stopping bleeding Check the operation of the float
from pilot line ensuring it does not hit internal walls of
fuel tank. Check valve seats for damage
or obstruction.
Fuel nozzle not Piston stuck open Check piston operation is free
shutting off Leakage in pilot line Check and replace if necessary
Float level set above breather Lower float level below the height of
height breather
Dislodged welsch plugs in fuel Visually check valves and confirm
filling valve or float control valve welsch plugs are fitted securely
Float level set too high, not Lower float level setting. Refer section
Fuel weeping from
allowing enough air space for fuel 2.2.4.C. of this manual on pages 9 & 10.
breather after the tank
expansion due to rise in
has been filled
temperature

Hydrau-Flo® valve - hardware
A range of Hydrau-Flo® valve adaptors and accessories are available for simple and
easy installation into most types of mobile and stationary equipment.
Hydrau-Flo® fuel filling valve kits provide customers with the fully packaged solution.
Some of the many accessories available are shown below.
Hydrau-Flo® fuel filling valve adaptors
HF1102Z0004 HF1102Z0002 HF1102Z0001

Adapts HF1105Z0001 Weld-on threaded ring to Adapts Hydrau-Flo® fuel filling black
to a 2” hose tail. mount HF1105Z0001 directly valve to fit to a 2” NPT (male) socket.
into tank.
HF1102Z0005 HF1102Z0012
Adapts HF1105Z0001 HF1102Z0010 HF1102Z0013
to fit to a 2 1/2” Weld-in flush mount to suit Weld-on threaded stand pipe.
hose tail. HF1105Z0001. Used to mount HF1105Z0001
to top tank.
(150mm, 310mm).
HF1102Z0003 HF1103Z0003
Bolt-in flush mount to suit Adapts CAT® D10R / D11R fuel
Komatsu® tanks. Suits internal inlet hose to HF1105Z0003.
mounting of HF1105Z0001 HF1103Z0002
or external mounting of Weld-in flush mount to suit
HF1105Z0003. HF1105Z0003.
ZNC3 / ZNC4
Wiggins® Bolt-on / Weld-on
HF1011Z0002 flush mount–suits HF1103Z0004
2” NPT Socket—weld into tank HF1105Z0002. Adapts HF1105Z0003 to
to allow direct mounting of CAT® D10R / D11R tank.
HF1105Z0003.
HF1012Z0002
Lever Float / Breather mounting HF1102Z0007
HF1102Z0008 flange–fits to HF1103Z0001 Adapts HF1105Z0001and valve
Adapts HF1105Z0001 to Cat® & HF1012Z0001. adaptor HF1102Z0001 to
fuel tanks. Liebherr® 994 / 996 excavator.
HF1011Z0001
HF1102Z0009 Adapts Hydrau-Flo® float
Adaptor fuel supply hose to control valve HF1008Z0001 HF1103Z0001
HF1105Z0001 valve to to CAT® D10R / D11R tank. Lever / Float breather screw-in
Liebherr® 994 & 996. flange. Fits to 2” NPT socket.
102907
HF1012Z0001 Adapts Hydrau-Flo® fuel filling HF1012Z0003
Lever Float / Breather black valve to fit to a 2” BSP Lever Float mounting flange
weld-in flange. (male) socket. fits to HF1103Z0001 &
HF1012Z0001.
209304 HF1204Z0004
Aluminium mounting flange fits Check valve to evacuate fuel 103042
to HF1105Z0001. tank. Used in conjuction with Adaptor Hitachi EH4000 truck.
standard receiver.
214441
Liebherr® 282B adaptor 216655 215249
John Deere® fuel tank breather Hitachi® EX3600-6 adaptor
adaptor
HF1102Z0011
Liebherr® adaptor 102350
216647 Komatsu® D375 fuel tank adaptor
John Deere® fuel tank adaptor
CATERPILLAR, KOMATSU, HITACHI, BUCYRUS, TEREX, LIEBHERR, CARGOTEC, KALMAR, WIGGINS, JOHN DEERE and BANLAW are trademarks of the OEM and are not trademarks of Weir Minerals Australia Ltd.
5 Page 12 of 13
Hydrau-Flo® fuel filling valve and float control valve adaptors are available in a
number of configurations designed for new equipment manufacture or fitment
to most makes of existing mobile and stationary equipment.
Hydrau-Flo® float control valve components
HF1014Z0001 HFS27-1212 HF802-1212

Barrel Nipple—For mounting Nipple 3/4” to 3/4” BSP. Used to Swivel hose tail 3/4” BSP to 3/4”
HF0304Z0003 rain cap breather connect HF1204Z0014 swivel tail hose. Connects 3/4” nipple to
to HF1012Z0002. to HF1012Z0002 breather mount breather hose.
or HF1014Z0002 weld-on bracket.
HF1014Z0002 HF1008Z0002
Weld-on Bracket to suit rain cap HF0304Z0003 Anti-Surge Breather—Fits 2” NPT
breather HF0304Z0003. Rain Cap Breather. socket or HF1102Z0002 weld-in
flange.
HF1008Z0003 HF1011Z0002
Adapts Anti Surge breather to 2” NPT Socket—Weld into tank
HF1012Z0002 lever float / wall to suit anti-surge breather
breather mounting flange. HF1008Z0001, HF1008Z0006, and
HF1008Z0002.
Pilot line fittings

HF1204Z0003 FS72-0406 HFS27-0806
1/4” BSPT Brass plug. Used to Adaptor Female 1/4” BSP to male Nipple 3/8” up to 1/2” BSP.
plug unused pilot line ports. 3/8” BSP. Used to connect push-on
fittings to check valves.
HF1204Z0001
Pilot line Check Valve. 3/8” BSP HF58-0409 HF1204Z0002
female to 3/8” BSP female, use Elbow 1/4” BSP x 9/16” JIC.” Pilot Line Check Valve.
where 1 x Lever Float Valve is 3/8” BSP female to 3/8”
connected to 2 x fuel filling BSP female. Used where 2
valves. Eg highwall applications. x Hydrau-Flo® fuel filling
HF805-0808 valves are connected to 1 x
Swivel Hose tail 90O 1/2” x 1/2”. float control valve. Includes
balancing port.
HFS27-0804
Reducing Nipple 1/4” x 1/2”.
HFS7-0409 104073
1/4” BSPT Male 9/16” JIC Male Pilot line magnetic anchor
nipple to suit 16.5mm to 18mm
HF802-0808
Swivel Hose tail straight hose OD. 68kg pull force.
1/2” x 1/2”.
HFT204-0607 104074
3/8” swivel fitting to suit hose Pilot line magnetic anchor
HF1204Z0012 HF1215Z0005 single wire braid. to suit 20mm to 22mm hose
3/8” BSP ‘tee’. OD. 68kg pull force.
Hoses
HF1215Z0002 HHP112 HF1215Z0003 HF1215Z0004
1/2” Pilot Line 3/4” Breather 1” Breather hose. 1 1/4” Breather
hose - standard. hose—suits rain hose—suits
cap breather. HF1008Z0001
float control
valve &
HF1008Z0002
HF1215Z0005 HHT16A HF1215Z0003 anti-surge
3/8” Single wire 3/8” Single 1” Oil Resistant hose. breather.
hose ‘Survivor’ wire hose ‘Ryco’
for inside tank for inside tank
installation. installation.
CATERPILLAR, KOMATSU, HITACHI, BUCYRUS, TEREX, LIEBHERR, CARGOTEC, KALMAR, WIGGINS, JOHN DEERE and BANLAW are trademarks of the OEM and are not trademarks of Weir Minerals Australia Ltd.
Page 13 of 13 6
VISMODE® CONTROLLER V4
Operation & Maintenance Manual

Vismode® Controller V4
© 2012, Weir Minerals Australia Ltd., trading as Weir Minerals MultiFlo® . All rights reserved. MULTIFLO® , VACTRONIC and HYDRAU-FLO are
registered trademarks of Weir Minerals Australia, Ltd. The document and its text, images, diagrams, data and information it contains must not be
copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals MultiFlo® Ltd. Due to
continuous product development, the information contained herein may change.
Date: 21/12/2012
© Copyright Weir Minerals Australia Ltd

CONTENTS
1. Introduction .......................................................................................................................... 1
1.1 SAFETY SYMBOLS .......................................................................................................................................... 1
1.2 VISMODE® CONTROLLER HE417 ................................................................................................................... 2
1.3 PRODUCT OVERVIEW .................................................................................................................................... 2
1.4 VISMODE® OPERATIONAL BUTTONS .............................................................................................................. 3
1.5 VISMODE® LED PANEL .................................................................................................................................. 4
1.6 VISMODE® CIRCUIT BREAKERS AND RELAYS .................................................................................................... 5
1.7 AVAILABLE MENUS ....................................................................................................................................... 6
1.7.1 CONFIGURATION MENU ........................................................................................................... 7
1.7.2 STATUS MENU ......................................................................................................................... 8
2. Operation ..................................................................................................................... ......10
2.1 STARTING THE PUMP USING THE VISMODE® CONTROLLER ............................................................................ 10
2.2 STOPPING THE PUMP USING THE VISMODE® CONTROLLER ............................................................................ 10
2.3 SCHEDULING .............................................................................................................................................. 10
2.4 FLOAT OPERATION.........................................................................................................................12
2.5 USERS LEVELS AND PASSWORDS.......................................................................................................13
2.6 RPM CONFIGURATION.....................................................................................................................13
2.7 HOW TO CHANGE THE DISPLAY CONTRACT.........................................................................................13
2.8 INPUT AND OUTPUT CONFIGURATION................................................................................................13
2.9 INPUT,OUTPUT AND ENGINE STATUS.................................................................................................13
2.10 VISMODE POWER SAVE MODE..........................................................................................................13
3. Maintenance.......................................................................................................................14
3.1 SAFETY NOTES...............................................................................................................................14
3.2 DIAGNOSTICS................................................................................................................................14
3.3 TROUBLE SHOOTING.......................................................................................................................15
4. Appendices..........................................................................................................................19

LIST OF FIGURES
1. VISMODE® FRONT PANEL .................................................................................................... .......3
2. VISMODE® CONNECTION ........................................................................................................... 3
3. VISMODE® SMC & SMA CONNECTORS ........................................................................................ 3
4. VISMODE® BUTTONS ................................................................................................................. 3
5. VISMODE®4 MAIN BUTTONS ...................................................................................................... 3
6. VISMODE®OPERATIONAL BUTTONS ........................................................................................... 3
7. LED PANEL ................................................................................................................................. 4
8. RELAYS PANEL ACCESS ............................................................................................................... 5
9. CIRCUIT BREAKER INDICATION LAMPS ....................................................................................... 5
10. RELAYS PANEL ......................................................................................................................... 5
11. BOOT SCREEN............................................................................................................................6
12. HOME SCREEN............................................................................................................................6
13. RPM/COOLANT DIAL...................................................................................................................6
14. RPM DIAL/FLOAT LEVEL...............................................................................................................6
15. J1939 DIAGNOSTICS.....................................................................................................................6
16. MODE MENU...............................................................................................................................6
17. CONFIGURATION MENU..............................................................................................................6
18. STATUS MENU.............................................................................................................................6
19. SCHEDULING SCREEN TOPRIOR TO SET UP...................................................................................10

20. SCHEDULING SCREEN WITH SCHEDULLING ENABLED...................................................................10
21. SCHEDULE SET UP SCREEN...........................................................................................................11
22. SCHEDULING MENU SHOWING SCHEDULE HAS BEEN SET............................................................11
23. RUN SCHEDULING SCENARIOS.....................................................................................................11
24. FLOAT SWITCH MENU.................................................................................................................12
25. NORMAL DIAGNOSTIC SCREEN....................................................................................................14
26. DIAGNOSTIC SCREEN SHOWING FAULT........................................................................................14

1. INTRODUCTION
1.1. Safety Symbols
The accompanying documentation supplied utilises the following safety symbols to highlight potentially
harmful situations to personnel, equipments and the environment, as per ISO 9001:2008.
Imminent risk of fatal or crippling Fatal or crippling injuries likely to result

injuries from any exposure.
Possibility
Minor or slight injuries possible.
of a harmful situation

environment.
Application
Hints and other useful Information
User has to refer accompanying manuals

Refer other documents
or other documents.

1.2. Vismode® Controller He417

This manual is to assist trained operators of WEIR Multiflo engines/pumps operating and
troubleshooting the Vismode® controller. All pumps supplied by Weir Multiflo are customised to each
customer’s requirements, location and setup. This customisation may include different configuration of
inputs and outputs.
Do NOT keep the door open during operation. Water may cause damage to the controller.
Do NOT put weight on the open door as this may cause damage to the hinges.
Do NOT remove the Vismode® control panel from its mounts inside the cabinet. Doing so
will void any warranty.
Each pump is configured specific to customer requirements. As such please make sure you
familiarise yourself with each pump and its specified settings prior to operation. If
required contact Weir Multiflo® for more details.
All pictures in this report are visual guides only. This pump unit may have different
settings to these displayed in this manual.
Refer to " Vismode® Pin Out Connection V0R3" in the Appendices manual of this section
for further information on Vismode® Pin Out Connections.
1.3. Product Overview

The Vismode® Controller is housed in a stainless steel enclosure with a hinged door. The door can be
locked with a key. The panel and work lighting can be switched on and off by pressing the Work Light
button at the front of the enclosure.
The Vismode® is connected to the engine ECU via the 40-pin Deutsch connector while the external
inputs and outputs are connected to the Vismode® via the 70-pin Deutsch connector as shown in
Fig.2. The wiring loom is factory fitted and should not be altered in the field (except as instructed by a
WEIR technician).
The controller is supplied by 3 power supply cables shown in Fig.2.
24V + (RED) 24V supply from the battery (Battery Positive)
24V – (BLACK) 24V supply from the battery (Battery Negative)
24V + (RED) 24V supply to the starter motor solenoid (Starter Solenoid)
The 3G GSM and GPS are connected via the SMC and SMA connectors at the bottom of the enclosure as
shown in Fig.1.

Fig.1. Vismode® Front Panel Fig.2. Vismode® Connection Fig.3. Vismode® SMC & SMA connectors
1.4. Vismode® Operational Buttons

The Vismode® has 4 engine control buttons shown in Fig.5. These are ‘start and stop’ used to start and
stop the engine and ‘RPM + and –‘to adjust the engine speed.
Additional to these is a directional keypad. The 4 arrows, enter button (circle), reset and return button
(cross) will enable you to navigate through the menu. The Menu structure will be explained in section
1.7.
The maintenance light will turn 'ON' when the engine has indicated that a service is to be carried out.
Once the service has been completed press the maintenance button and follow the instructions to erase
the warning message and turn of the maintenance light.
Only use this function after having dealt with the warning message.
The stage pumping buttons are to enable (circle) and disable (cross) the stage pumping function. By
enabling the stage pumping function the vacuum pump will become disabled.
If the pump is not operating as a staging pump, this should not be activated.
The timer button enables the operator to view all present schedules. If required, schedules can be
changed in the main menu.
Fig.4. Vismode® Buttons Fig.5. Vismode® 4 Main Buttons Fig.6. Vismode®Operational Buttons

1.5. Vismode® LED Panel

The bottom part of the controller consists of an LED display which indicates the status of all alarms as
shown in
Fig.7. When the unit is first powered up the Vismode® will do a self check going through all the inputs
and outputs at which time all LED’s will be highlighted for a short period (to make sure they work).
Fig.7. LED Panel
Table.1. LEDs Colour Scheme

1.6. Vismode® Circuit Breakers and Relays

Open the LED panel door shown in
Fig.8. for access to the circuit breakers and relays. The power, controller over current, ACC over current
and sensor over current indication lights are located in the green section inside the unit as shown in
Fig.9.
The power LED will be on when the Vismode® is connected to power.

The controller over current, ACC over current and the sensor over current will be on when the
designated breaker is tripped.
The Vismode® is equipped with 8 additional circuit breakers as listed in Table.2.
Circuit Breaker Rating

Aux 10A
ECU 15A
Fan 20A
Ignition 20A
Start 5A
Strobe 5A
Vacuum Clutch 3A
Work light 20A
Table .2. Circuit Breakers List
Fig.8. Relays Panel Access Fig.9. Circuit Breaker Indication Lamps Fig.10. Relays Panel

1.7. Available Menus

This section explains the available displays and how they interact with each other.
Fig.11. Boot Screen
Fig.12. Home Screen
Fig.13. RPM/Coolant Dial Fig.16. Mode Menu

Use and keys
To navigate through the menu
Fig.14. RPM Dial / Float Level Fig.17. Configuration Menu

Use the key
To return to the
home screen
Fig.15. J1939 Diagnostics Fig.18. Status Menu

1.7.1. Configuration Menu
Use the keys to scroll up and

down though the configuration menu
There is a level 2 password required

for editing the input and output
configuration.

1.7.2. Status Menu
Use the Keys to scroll up and down

through the status menu and the sub menus.


2. OPERATION
2.1. Starting the Pump using the Vismode® Controller
The pump can be started either manually using the “Start” pushbutton on the front of the Vismode® or
alternatively using the timer or float mechanisms.
2.2. Stopping the Pump using the Vismode® Controller

The pump can be stopped in a number of ways. To manually stop the pump it is recommended to use
the “Stop” pushbutton on the front of the controller. This will send the engine in to a controlled
shutdown where the engine will cool-down for the programmed period before turning off (pressing the
Stop button during this period will shut the unit down immediately). The engine will also shutdown if
any faults occur and the programmed time surpasses without the fault being rectified or if triggered by a
schedule or float switch.
2.3. Scheduling
The Vismode® can be set up such that the pump will turn on and off at desired times as set through
schedules.
To set a schedule, enter the mode screen and select scheduling using the enter button on the keypad.
Upon entering the password (shown in section 2.5) the following screen will be displayed.
Fig.19. Scheduling screen prior to set up

Select the enter button to edit this screen and then press the right arrow to enable global scheduler
status. The following screen should now display.
Fig. 20. Scheduling screen with scheduling enabled

Once this has been enabled scroll down using the down arrow to schedule one and press enter. The
following screen will display showing parameters of the schedule to be set.

Fig. 21. Schedule set up screen

Press the enter button to edit the schedule and then set the day, time and desired running RPM using
the control panel. Once set to the desired settings press the select button to confirm and then the back
button to return to the scheduling screen. Confirm that the schedule appears as shown below.
Fig. 22. Scheduling menu showing schedule has been set

Repeat this process for all desired scheduled start and stops.
Fig.23.RunScheduleScenarios

Fig.23. shows all the possible scenarios that could arise when schedules have been set and how the
pump will react.
Scenario 1:
Pump starts at first scheduled time and runs at scheduled RPM until scheduled stop arrives. Pump starts
at second scheduled time and runs at scheduled RPM until scheduled stop arrives
Scenario 2:
Pump is already running when first scheduled start arrives. The pump will change to the scheduled RPM
and turn off when the scheduled stop arrives. Pump starts at second scheduled time and runs at
scheduled RPM until scheduled stop arrives
Scenario 3:
Pump starts at first scheduled time and runs at scheduled RPM until scheduled stop arrives. Pump is
manually started during the period where the pump is scheduled to be off. When the second scheduled
start arrives the pump changes RPM to the scheduled RPM and runs until the scheduled stop arrives.
Scenario 4:
Pump starts at first scheduled time and runs at scheduled RPM until manually stopped prior to
scheduled stop arriving. Pump remains off until second scheduled start time and runs at scheduled RPM
until scheduled stop arrives
Scenario 5:
Pump starts at first scheduled time and runs at scheduled RPM until second scheduled start arrives.
Pump changes to second RPM. Pump runs at second scheduled RPM until first scheduled stop arrives
when pump turns off. Pump starts at third scheduled start and runs at scheduled RPM until third
scheduled stop arrives.
2.4. Float Operation

The Vismode® can be set up such that the pump will turn on and off depending on the level of the
reservoir to be filled or pumped out using float switches.
To enable automatic start and stop using float switches enter the mode screen and select “Float Switch”.
Upon entering the password the following screen will display.
Fig.24. Float Switch Menu

Depending on the mode of operation that is desired select the relevant float mode.

Table 3 illustrates the conditions needed for the pump to turn on and off.
CONDITION FOR CONDITION FOR
START STOP
Fill FS1 FS1 Low FS1 High
Fill FS1 & FS2 FS1 & FS2 Low FS1 & FS2 High
Empty FS1 FS1 High FS1 Low
Empty FS1 & FS2 FS1 & FS2 High FS1 & FS2 Low
Table 3. Condition of Float Switches for Pump Operation
2.5. User Levels and Passwords

The Vismode® Controller has two password levels. The level 1 password is for customer settings while
the level 2 password is for Weir Minerals Multiflo settings which have been set specific for the pump.
The level one password for this pump is D477.
Do not modify the level two password.
2.6. RPM Configuration

The Vismode® has several RPM settings which can be configured by the user. These include the
maximum operating RPM, minimum operating RPM, warm up time, cool down time, and the operating
RPM the pump will ramp up to on start up. The maximum and minimum RPM values are limited by the
ECU on the engine. This menu is accessible by level 1 password.
2.7. How to change the Display Contrast
The contrast of the screen can be made lighter by holding the up and enter buttons or darker by holding
the down and enter buttons
2.8. Input and Output Configuration
The unit Inputs and Outputs can only be configured by Weir Minerals Multiflo® trained personnel.
Multiflo® pumps inputs and outputs are configured respectively to suit your needs, hence changing it
will disturb the operational of Multiflo® pumps.
2.9. Input, Output and Engine Status
This menu is designed to see what Vismode® Inputs and Outputs are enabled or disabled, and to view
the complete information about the engine. Please refer section 3.2 for full detail to access this feature.
2.10. Vismode® Power Save Mode
The Vismode® will enter power save mode after the preset time as identified in the display settings
menu, if the engine is shut down for any reason to conserve battery voltage. At this time all lighting will
be switched off and the LCD display will go blank. To reinstate the Vismode® to its normal operation
press the enter button on the control panel. At this time any error indications will reappear.
DO NOT PRESS THE STOP BUTTON TO REINSTATE THE VISMODE®. THIS WILL CAUSE ANY
EXISTING FAULT TO CLEAR

3. MAINTENANCE
3.1. Safety Notes
The following precautions should be followed to avoid any personal injury or damage to the unit.
Ensure main isolator switch is off before installing/connecting or servicing the Vismode®
unit.
The pump, engine and Vismode® controller should not be operated with suspected failures.
Inspections and checks should be conducted in accordance with the operating procedure.
Maintenance should be conducted in accordance with the maintenance schedule.

The Vismode® has two starting inputs, one from the Start Key the other is an external input
which should be grounded (Battery -) switch.
The enclosure door should be kept closed to prevent water and dust ingress into the
controller.
The controller should not be disassembled. It does not contain any serviceable parts.
3.2. Diagnostics
The diagnostic menu shows the engine status which is controlled by the engine ECU. Fig.27. shows the
conditions when the engine is in normal condition. If a fault occurs within the engine this screen will
appear as shown in Fig.26.
Fig.25. Normal Diagnostic Screen
Fig.26. Diagnostic Screen Showing Fault
Refer to the Caterpillar Manual for Diagnostic Fault Identification and Trouble Shooting.

3.3. Trouble Shooting

LED CONDITION CONDITION CONDITION COMMENTS TROUBLESHOOTING
DEFINITION WHEN LED IS WHEN LED IS WHEN LED IS
SOLID FLASHING OFF
Power Vismode has Vismode is in Vismode has Indication Check power
power power save no power only connection to
mode Vismode
Wait to start Engine is Engine is Engine is Indication
cranking starting in 5 running only
seconds
Starting Engine During auto Engine Indication
starting start such as running or only
schedule or engine
float stopped
Running Engine N/A Engine Indication
running stopped only
Engine If a fault has If engine No faults are
fault/shutdo occurred and warning input present
wn caused is active and
engine to timeout is
shutdown running
Engine If engine If engine If engine Check all engine
warning/diag diagnostic diagnostic diagnostic sensors are
nostic input is input is active input is connected
active or and timeout is inactive and contact engine
DTC'S running or no received manufacturer
received and DTC'S DTC'S
action is received and
scheduled action is
maintenance shutdown or
maintenance
asap
Emergency If emergency N/A If emergency Ensure no hazards
stop stop has stop is not are present and reset
been pressed pressed emergency stop
Stage If stage N/A If stage Indication
pumping pumping is pumping is only
enabled disabled
Priming N/A When vacuum When no Indication
pump is priming is only
priming occurring
Aux 1 If aux1 input If aux1 input is If aux1 input Will only be
is active active and is inactive active if
timeout is your pump
running has auxiliary
sensors
connected


SOLID FLASHING OFF
sensors
connected
sensors
connected
sensors
connected
Start fail/over If engine N/A No starting Signal from
crank cranked for issue engine
more than 10 control unit
seconds
Low engine If engine oil N/A If engine oil Signal from Check engine oil
oil pressure pressure is < pressure is > engine pressure
20 20 control unit
High engine If engine N/A If engine Signal from Check coolant
temperature coolant temp temp ok engine temperature
reaches 103 control unit let unit cool down
degrees and top up coolant
Celsius level
automatic
shutdown
has occurred
Engine If coolant N/A If coolant ok Signal from Fill coolant level
coolant loss level engine
becomes too control unit
low
automatic
shutdown
will occur
SOLID FLASHING OFF

Over If actual RPM N/A If RPM ok Signal from

speed/under and required engine
speed RPM differ by control unit.
more than Warning
100RPM only. Will
not cause
shutdown
Charge If pump N/A If pump Signal from
fail/low running and running and engine
battery voltage < 26v voltage ≥26v control unit
voltage or pump off or pump off
and voltage < and voltage
21v ≥21v
Low fuel level If engine has If fuel level is If fuel level is Fill fuel tank
stopped due below low satisfactory
to low fuel limit and
level timeout is
running
High If engine has If transmission If Let unit cool down
transmission stopped due temp input is transmission
temperature to high active and temperature
transmission timeout is is satisfactory
temperature running
Priming If engine has If water loss If water is Check that wet end is
water loss stopped due input is active present in sucking water
to lack of and timeout is the vacuum check that strainer is
water in running tank clear of debris
vacuum tank check that priming
pump is working
No water If engine has If water flow If water is Check that wet end is
flow stopped due input is active flowing sucking water
to lack of and timeout is through the check that water is
water flow running pump flowing through
through discharge pipe
discharge
pipe
Low pump oil If engine has If pump oil If pump oil Check the pressure in
pressure/gre stopped due pressure is pressure is the oil hose is at
ase level to low pump active and satisfactory 100psi
oil pressure timeout is check that oil is
after 10 running present in oil tank
second delay
SOLID FLASHING OFF

High pump If pump If pump If pump Check bearing

temperature temperature temperature temperature
has caused input is active is satisfactory
engine and timeout is
shutdown running
Table.4. LED Diagram

HE417 Multiflow Vismode Controller
Deutsch DRC 70-way connector pinout
Enclosure Connector P/N: DRC12-70PA
Loom Connector P/N: DRC16-70SA
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RS232 RX1 AUX IN 3 E-STOP VAC PROBE FLOW S/W FUEL S/W WATER RRES BATT NEG (-) BATT NEG (-) AUX OUT STROBE1 SRTOBE 2 VAC FAN
15 16 17 18 19 20 21 22 23 24 25 26 27 28
RS232 RX2 EXT STOP AUX IN 1 WATER PROBE PUMP TEMP AUX IN 2 PWR ACC BATT NEG (-) BATT NEG (-) BATT NEG (-) BATT NEG (-) FAN FAN FAN
29 30 31 32 33 34 35 36 37 38 39 40 41 42
RS232 TX1 OIL PRES EXT START AUX IN 4 VAC TEMP TRANS TEMP PWR ACC BATT NEG (-) BATT NEG (-) BATT NEG (-) BATT NEG (-) WORKLIGHT WORKLIGHT WORKLIGHT
43 44 45 46 47 48 49 50 51 52 53 54 55 56
RS232 TX2 PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR BATT NEG (-) BATT NEG (-) BATT NEG (-) BATT NEG (-) WORKLIGHT WORKLIGHT WORKLIGHT
57 58 59 60 61 62 63 64 65 66 67 68 69 70
PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR PWR SENSOR BATT NEG (-) BATT NEG (-) BATT NEG (-) BATT NEG (-) BATT NEG (-) WORKLIGHT WORKLIGHT
Misc Realy Output
Fan Output Motor Run Output (24V)
Misc. Input Worklight Output (24V)
Sensor Power (24V) Fan Output (24V)
Comms GND Output (0V/Batt '-')
* All connections should not exceed 13A per pin.

Use AWG16 to AWG18 and appropriate deutsch female/socket crimp pins for all connections
Version Date
V0R3 24/01/2011 J. Channells
sĞƌƐŝŽŶϭ͘Ϭ͘ WĂŐĞϮϬŽĨϮϰ
PIN DESCRIPTION
PIN N.o DESCRIPTION Colour *MAX A I/O PIN N.o DESCRIPTION Colour *MAX A I/O
1 RS232 RX1 (RS232 COMMS) N/A I 36 BATTERY NEGITIVE (-) 10A(60A) O
2 AUX INPUT 3 1mA I 37 BATTERY NEGITIVE (-) 10A(60A) O
3 EMERGENCY STOP 5A I 38 BATTERY NEGITIVE (-) 10A(60A) O
4 VACUUM OFF PROBE N/A I/O 39 BATTERY NEGITIVE (-) 10A(60A) O
5 WATER FLOW SWITCH 1mA O 40 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
6 LOW/NO FUEL SENSOR 1mA O 41 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
7 DISCHARGE PRESSURE SENSOR 1mA O 42 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
8 BATTERY NEGITIVE (-) 10A(60A) I 43 RS232 TX2 (RS232 COMMS) N/A O
9 BATTERY NEGITIVE (-) 10A(60A) I 44 SENSOR POWER (1.5A) O
10 AUX OUT (SWITCHES BATTERY +) 10A I 45 SENSOR POWER (1.5A) O
11 STROBE 1 (SWITCHES BATTERY +) 5A I 46 SENSOR POWER (1.5A) O
12 STROBE 2 (SWITCHES BATTERY +) 5A I 47 SENSOR POWER (1.5A) O
13 VAC PUMP CLUTCH (SWITCHES BATTERY +) 3A I 48 SENSOR POWER (1.5A) O
14 THERMO FAN (SWITCHES BATTERY +) 10A(20A) I 49 SENSOR POWER (1.5A) 0
15 RS232 RX2 (RS232 COMMS) N/A I 50 BATTERY NEGITIVE (-) wh 10A(60A) O
16 EXTERNAL STOP SWITCH 1mA I 51 BATTERY NEGITIVE (-) wh 10A(60A) O
17 AUX INPUT 1 1mA I 52 BATTERY NEGITIVE (-) wh 10A(60A) O
18 WATER LOSS PROBE N/A I/O 53 BATTERY NEGITIVE (-) wh 10A(60A) O
19 PUMP TEMPERATURE SWITCH 1mA I 54 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
20 AUX INPUT 2 1mA I 55 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
21 ACCESSORIES POWER (1.5A) O 56 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
22 BATTERY NEGITIVE (-) 10A(60A) O 57 SENSOR POWER (1.5A) O
26 THERMO FAN (SWITCHES BATTERY +) 10A(20A) O 61 SENSOR POWER (1.5A) O
29 RS232 TX1 (RS232 COMMS) 1mA I 64 BATTERY NEGITIVE (-) 10A(60A) O
30 PUMP OIL PRESSURE 1mA I 65 BATTERY NEGITIVE (-) 10A(60A) O
31 EXTERNAL START SWITCH 1mA I 66 BATTERY NEGITIVE (-) 10A(60A) O
32 AUX INPUT 4 1mA I 67 BATTERY NEGITIVE (-) 10A(60A) O
33 VACUUM PUMP TEMP SWITCH 1mA I 68 BATTERY NEGITIVE (-) 10A(60A) O
34 TRANSMISSION TEMPERATURE SWITCH 1mA I 69 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
35 ACCESSORIES POWER (1.5A) O 70 WORKLIGHT (SWITCHES BATTERY +) 10A(20A) O
*"Max A" shown as "xA(yA)" where x = power per pin, y = total power for all pins on the same circuit.
Version Date
sĞƌƐŝŽŶϭ͘Ϭ͘ WĂŐĞϮϭŽĨϮϰ
Deutsch DRC 40-way connector pinout
Enclosure Connector P/N: DRC12-40PA
Loom Connector P/N: DRC16-40SA
1 2 3 4 5 6 7 8 9 10
SERV CLR WTS SERVICE IN RS485 H RS485 L BATT NEG (-) BATT NEG (-) BATT NEG (-) REMOTE S/D RPM DOWN
11 12 13 14 15 16 17 18 19 20
ENG AUX IN 2 DIAGNOSTIC WARNING ENG AUX IN 1 J1939 L BATT NEG (-) BATT NEG (-) BATT NEG (-) RPM UP AUX ENG OUT
21 22 23 24 25 26 27 28 29 30
IGN POWER IGN POWER IGN POWER IGN POWER J1939 SHIELD BATT NEG (-) BATT NEG (-) BATT NEG (-) ECU PWR ECU PWR
31 32 33 34 35 36 37 38 39 40
IGN POWER IGN POWER IGN POWER IGN POWER J1939 H BATT NEG (-) BATT NEG (-) BATT NEG (-) ECU PWR ECU PWR
Misc Realy Output
ECU Power
Misc. Input
IGN Power AUX Relay Output (SINK)
Comms GND Output (0V/Batt '-')
* All connections should not exceed 13A per pin.

Use AWG16 to AWG18 and appropriate deutsch female/socket crimp pins for all connections
Version Date
sĞƌƐŝŽŶϭ͘Ϭ͘ WĂŐĞϮϮŽĨϮϰ
WEIR Minerals Multiflo
Head Office Tel: +61 7 5449 3000

15 Dacmar Road Fax: +61 7 5446 4304
Coolum Beach E-mail: multifloparts@weirminerals.com
QLD 4573 multiflo@weirminerals.com
Australia

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MF-385-183-09.

ASSEMBLY, OPERATION, MAINTENANCE MANUAL & SPARE

DO NOT CONVERT OR USE VACUUM PRIMED PUMP

Project Name MF-385 Base Mounted Pump Unit

Customer Name PT Weir Minerals Indonesia (PT Sukses Inti Solusindo)

WMM Job Numbers 20250001

Multiflo model MF - 385GSS, Base Mounted, Vacuum Primed

Version 1.0 © Copyright Weir Minerals Australia Ltd

MF - 385 MAJOR COMPONENTS ....................................... 51

Version 1.0 © Copyright Weir Minerals Australia Ltd

FIG.1.1 MF-385GSS UNIT MAJOR COMPONENTS ......................................................................................................................................... 8

FIG.2.1 PUMP UNIT ORIENTATION ............................................................................................................................................................ 21

Part III Maintenance

FIG.3.1 GLAND PACKING REMOVAL TOOL ................................................................................................................................................... 38

Version 1.0 © Copyright Weir Minerals Australia Ltd

Version 1.0 © Copyright Weir Minerals Australia Ltd Page i

Version 1.0 © Copyright Weir Minerals Australia Ltd Page ii

Version 1.0 © Copyright Weir Minerals Australia Ltd Page iii

Version 1.0 © Copyright Weir Minerals Australia Ltd Page iv

Version 1.0 © Copyright Weir Minerals Australia Ltd Page v

O.E.M GENERAL SALES CONDITIONS

Version 1.0 © Copyright Weir Minerals Australia Ltd Page vi

Version 1.0 © Copyright Weir Minerals Australia Ltd Page vii

Version 1.0 © Copyright Weir Minerals Australia Ltd Page viii

Version 1.0 © Copyright Weir Minerals Australia Ltd Page ix

Version 1.0 © Copyright Weir Minerals Australia Ltd Page x

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xi

O.E.M CONTACT DETAILS

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xii

Rockhampton Local contact details:

Kalgoorlie & Goldfields

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xiii

INTRODUCTION & SAFETY

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xiv

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xv

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xvi

SYMBOLS DEFINITIONS CONSEQUENCES

Imminent risk of fatal or Fatal or crippling injuries likely to result

Failure to follow may lead to fatality,

Possible damage to the product,

Fatal or crippling injuries likely to result

Mandatory Personal Fatal or crippling injuries likely to result if

Possibility of explosion if instructions not

Application hints and other

User has to refer accompanying manuals

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xvii

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xviii

PUMP UNIT DESIGN & TECHNICAL

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xix

PUMP UNIT DATA - 2025-0001

OWNER PT Weir Minerals Indonesia (PT Sukses)

PURCHASE ORDER NUMBER 4500006380

Multiflo® model MF-385, Base mounted,

PUMP UNIT SERIAL NUMBER MF-385-183-09.25

Version 1.0 © Copyright Weir Minerals Australia Ltd Page xx

BARE SHAFT PUMP DATA - 2025-0001

PUMP DESIGNATION Multiflo® MF 385GSS

BARE SHAFT PUMP MATERIAL Standard

BARE SHAFT PUMP SERIAL NUMBER 6A-385GSS-289

IMPELLER MATERIAL 316 stainless - (AS 2704)

IMPELLER TYPE Open

IMPELLER DIAMETER 500 mm

MIN. PASSAGE SIZE 45 mm