CF - 48H

INSTALLATION, OPERATION, MAINTENANCE MANUAL &

SPARE PARTS LIST FOR MULTIFLO® DIESEL POWERED PUMP
UNIT CF - 48H

©2013, 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: 01/08/2013
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VACUUM PRIMED PUMP UNITS ARE NOT

DESIGNED FOR BOOSTER / STAGE
PUMPING
CONTACT WEIR MINERALS MUTIFLO FOR
MORE DETAILS ON THE BOOSTER / STAGE
PUMP CONVERSION KIT

Office of Origin: Head Office, WMMultiflo, Coolum Beach, QLD, Australia

Date: 01/08/2013
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Table of Contents
Sl.No Description Pg.No.
.
O.E.M Certifications Part II – Operation
OHSAS 18001: 2007........................................ ii
AS/NZS 4801: 2001......................................... iii 2.1 Safety Notes – Operation............................. 20
AS/NZS 14001: 2004....................................... iv 2.1.1 Safety Notes - CAT C9 Engine.................. 20
AS/NZS 9001: 2008......................................... v 2.1.2 Safety Notes - Bare Shaft Pump……........ 21
General conditions of sale.............................. vi 2.1.3 Noise and Radiation................................ 21
Contact Details of O.E.M................................. xii 2.2 General Description & Function of the
Introduction & Safety………………………………….. xiv Equipment................................................... 21
Safety Notes & Symbols.................................. xvii 2.2.1 Principle of Orientation.......................... 21
Risks, Intended Use, Manufacturer 2.3 Pump Unit Orientation................................. 22
Information.................................................... xviii 2.3.1 Operating Observations.......................... 22
Pump Unit Design & Technical Data 2.4 Normal Operating Procedures...................... 23
Pump Unit Data.............................................. xx 2.4.1 Daily Pre-start checks.............................. 23
Bare Shaft Pump data..................................... xxi 2.4.2 Starting Procedure.................................. 24
2.4.3 Optimum Operating Speed..................... 25
Part I – Assembly & Installation 2.4.4 Cavitation................................................ 26
2.4.5 Normal Operation.................................. 26
1.1 Pump Unit Packing and Delivery................... 2 2.4.6 Shutdown Procedure.............................. 26
1.1.1 Transport................................................. 2 2.4.7 Pump Shutdown System........................ 27
1.1.1.1 Packing................................................. 2 2.5 Description of Major Components............... 28
1.1.1.2 Loading and Unloading........................ 2 2.5.1 Diesel Engine - CAT C9............................ 28
1.1.1.3 Repacking............................................ 3 2.5.2 Bare Shaft Pump..................................... 28
1.1.1.4 Dimensions and Weight of the Pump 2.5.3 Vacuum Pump - Model 39...................... 29
Unit........................................................ 3 2.5.4 Torque Settings....................................... 29
1.1.2 Storage Procedures.................................. 3 2.5.5 Vacuum Tank.......................................... 29
1.1.2.1 Storage Recommendations about 2.5.6 CF - 48H Mechanical Priming System... 30
transmission.......................................... 4 2.5.7 Vacuum Gauge....................................... 31
1.1.2.2 Short term storage................................ 4 2.5.8 Non Return Valve (VOOOM).................. 32
1.1.2.3 Long Term Storage................................ 4 2.5.9 Hydrau-Flo® fuel filling valve.................. 33
1.1.2.4 Storage Recommendations about 2.5.10 Engine Monitoring System (EMS).......... 33
Heat Exchangers.................................... 4 2.5.11 Work Light Timer…………………................ 33
1.1.2.5 Storage Recommendations about V- 2.5.12 Drive Coupling....................................... 33
Belts....................................................... 4
1.2 Safety Notes - Pre - Operational & Part III – Maintenance
Installation................................................... 5
1.2.1 Bare Shaft Pump Safety.......................... 5 3.1 Normal Maintenance Procedures................. 35
1.2.2 Transmission Safety............................... 5 3.1.1 Safety Notes – Maintenance................... 35
1.3 Pump Unit Description................................. 6 3.1.2 Safety Notes – Bare Shaft Pump............. 36
1.3.1 Environmental Conditions...................... 6 3.2 CAT C9 Engine............................................. 37
1.3.2 Major Components................................. 6 3.3 Maintenance – Bare shaft Pump.................. 37
1.4 Pump Unit Assembly.................................... 7 3.4 Hydrau- Flo.................................................. 37
1.4.1 Safety Notes – Assembly........................ 7 3.5 Flow Switch................................................. 37
1.4.2 Installation sequences............................ 8 3.6 Maintenance & Servicing Guide................... 37
1.4.2.1 Pre Installation Checks........................ 8 3.6.1 Every 10 Operating Hours Daily.............. 37
1.4.2.2 Safety Notes – Installation & Moving. 8 3.6.2 Every 250 Operating Hours (Perform in
1.4.2.3 Space Requirements........................... 8 addition to daily checks)......................... 38
1.4.2.4 Pump Site Preparation........................ 9 3.6.3 Every 1000 Operating Hours (Perform in
1.4.2.5 Moving and Locating the Pump Unit.. 9 addition to 250 hours of maintenance
1.4.2.6 Assembly of Pump Unit onto skid....... 10 items)...................................................... 38
1.4.3 Discharge Components Assembly........... 11 3.6.4 Every 2000 Operating Hours (Perform in
1.4.4 Suction Components Assembly............... 11 addition to 1000 hours of maintenance
1.4.5 Correct Position of the Suction Boom…. 14 items)...................................................... 38
1.4.6 Preparation for lifting............................. 14 3.7 Trouble Shooting Guide............................... 39
1.4.7 Pump Unit Sitting Angle.......................... 15 3.7.1 Finding and Diagnostic Guide…............... 39
1.4.8 Installation Checks................................ 18 3.7.1.1 Pump Unit Trouble Shooting................ 39
1.4.9 Electrical Connections........................... 18 3.7.2 Link-Belt Trouble Shooting…………………. 42

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3.7.3 Hydrau-Flo Valve……………………………….. 43 8.0 ANCILLIARY SECTION……………………………….... 96

3.8 Vacuum Gauge Readings……………………………. 44 8.1 Fire Extinguisher……………………………………….…. 97
3.8.1 Faulty Vacuum Pump…………………………. 46 8.2 High Lift Skid……………………………………………….. 98
3.8.2 Pump Primes but Fails to Deliver at a
reduced rate……………..………………………. 46 Part V Appendices
3.9.3 Pump Overloads Engine…………….……….. 46
3.9 Torque Settings………………………………………….. 46
Tightening Torque Values................................. 100
3.10 Lubrication Schedule…………………………………. 47
CF-48H Pump Performance Curve……………….. 101
3.10.1 Grades and Frequency of Lubrication. 47
CF-48H Wiring Diagram.................................... 102
3.10.2 Re starting the Pump Unit after an
Intervention………………………..………….. 47
3.11 Piston & Re-Ringing Instructions................ 47 Part VI Accompanying Manuals
3.11.1 Assembly of 3-Piece Oil Ring
assembly............................................. 48 CF - 48H Assembly & Disassembly Procedure
3.12 Maintenance – Drive Components……………… 51 for CF-48H Bare Shaft Pump
i. Drive Belt Tensioning…................................ 51
ii. Belt Tensioning Forces…………………………….. 52 Installation, Operation, Maintenance Manual
iii.Installation & Operation of Link Belt Drives 52 for Hydrau-flo Valves

Part IV Spare Parts List Low Flow Switch

CF - 48H MAJOR COMPONENTS...................... 55

1.0 DRIVE SECTION………………………………………….. 57
1.1 CF - 48H DRIVE MAIN COMPONENTS............. 58
1.2 MODEL 39 VACUUM PUMP……………………….... 59
1.3 MODEL 39 VACUUM PUMP(Continued)..….... 60
1.4 MODEL 39 VACUUM PUMP(Continued)..….... 61
1.5 MODEL 39 VACUUM PUMP(Continued)..….... 62
1.6 MODEL 39 VACUUM PUMP(Continued)..….... 63
1.7 CF - 48H VACUUM PUMP ASSEMBLY….......... 64
1.8 CF - 48H DRIVE COUPLING............................. 65
2.0 PUMP SECTION.......................................... 66
2.1 CF - 48H BARE SHAFT PUMP.......................... 67
2.2 CF - 48H WET END PARTS............................... 68
2.3 CF - 48H DRIVE END PARTS............................. 69
2.4 CF - 48H DRIVE END PARTS(Continued).......... 70
2.5 CF - 48H DRIVE END PARTS(Continued).......... 71
2.6 CF - 48H BEARING HOUSING………………......... 72
2.7 CF - 48H PUMP UNIT……………………………………. 73
3.0 SUCTION SECTION……………………………………… 74
3.1 CF - 48H SUCTION ASSEMBLY……………………... 75
4.0 DISCHARGE SECTION.................................. 76
4.1 CF - 48H NON RETURN VALVE........................ 77
4.2 CF - 48H SUCTION WINCH ASSEMBLY….......... 78
5.0 PRIMING SECTION………………….................... 79
5.1 CF - 48H Vacuum Tank…………………………….….. 80
5.2 CF - 48H VACUUM TANK LID COMPONENTS.. 81
5.3 CF - 48H VACUUM TANK LID COMPONENTS
(200115)......................................................... 82
5.4 CF - 48H PRIMING SYSTEM……....................... 83
6.0 ELECTRICAL SECTION…………………………………. 84
6.1 CF - 48H EMERGENCY STOP………………………… 85
6.2 CF - 48H LED BEACON AND WORK LIGHT....... 86
6.3 CF - 48H BATTERY BOX……………………………….. 87
6.4 CF - 48H LOW FLOW SWITCH…………………….. 88
6.5 CF - 48H OIL PRESSURE SWITCH…………………… 89
6.6 CF - 48H BATTERY ISOLATOR..……………………... 90
7.0 LUBRICATION SECTION………………………………. 91
7.1 CF - 48H HYDRAU - FLO FLAOT…………………….. 92
7.2 CF - 48H SERVICE POINT…………..……………….... 93
7.3 CF - 48H FUEL FILLER…………..…………………..….. 94
7.4 CF - 48H Fuel and Vacuum Tank Hoses………… 95

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List of Figures
Fig. No. Description Page No.

1. Part I Assembly & Installation

1.1 CF 48H Pump Unit Dimensions................................................................................ 3
1.2 Major Components………………………………………………………………................................ 6
1.3 Pump Unit Lifting Point…………………………………………………………………....................... 9
1.4 Installing Pump Unit onto Skid…………………………………………..................................... 10
1.5 Suction Hose with Spreader bar……………………………………………………………….………... 11
1.6 Inserting Boom Locking Bolts……………………………………………......…........................... 12
1.7 Attaching Winch rope to Boom pulley……………………………………...…......................... 12
1.8 Fitting the Boom Chain and Suction Strainer…………………………………………………..…. 13
1.9 Correct Position of Suction Boom…………………………………........................................ 14
1.10 Incorrect Pump Positioning………………………............……………................................... 15
1.11 Incorrect Pump Positioning Examples...……………………………………………………..…….... 15
1.12 Correct Pump Positioning……………………………....................……................................ 16
1.13 Correct Pump Positioning Examples………………………………....................................... 16
1.14 Maximum Tilt……………………………….............................................……....................... 17

Part II Operation
2.1 Pump Unit Orientation............................................................................................ 22
2.2 CF - 48H Pump Unit…………………………………………………………………………..................... 24
2.3 Result of Cavitation................................................................................................. 26
2.4 Bare Shaft Pump CF-48H......................................................................................... 28
2.5 Vacuum Pump.......................................................................................................... 29
2.6 Vacuum Tank Components...................................................................................... 30
2.7 Ball Valve Float Assembly........................................................................................ 30
2.8 Ball Float Operation................................................................................................. 31
2.9 Vacuum Gauge......................................................................................................... 31
2.10 NRV Operation…………………………………………………………………………………………………… 32
2.11 Drive Coupling………………………………………………………………………………....................... 33

Part III Maintenance

3.1 Vacuum Gauge Readings…………………………………………………………………………………… 46
3.2 Belt Tension Indicator Applied to Mid Span……………….……………………………………… 51
3.3 Belt Tensioning Indicator…………………………………………………………………………………… 52
3.4 Belt Alignment…………………………………………………………………………………………………… 53

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O.E.M CERTIFICATES

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O.E.M GENERAL SALES CONDITIONS

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1. APPLICATION 5.3 Where Goods or raw materials or components for

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

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insurance upon written instructions from Purchaser and (a) Purchaser has given written notice to Weir of any
at the cost of Purchaser. alleged defect within the warranty period;
8. AMENDMENT AND CANCELLATION (b) Purchaser has provided Weir a reasonable
Purchaser shall not, after acceptance of order, cancel or opportunity to perform all appropriate tests on the
amend it in any way without the written approval of Weir. Goods;
Weir may, on consenting to an amendment, revise its price (c) the defective Goods or parts are promptly returned
and delivery schedule and amend the terms and conditions to a designated Weir service centre. Any defective Goods
to reflect such change. In the event of an amendment or or parts replaced will become Weir property and the
cancellation, Purchaser shall reimburse Weir for all costs repaired or new Goods or parts will be delivered free to
and expenses already incurred by Weir or for which Weir Purchaser’s site; and
has or will become liable, and for any additional costs and (d) no warranties are given by Weir as to the water
expenses resulting from the amendment or cancellation. performance of pumps other than in a test facility
The specification by Weir of any particular personnel, in designated by Weir.
any quotation or tender, is subject to availability of those 11.2 Repaired Goods For repaired Goods, excluding
personnel and Weir reserves the right to substitute any rubber lining, the warranty period is 6 months from the
nominated personnel at any time. date of repair and shall only apply to Goods or parts
9. DEFAULT repaired or replaced by Weir. No separate warranty shall
If Purchaser makes default in payment or fails to carry out apply to repaired Goods as a whole or to parts not
any part of any contract of which these General Conditions repaired or replaced by Weir. This warranty does not
of Sale form part or shall become bankrupt or commit any apply to repair of rubber
act of bankruptcy or compound with its creditors or have 11.3 Rubber Lining For rubber lining services the
judgment entered against it in any court or, being a warranty period is 12 months from the date of
company, have a provisional liquidator, receiver or application if the application is performed in accordance
manager appointed or enter into any other form of with Weir Minerals Standards RL101 Linatex Adhesives &
insolvency administration, Weir may at its option and Bonding and RL120 Lining Equipment & Vessels. Copies
without prejudice to any of its rights and remedies under of these standards will be provided on request.
the contract, suspend or terminate the contract or require 11.4 Exceptions The warranties given by Weir in clauses
payment in cash before or on delivery notwithstanding any 11.1, 11.2 and 11.3 above do not cover:
other terms of payment specified in the contract. If Weir (a) Fair “wear and tear”, or failures or damage not
terminates the contract pursuant to this clause, all reported to Weir within the warranty period;
amounts payable for work performed up to the date of (b) Failures or damage due to misapplication, abuse,
termination, whether or not otherwise then due for improper installation or abnormal conditions of
payment, will become immediately due and payable. Weir operation;
will not be liable to Purchaser for any loss or damage (c) Failures or damage due to operation, either
Purchaser suffers because Weir has exercised its rights intentional or otherwise, above or below rated
under this clause. capacities or in an otherwise improper manner;
10. RETURN OF GOODS (d) Failures or damage resulting from Goods which have
Weir may, at its absolute discretion, agree to accept the been in any way tampered with or altered by anyone
return of any of Goods which have not been made or other than an authorised representative of Weir;
purchased specifically for Purchaser and credit Purchaser (e) Goods damaged in shipment or without the fault of
with the invoice value of the Goods provided the Goods is Weir;
returned in “as purchased” condition and the prior written (f) Failures or damage resulting from the incorporation
approval of Weir has been obtained by Purchaser for the of, or failure of, non-Weir manufactured or supplied
return of the Goods. Weir reserves the right to charge a parts in the Goods; or
restocking fee for the return of Goods to stock. (g) Repairs to rubber lining.
11. WARRANTIES 11.5 Purchased Equipment Weir does not warrant any
11.1 New Goods If within a period of 12 months from the equipment or other goods of other manufacturers which
date of delivery (“warranty period”) any new Goods sold is designated by Purchaser or purchased by Weir for
by Weir (other than purchased equipment as referred to resale to Purchaser either separately or as a part of or
in clause 11.4) are found to be defective in materials or operating in conjunction with equipment or other goods
workmanship, or do not conform to any applicable manufactured by Weir. For such equipment or other
drawings and specifications approved in writing by Weir, goods, Purchaser must rely on the warranty given by the
or (in the case of Goods which are Weir-manufactured manufacturer of the equipment or other goods.
pumps) do not perform in accordance with the current 11.6 Supply of Services When Weir supplies Services to
applicable water performance curves supplied as part of Purchaser including laboratory testing, process
the Weir quotation or published by Weir as at the date of development, equipment selection, design (as part of
the quotation (within the tolerances specified in design and manufacture), detail, contract supervision
applicable Australian Standards), then Weir will, at its and contract management, Weir shall exercise due care
option, either repair or provide replacement parts or and skill in undertaking such Services.
Goods provided that: 11.7 Limitation of Liability

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(a) Subject to clause 11.6(b), Weir’s total liability under (a) Purchaser’s failure to comply with any laws, rules,
any contract of which these General Conditions of Sale standards or regulations applicable in relation to the
form part shall in no event exceed the total price of the Goods or Services or the use of the Goods or Services;
Goods and/or Services supplied. (b) any use of the Goods or Services contrary to any
(b) If any term, condition, guarantee or warranty is instructions or warnings given by Weir;
implied into these General Conditions of Sale by law, (c) any other negligence or any breach of duty by
including the Australian Consumer Law, which cannot be Purchaser;
excluded or modified, then the term, condition, guarantee (d) any compliance or adherence by Weir with any
or warranty shall be deemed to be included in these instructions by Purchaser in relation to the Goods or
General Conditions of Sale, and the exceptions and Services or their manner of preparation or delivery; or
limitations in clauses 11.1 to 11.5 do not apply to such (e) any failures resulting from the incorporation of, or
term, condition, warranty or guarantee, provided that failure of, non-Weir manufactured or supplied parts in the
Weir’s liability for a breach of or failure to comply with Goods.
any such term, condition, warranty, or guarantee (other 13. DRAWINGS AND SPECIFICATIONS
than a guarantee under sections 51, 52 or 53 of the 13.1 All descriptions, specifications, drawings and
Australian Consumer Law) including any consequential particulars of weights and dimensions attached to or
loss which Purchaser may sustain, shall be limited, at the submitted with any quotation or tender are approximate
option of Weir, to either replacing or repairing the Goods only and the descriptions and illustrations contained in
or, in the case of Services, to supplying the Services again. the catalogues, price-lists and other advertisement matter
(c) Subject to clause 11.6(b): of Weir or Linatex, as applicable, are intended merely to
(i) All conditions, warranties, terms, undertakings, present a general idea of the Goods or the Services
representations, guarantees and obligations, not described therein, and none of these shall form part of
expressly set out in these General Conditions of Sale or any contract between Weir and Purchaser.
in any written contract of which these General 13.2 Only such descriptions, specifications, drawings and
Conditions of Sale form part, whether arising under particulars of weights and dimensions as are specifically
statute, common law, equity, custom, trade usage or agreed by Weir in writing to form part of the contract
otherwise (including without limitation, any implied shall do so. The designs and information concerning the
condition, warranty, term, representation or guarantee Goods or the Services and as contained on any drawings
as to the correspondence of the Goods or Services with which are supplied must not be disclosed to a third party
any contract description or as to merchantable quality, without Weir’s prior written consent.
fitness for any purpose or safety of the Goods or 14. INSPECTION AND TESTING
Services, or operating performance where such 14.1 Representatives of Purchaser approved by Weir will
performance is conditional on empirical factors or on be given access to Weir’s works or another site designated
the whole installation or on the individual or overall by Weir during normal office hours, for the inspection of
operation or on the skills of an operator), whether the Goods and (subject to clauses 14.2 and 14.3) for any
made known or not and any liability of Weir to testing of the Goods which is specified in the scope of
compensate or indemnify any person or persons in works attached to or referred to in Weir’s quotation, in
respect of the foregoing, are expressly negatived and order to ensure compliance with specification. Purchaser
excluded; must make appointments for those inspections through
(ii) In no event shall Weir be liable for any special, Weir’s nominated representative, giving at least 5 days’
indirect, consequential, incidental or punitive losses or written notice (or such shorter period as may be agreed
damages whether in contract, tort (including without by Weir), and must be accompanied on such inspections
limitation negligence), equity, under statute or on any by Weir personnel or other persons designated by Weir.
other basis, and whether or not such loss or damage 14.2 Where practicable, Weir will subject Goods to Weir’s
was foreseeable. The term "consequential damages" in standard tests before delivery. If tests other than Weir’s
these General Conditions of Sale shall include, but not standard tests are required, these, unless otherwise
be limited to, economic loss including loss of actual or agreed, shall be conducted at Weir’s nominated place of
anticipated profits, business interruption, loss of use, works or at some other place nominated by Weir in its
revenue, reputation and/or data, .increased cost of sole discretion and may at its option be charged for as
working, loss or damage to equipment or other extras. Any such charges will be payable by Purchaser
property, and liabilities of Purchaser to its customers or within 30 days from the date of Weir’s invoice.
third persons. 14.3 If Purchaser or its representative fails or is unable to
12. INDEMNITIES attend the tests after being given notice by Weir of not
Subject to clause 11, Purchaser indemnifies and holds Weir less than 7 days that it is ready to carry out the tests
harmless from and against all liabilities, losses, damages, referred to in clauses 14.1 and/or 14.2, the tests will
costs or expenses incurred or suffered by Weir and from proceed in the absence of Purchaser or its
and against all actions, proceedings, claims or demands representatives.
made against Weir, arising in either case as a result of: 14.4 The water performance of Weir-manufactured
pumps in accordance with clause 11.1 above can be
verified where required by Purchaser with water

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performance tests carried out in a test facility designated Sydney. The costs of the mediator shall be borne by the
by Weir. Additional charges and delivery extension apply if parties equally.
this verification is required. 16.3 If any dispute, controversy or claim has not been
15. INTELLECTUAL PROPERTY RIGHTS resolved within 30 days after written notice from one
15.1 Weir or Linatex, as applicable, is the owner of certain party to the other giving details of the dispute,
patents and registered designs as well as other intellectual controversy or claim, each party will be entitled to seek
property rights, including, but not limited to, copyright relief from an appropriate court.
(together the “Intellectual Property Rights”), and Weir has 16.4 This Clause 16 does not prevent either party from
also made certain applications for patents. Purchaser seeking or obtaining from a court any injunctive or other
must not directly or indirectly manufacture or purchase interlocutory relief which it may urgently require.
from any third party the subject matter of the Intellectual 17. RETENTION OF TITLE, CHARGE & SECURITY
Property Rights or the patent applications, or in any way 17.1 The Goods shall remain the sole and absolute
infringe the Intellectual Property Rights or patent property of Weir or Linatex, as applicable, as legal and
applications. The Intellectual Property Rights remain at all equitable owner, and the property in and title to the
times the exclusive property of Weir or Linatex, as Goods shall not pass from Weir or Linatex, as applicable,
applicable. to Purchaser until Purchaser has paid Weir in full for the
15.2 Weir or Linatex, as applicable, retains ownership of Goods and for all other goods supplied by Weir or Linatex,
the copyright and all other intellectual property rights in as applicable.
all drawings, manuals and other documents and materials 17.2 Until title and property in the Goods passes,
provided to Purchaser in connection with the Goods Purchaser holds the Goods as bailee in the capacity of a
and/or Services. Purchaser may only use such documents fiduciary for Weir, and must mark the Goods or store
and materials for its own internal business purposes and them separately and keep all necessary records, so that
to the extent necessary for it to enjoy the benefit of the the Goods can at all times be clearly identified and
Goods and/or Services, and may not disclose any of them distinguished as the property of Weir.
to any third party without the prior written consent of 17.3 If the Goods in any way become attached to or a part
Weir, which may be granted or withheld in the absolute of another object before Purchaser has paid Weir in full
discretion of Weir. for the Goods and for all other goods supplied by Weir,
15.3 Purchaser must keep confidential all information property in so much of the object as is comprised by the
contained in all drawings, manuals and other documents Goods shall remain with Weir or Linatex, as applicable,
and materials provided by Weir to Purchaser in and shall not pass to Purchaser until the Goods and all
connection with the Goods and/or Services, except to the other goods supplied by Weir have been paid for in full.
extent that such information is in or comes into the public Until Weir is paid in full for the Goods and all other goods
domain otherwise than through any act or omission of supplied by Weir Purchaser holds any objects to which the
Purchaser. It must only disclose such information to its Goods are attached or of which the Goods form a
employees, directors and advisers on a need-to-know constituent part as bailee in the capacity of a fiduciary for
basis. Weir and shall store such objects separately so as to be
15.4 Where and to the extent that the Goods or the readily identifiable.
Services ordered have been designed by Purchaser, 17.4 If the Goods (or any objects to which the Goods are
Purchaser is liable for and agrees to indemnify Weir attached or of which the Goods form a constituent part)
against any and all costs, expenses, liabilities and losses are on sold by Purchaser to a third party prior to payment
suffered or incurred by Weir arising from any claims of by Purchaser in full for the Goods and all other goods
infringement or alleged infringement of any third party’s supplied by Weir, Purchaser does so as agent for Weir and
intellectual property rights. Purchaser unconditionally agrees to keep the proceeds of
15.5 Where the Goods or the Services supplied are such on sale in a separate bank account on trust for Weir
designed by Weir and are found by a Court to have and, at Weir’s request, to assign to Weir any debt owed to
breached a third party’s intellectual property rights, Weir Purchaser in respect of the on sale, until Weir has been
shall have the right to do such things as are necessary to paid in full for the Goods and for all other goods supplied
remedy that breach. by Weir. Notwithstanding this paragraph, Purchaser shall
16. DISPUTE RESOLUTION not represent to any third parties that it is in any way
16.1 If any dispute arises between Purchaser and Weir in acting for Weir and Weir will not be bound by any
relation to or in connection with a sale or supply of Goods contracts with third parties to which Purchaser is a party.
or Services by Weir to Purchaser, they will use their best 17.5 If any payment by Purchaser to Weir is overdue, in
endeavours to resolve that dispute in a spirit of good faith whole or in part, or Purchaser is otherwise in default
and on a commercially realistic basis by mutual under any contract with Weir, or Purchaser shall become
negotiation or by mediation prior to commencing bankrupt or commit any act of bankruptcy or compound
litigation proceedings. with its creditors or have judgment entered against it in
16.2 Any mediator shall be an independent person chosen any court or, being a company, have a provisional
by the parties or, at their request, nominated by the liquidator, receiver or manager appointed or enters into
Australian Commercial Disputes Centre. Each party shall any other form of insolvency administration, all sums then
bear its own costs. Any mediation shall take place in owing by Purchaser to Weir in respect of the Goods or in

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 CF - 48H

respect of other goods supplied by Weir shall become 18.2 Non-waiver The fact that Weir fails to do, or delays in
immediately due and payable and Weir may (without doing, something it is entitled to do under any contract of
prejudice to any of its other rights) recover and resell the which these General Conditions of Sale form part, does
Goods and any other goods supplied by Weir and may, for not amount to a waiver of any right or remedy with
that purpose, enter upon Purchaser’s premises by its respect to any existing or subsequent breach or default.
servants or agents, and Weir is irrevocably authorised to 18.3 Severability If any provision of any contract of which
effect such entry, including the use of such reasonable these General Conditions of Sale form part is void,
force as is necessary to effect such entry, and to use the voidable, illegal or unenforceable it shall be severed from
name of Purchaser and to act on behalf of Purchaser, if the contract but without in any way affecting the
necessary, to recover possession of the Goods and any effectiveness, validity, legality or enforceability of the
other goods supplied by Weir and to detach the Goods remaining provisions of the contract.
and any such other goods from any other object to which 18.4 Force Majeure Weir shall not be considered in
the Goods have been attached or of which the Goods default or liable if there is any failure to perform or delay
form a constituent part. in performing any of its obligations under any contract of
17.6 Weir is entitled to register its security interest in this which these General Conditions of Sale form part, to the
Clause 17 under the Personal Properties Securities Act extent that such failure or delay is due to an event of
2009 (‘PPSA’). Purchaser agrees to do all acts and things to force majeure, but Weir shall use all reasonable
assist in such registration. Purchaser shall reimburse Weir endeavours to cure such event (if curable) and to comply
for all costs, and expenses incurred in registering its with its obligations under that contract, and as soon as
security interest under the PPSA. Purchaser acknowledges any such event ceases to affect the performance of its
and agrees, to the extent permitted by law, to waive each obligations under that contract Weir shall use all
right to receive a notice which section 144 or 157(3) of the reasonable endeavours to resume compliance with such
PPSA permits and to contract to exclude the operation of obligations. In these General Conditions of Sale, an “event
sections 95, 121(4), 130, 132(3)(d), 135 and 143 of the of force majeure” means any act of God or other
PPSA. occurrence outside the reasonable control of Weir
17.7 Weir and Purchaser each agree to keep all including, but not limited to, war (whether declared or
information of the type contemplated by section 275(1) of not), acts of public enemies, industrial disputes, strikes,
the PPSA strictly confidential unless the other party lock-outs, accidents, hurricanes, fire and flood.
provides prior written consent to the disclosure or 18.5 Interest Purchaser must pay Weir interest on all
disclosure is required by law. overdue payments due to Weir under these General
18. GENERAL Conditions of Sale at the Corporate Overdraft Interest rate
18.1 Compliance with Export Laws and Sanctions The (monthly Charging Cycle) (or its successor) from time to
Customer shall comply with all applicable national and time charged by the Commonwealth Bank of Australia,
international export, re-export and/or economic sanctions plus 2% per annum, calculated on daily rests from and
laws and regulations, including obtaining any required including the due date to and including the date of
authorizations or approvals, in relation to any export of payment.
the Goods. Weir reserves the right to cancel or delay 18.6 Governing Law These General Conditions of Sale and
delivery of the Goods if it becomes aware that Purchaser each contract of which they form part are governed by
intends to unlawfully export the Goods to countries and must be construed in accordance with the laws of
subject to economic sanctions laws or identified as New South Wales.
“sensitive” by Weir Group policy.

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 CF - 48H

O.E.M CONTACT DETAILS

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 CF - 48H

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
[email protected] 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
[email protected] Fax: 08 9726 2303

Kalgoorlie & Goldfields

Authorised 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
Authorised 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 Banjarbaru Branch Office
Jl Mulawarman No 29A RT Jl. Ahmad Yani Km 33,6 Ruko No. 04 RT.
003 Batakan Kecil Kelurahan Manggar 003 RW.001 Kelurahan Loktabat Selatan
Balikpapan 76117 Banjarbaru 70712
East Kalimantan South Kalimantan
Indonesia Indonesia
Ph: 62 542 746098 Ph: 62 511 4773027
Fax: 62 542 746099 62 511 4772357
Fax: 62 511 477 3583

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 CF - 48H

INTRODUCTION & SAFETY

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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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 CF - 48H

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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 CF - 48H

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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 CF - 48H

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.
Adequate safety measures MUST be taken before performing any operation.

INTENDED USE OF THE PRODUCT

The CF pump unit is designed to be used as a mine dewatering pump in accordance with the pump
performance data contained in this manual.
The Pump Unit application is to move liquids (corrosive and non- explosive). The specific gravity of the
liquid should be lesser than equal to 1.05 and the PH level should be lesser than or equal to 3.6.
It is the User’s responsibility to ensure that Pump Unit as a whole or any of its components are not used
for any other purpose other than the intended usage mentioned in this manual. The procedures followed
must be in line with the technical data and instructions provided in this manual.
It is forbidden to physically modify any components of the Pump Unit or the Pump Unit as a whole. Weir
Minerals Multiflo® does not take responsibility if the Pump Unit were used after such modifications.

MANUFACTURER AND PRODUCT INFORMATION

The Weir Minerals Multiflo® CF-48H Pump Unit is provided with Equipment Identification which contains
the following information.
 Model Number
 Part Number
 Mass
 Serial Number
 Date of Manufacture
 Any Specific instructions related to the manual if applicable
The Weir Minerals Multiflo® CF-48H Pump Unit is also provided with tags that contain information such
as greasing cycles on the Bare Shaft Pump. Start up procedures, Shutdown procedures if applicable.
Pump Unit and Bare Shaft Pump Technical data is provided in the subsequent sections of the manual.

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 CF - 48H

PART I
ASSEMBLY & INSTALLATION

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 CF - 48H

1 ASSEMBLY & INSTALLATION

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

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

Illustrations used are only suggestive. Not actual.

1.1.1 TRANSPORT
1.1.1.1 PACKING
Each shipment is sent through approved transport companies. Containers are used for
overseas transport while trucks can be used for local transport. Depending on the size and
number of components present, the unit can be disassembled if required and packed in
suitable containers. The Components are packed in such a way so that the integrity of the
components is not damaged during shipment.
Heavier components are left free standing in the truck/container. However timber or any
suitable equipment may be used to prop them. These structures will sometimes be steel
strapped to the base of the vehicle if required. Smaller items are bundled with nylon ropes
or similar binding material or packed with appropriate packing material such as Dunnage
or timber in wooden crates. The wooden crates are sealed using duct tape or nylon tape.
The wood packing material used on CF - 48H pump unit is heat treated.
1.1.1.2 LOADING AND UNLOADING
The CF-48H Pump Unit is loaded onto the truck/container using appropriate lifting
equipment. Consideration is given to the mass, dimensions of the unit while selecting the
lifting equipment. Only designated lifting points are used while lifting the components.
The Wooden crates and smaller components are loaded using a fork lift. Dimensions and
mass are again taken into consideration while selecting a suitable fork lift.
The user must unload the components using appropriate lifting & unloading procedures
and equipment. The CF-48H Pump Unit dimensions and mass are shown below. After
unloading, the duct tape and nylon tape on the crates can be removed using appropriate
cutting equipment.
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 CF - 48H

1.1.1.3 REPACKING
If the CF-48H Pump Unit or any of its 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 should be followed so as to
not to damage the integrity of the component.
Weir Minerals Multiflo® does not bear any responsibility for damage if the unit or any of its
components are damaged during repacking and transport.
1.1.1.4 DIMENSIONS AND WEIGHT OF THE PUMP UNIT
A mm (inch) B mm (inch) C mm (inch) Mass Wet kg. (lbs) Mass Dry kg. (lbs)
3685 1872 1685 4500 3550
(145) (73) (66) (9921) (7827)

A C

All wetted parts available in stainless steel for aggressive applications.

Fig.1.1 CF-48H Pump Unit Dimensions

1.1.2 STORAGE PROCEDURES
It is the responsibility of the purchaser to store the equipment of supplied items prior to
use. The pump unit and any associated equipment must be stored in a manner which will
not interfere with the integrity of the equipment whether through exposure to an
unsuitable environment, undue rough handling and on-site transportation or the
loss/damage of equipment components.
Upon receipt of the pump Unit, it should be stored (above -20°C) in a dry, vibration, shock
and dust free environment. Humidity should 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.

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 CF - 48H

Ensure that the enclosure of any electrical component physically prevents contact with
live circuits.

Carry out regular checks to ensure that the product is in good condition.

THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP UNIT AND ANY ASSOCIATED
EQUIPMENT WHEN STORED, HANDLED AND TRANSPORTED ON-SITE.
1.1.2.1 STORAGE RECOMMENDATIONS ABOUT TRANSMISSION
It is sometimes necessary to store Twin Disc transmissions. In order to prevent corrosion
damage, the following procedures are recommended.
1.1.2.2 SHORT TERM STORAGE (LESS THAN ONE YEAR)
(Transmission installed on an engine that can be run)
i. To the extent possible, store in a location that minimizes exposure to the elements.
ii. Prior to storage, drain oil and refill to full level on the dipstick with recommended new
oil. Install new filter, if applicable.
iii. Use only recommended oils to maintain proper levels. Do not use preservative-type
oil.
iv. Every three months, check oil level and availability of coolant. Start engine and run
approximately 1000 rpm to bring oil temperature up to normal operating range. Run
engine at least five minutes, shifting into each range and shut down.
v. Drain and refill with recommended oil and change filters if applicable, prior to
returning unit to regular service.
1.1.2.3 LONG TERM STORAGE (MORE THAN ONE YEAR)
(Transmission installed where the engine cannot be run)
i. Seal breather, dipstick tube and all other openings with waterproof tape.
ii. Grease exposed members that are subject to corrosion.
iii. Every three months rotate output shaft four or five revolutions.
iv. Tag transmission to show date it was placed in storage and current status relating to
storage procedure.
v. To remove from storage and place in regular service:
vi. Remove waterproof tape from breather, dipstick tube and all openings.
vii. Drain oil and remove oil filter.
viii. Install new oil filter and fill transmission with new recommended oil to full mark on
the dipstick.
1.1.2.4 STORAGE RECOMMENDATIONS ABOUT HEAT EXCHANGERS
When storing a heat exchanger, oil and water ports must be kept sealed.
1.1.2.5 STORAGE RECOMMENDATIONS ABOUT V-BELTS
‘V’ Belts should be stored in a dry stockroom, and contact with hot pipes and direct
sunlight carefully avoided. Where possible, handle the belts loosely in single (or triple)
coils. Always avoid tying belts with thin string.

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 CF - 48H

1.2 SAFETY NOTES - PRE - OPERATIONAL & INSTALLATION

1.2.1 BARE SHAFT PUMP SAFETY

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 CF Parts are for lifting individual
parts only.

To eliminate the possibility of brinelling of the pump bearings, shaft locking devices may
be employed. These should be removed and the free rotation at the pump should be
checked before use.
It must be checked that the intake and discharge openings are totally isolated from all
potentially pressurized connections and that they are and can only be exposed to
atmospheric pressure.

Refer to “CF - 48H Bare Shaft Pump IOM” in the Accompanying Manuals section of this
manual for further information on Safety Procedures.

1.2.2 TRANSMISSION SAFETY

Selecting the neutral, disengages transmission clutches and does not prevent propeller
shaft rotation. If you require positive neutral (prop shaft locked), a shaft brake or other
shaft-locking device must be used.
All personnel servicing this equipment should employ safe operating practices. Twin Disc,
Incorporated will not be responsible for personal injury resulting from careless use of
hand tools, lifting equipment, power tools, or unaccepted maintenance/working
practices.
Inspect as necessary to assure safe operations under prevailing conditions. Proper guards
and other safety devices that may be specified in safety codes should be provided.

Specific product details and performance characteristics can be obtained by contacting

the nearest Twin Disc authorized distributor or service dealers.

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 CF - 48H

1.3 PUMP UNIT DESCRIPTION

1.3.1 ENVIRONMENTAL CONDITIONS
The Weir Minerals Multiflo® CF - 48H Pump Unit is of a robust construction and is designed
to operate and sustain in harsh weather conditions. The Pump Unit can operate effectively
in temperatures between 00 C and 450 C. Rain will not affect the operation of the Pump Unit.
1.3.2 MAJOR COMPONENTS
The Weir Minerals Multiflo® "CF - 48H" Pump Unit is a cost effective pumping solution. The
CF Unit is auto vacuum primed, diesel driven pump unit.
A Caterpillar C9 ACERT 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 procedures.
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.
LED Beacon

Canopy Roof

Vacuum Pump

Non Return Valve

Vacuum Tank

Suction End

Battery Box
Base
Caterpillar C9 ACERT Engine

Bare Shaft Pump

Fig.1.2 CF-48H Pump Unit Dimensions

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 CF - 48H

1.4 PUMP UNIT ASSEMBLY

1.4.1 SAFETY NOTES – ASSEMBLY
Lifting of the pump unit should 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 AND INSTALLATION PROCEDURES.

Installation 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 regarding the installation
of items not specifically for use of this pump unit.

PPE must be worn all the time while moving, installing, operating or
overhauling the unit.

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.

Refer to "Part IV - Spare Parts List" of this manual for a complete list of parts/Spare
Parts.

Refer to "Tightening Torque Values" in the appendices section of this manual for torque
setting values.

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1.4.2 INSTALLATION SEQUENCES

1.4.2.1 PRE INSTALLATION CHECKS
Before carrying out any installation procedures, please check the following:
i. No damage has occurred to the Pump Unit or any of its components during transport
of the unit or its handling.
ii. All the mechanical and electrical connections remain undamaged.
iii. Please contact Weir Minerals Multiflo® customer services for any queries.
1.4.2.2 SAFETY NOTES - INSTALLATION & MOVING
Pump unit to be moved by experienced personnel only.
USE DESIGNATED LIFT EYES ONLY.
Pump unit to be connected to prime-mover by suitable towing apparatus.
Suitability of towing apparatus to be determined according to local site
requirements.
Carefully lift and locate all the components. Do not drag on rugged terrain.
All assembly and installation is to be performed on solid level ground.
Pump unit to be locked out and tagged out before any maintenance or service is
performed.

Pushing the pump unit over long distances or over uneven ground is to be avoided.

Pump unit moving and locating instructions are intended as a guide only. Site
preparation, unit towing and positioning are to be undertaken with regards to site
conditions and procedures.
Pictures used to illustrate the various procedures are not actual, but suggestive.

PPE must be worn all the time while moving, installing, operating or overhauling
the unit.

1.4.2.3 SPACE REQUIREMENTS

Ensure a minimum of one meter free space around the unit before performing any
procedures.

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1.4.2.4 PUMP SITE PREPARATION

Proper pump site preparation is important. It should provide a good approach for the final
positioning of the pump and allow access for service vehicles. Before preparing the pump
site, consideration must be given to the best pumping location, with the aim at positioning
the pump as near as possible to the deepest part of the water catchment area.
1.4.2.5 MOVING AND LOCATING THE PUMP UNIT
Multiflo® Pumps are designed and fabricated around a robust base chassis which can then
be mounted onto a heavy duty high lift skid chassis or pontoon if necessary.
It is the User's responsibility to identify appropriate lifting equipment based on the site and
terrain conditions. The mass and centre of gravity of the unit should also be taken into
consideration.
Lifting the unit must be done using only the single lifting lug as shown in Fig.1.3.
All Assembly and Installation procedures should be performed on level ground.

Due to its lightweight design the CF pump cannot be towed and must only be lifted from
its central lift eye in a vertical lift.

Lifting Point

Fig.1.3 Pump Unit Lifting Points

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1.4.2.6 ASSEMBLY OF PUMP UNIT ONTO SKID

i. Using suitable lifting equipment, lift pump base over high lift skid.
ii. Make sure the skid is clean of all rocks and debris.
iii. When pump base is suspended over skid, gently lower base onto skid.
iv. Make sure the pump is sitting flat in the skid.
v. When base is sitting on skid frame, fit the bolts and tighten them.

Do not attempt to insert bolts until pump base is sitting on skid frame and is not
suspended by lifting equipment.

Skid

Fig.1.4 Installing Pump Unit onto Skid

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1.4.3 DISCHARGE COMPONENTS ASSEMBLY

The Non Return Valve marks the discharge end of the CF-48H Pump Unit. Discharge
Components can be connected to the Non Return valve.

It is the user’s responsibility to correctly assemble and install the discharge components
to the Non Return Valve.

1.4.4 SUCTION COMPONENTS ASSEMBLY

Installation of the boom assembly components to be undertaken by experienced &
trained personnel only. Refer to site procedures for lifting, personnel and equipment
requirements.
Chains to be connected with Hammerlocks only.
Pump unit lifting and locating instructions are intended as a guide only. Site preparation,
unit lifting and positioning are to be undertaken with regard to site conditions and
procedures.
The following graphical descriptions are intended as a guide only. The following
instructions may contain information & illustrations regarding the installation of items
not specifically used with this pump unit.
The CF - 48H unit is completely assembled and shipped except for the 4 m long suction
boom, suction hose and a stainless steel strainer. Fit the Suction Hose to the Vacuum Tank
flange. The suction hose is already fixed with a spreader bar.

Spreader Bar

Fig.1.5 Suction Hose with Spreader bar

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vi. With boom lying flat, insert boom locking bolts in boom and pump unit.
vii. If not already done so, attach winch to pump base winch mount.

Suction Boom

Fig.1.6 Inserting Boom Locking Bolts

viii. With boom lying flat, run winch rope through boom pulley. Removal of the pulley may
be necessary.

D’ Shackle
Suction Boom

C Boom Bolts B

Fig.1.7 Attaching Winch Rope to Boom Pulley

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ix. Connect boom chains to boom using Hammerlocks.

x. Using suitable lifting device, pick up boom and lift into a position that will allow the
boom chains to reach the boom chain mounting points on the pump.
xi. Fit boom chains to mounting points using Hammerlocks only.
xii. Connect winch rope to spreader bar using an approved shackle.
xiii. Fit Suction Strainer to hose.

A A

Fig.1.8 Fitting the Boom Chain and Suction Strainer

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1.4.5 CORRECT POSITION OF SUCTION BOOM

The suction boom supports the suction hose and allows it to be raised and lowered using a
hand winch. The boom is to be installed so that it sits at an angle of 45° to the deck of the
pump unit (See Fig.1.9.). It should be checked that the support chains that run back to the
Lifting Eye on the canopy of the unit are of equal length.

450

Fig.1.9 Correct Position of Suction Boom

Caution should be exercised when moving the pump unit, especially over rough terrain, in
order to avoid excessive movement of the suction hose.

If there are any questions regarding the positioning of the suction boom, please contact
Weir Minerals Multiflo® service centres.

1.4.6 PREPARATION FOR LIFTING

i. Ensure the pipes or hoses are disconnected from the wet end pump discharge.
ii. Show any loose items of pump hardware, such as clamps, connectors, lengths of pipe etc.
that be may be lying around the deck.
iii. Raise and secure the suction strainer and suction hose well clear of the ground. The
suction boom can remain in its normal suspended position.
iv. Connect appropriate lifting chains/straps to the main lift point of the unit.
v. If ground is excessively rough, have it levelled first.
vi. Lifting and locating should be done at a safe speed.
vii. Under no circumstances should this pump unit be pushed or towed.

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1.4.7 PUMP UNIT SITTING ANGLE

Incorrect Positioning:
Pump position - Not on Flat Ground
Discharge Hose - Kinked
Discharge from pump to water surface is more than 10 m

Fig.1.10 Incorrect Pump Positioning

Fig.1.11 Incorrect Pump Positioning Examples

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Correct Positioning:

Pump position - Flat Ground

Suction Lift - Less than 10 m
Discharge hose - Curved where possible

Fig.1.12 Correct Pump Positioning

Fig.1.13 Correct Pump Positioning Examples

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If it is not possible to position the Pump Unit on level ground, the pump unit can be
positioned at a maximum tilt of 15° from ground level.

Caution should be exercised when positioning the Pump Unit. The maximum permissible
tilt at which the Pump Unit can be placed at is 15°. Positioning the Pump Unit above this
angle of inclination might affect the performance of the Pump Unit or cause damage to
the components. See Fig.1.14.

15° 15°

15° 15°

FLAT GROUND LEVEL

ACTUAL GROUND LEVEL

Fig.1.14 Maximum Tilt

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1.4.8 INSTALLATION CHECKS

On-site pump unit alignment checks to be carried out prior to pump unit operation.

All units are assembled, aligned and test run at Weir Minerals Multiflo® factory before
they are dispatched. This alignment may be affected during transportation, therefore
should be checked before the unit is used on site.
1.4.9 ELECTRICAL CONNECTIONS

Refer to “CF-48H Wiring Circuit Caterpillar C9 ACERT” in the appendices section of this
manual for further information.

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PART II
OPERATION

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2 OPERATION
2.1 SAFETY NOTES – OPERATION
Bare shaft pump 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.
Personal protective equipments are to be worn while operating or servicing the
unit.
Pump unit to be locked and tagged before any maintenance or service is
performed.
Pump unit may start at any time by remote operation.
Ensure that there is at least one meter free space around the unit before
performing any operational procedures.
Pump unit must be operated by trained personnel only.
Suction strainer should be fitted to the suction hose and it should be no less
than 1 meter below the surface of the water.
Always use a large diameter hose for the suction, and use the correct size pipe
on the discharge to obtain maximum performance from the unit.
Protective Devices: Belt guards, Top and Bottom seal guard for pump are used
as protective devices.
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.

PPE must be worn all the time while moving, installing, operating or
overhauling the unit.

It is the user’s responsibility to provide appropriate safety training according to

the nature of the operation.

2.1.1 SAFETY NOTES - CAT C9 ACERT ENGINE

Refer to the CAT C9 ACERT Engine manual supplied for Safety Notes related to the CAT C9
ACERT Engine.

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2.1.2 SAFETY NOTES – BARE SHAFT PUMP

Refer to “CF - 48H Bare Shaft Pump IOM” in the Accompanying Manuals section of this
manual for Safety Notes on the Bare Shaft Pump.

2.1.3 NOISE AND RADIATION

The CF-48H Pump Unit does not emit any harmful gases or radiation. The only exhaust is
from the CAT C9 ACERT engine and there is no dust.

The noise level generated by the Pump Unit is greater than 75 dBA until 7 m from the
Pump Unit. The user MUST use PPE to protect against Noise.

2.2 GENERAL DESCRIPTION & FUNCTION OF THE EQUIPMENT

2.2.1 PRINCIPLE OF OPERATION
The type of Bare Shaft Pump used on Multiflo® pumps is of the centrifugal design. This type
of Pump will not operate until initially filled with water (primed). Multiflo® pumps use an
automatic prime system to initially prime and to maintain prime as long as fluid is available.
When the CF-48H pump unit is started, the priming system will quickly and efficiently lift the
water up into the priming tank and the pump will then be primed. The level of the water in
the priming tank is controlled by a “Ball Float” system, ensuring the system remains primed
at all times.
The automatic priming system consists of the vacuum tank, vacuum pump and the “Ball
Float System”. A vacuum gauge which is mounted in the vacuum tank indicates, while the
pump unit is operating, dynamic head loss in the suction system. As this reading will vary
with different pumping conditions, i.e. varying lengths of suction hose, height of pump unit
above fluid, quantity of fluid being pumped etc., it is impractical to predict a general
vacuum gauge operating reading.
As the unit 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 from the discharge side of the pump which would cause the auto vacuum prime
system to malfunction.

For further information, refer to Section “2.5.6. CF-48H Mechanical Priming System".

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2.3 PUMP UNIT ORIENTATION

The front end of the pump unit is the radiator end. The back (or rear) end is the vacuum
tank end. Like driving a vehicle, the engine and radiator are always in front of the driver,
thus the left and right hand sides then correspond accordingly.
Pump Unit Front
End (Radiator End)

Pump Unit Left End

Pump Unit Rear End

(Vacuum Tank End) Pump Unit Right Side

Fig.2.1 Pump Unit Orientation

2.3.1 OPERATING OBSERVATIONS
 Ensure the pump unit is positioned as close as possible to the level of the fluid being
pumped. (If the height of the wet end pump is above 8 meters from the level of fluid,
the pump will not pump).
 As the pump is vacuum primed, ensure that the hose couplings to the bare shaft pump,
both suction and discharge, are completely sealed.
 Ensure that the suction strainer is free from blockages and fully submerged in the fluid.
 Ensure that the largest possible pipe diameter for suction and the correct size pipe at
the discharge is used to obtain optimum performance from the pump unit.
 Ensure that the vacuum tank gauge reading is within the normal range (depending on
suction height).
 Ensure that the wet end pump is operating without cavitation and ensure that there is a
good rate of liquid flow coming from the end of the discharge line.
 Ensure that the pump unit is situated in a safe position and not operating at an angle of
more than 15°.
 Ensure that the engine is set at the correct speed (RPM) to give maximum pump
efficiency.

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2.4 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.
Pump unit can be activated remotely and can start any time. Keep clear.

Refer to the CAT C9 ACERT Engine manual supplied for the engine operating procedures

2.4.1 DAILY PRE-START CHECKS

Engine Oil Maintain oil level between ‘add’ and ‘full’ marks on the dipstick.
While the engine is running, check that the Green indication light is
Bare Shaft Pump Auto
ON. If the Green indication light is not on, then the grease unit is
Lubrication System (if fitted)
not pumping grease and a fuse may have blown.
Vacuum Pump Oil Maintain level between ‘high’ and ‘low’ mark on the dipstick.
Make sure engine is stopped and cold. Maintain level in range
Coolant Level
above baffle plate and filler neck.

Fuel Tank Fill as required. Use dipstick.

Battery Maintain level in range above plates and filler bridge.

Drive Belts
Check condition and re-tension if required or replace if necessary.
(Fan/Generator/Vacuum Pump)

Water Trap Drain and clean the bowl.

Air Cleaner Indicator (if fitted) If indicator piston locks in the ‘up’ position, service the element
Check the suction hose and strainer for blockages or damage.
Suction Strainer
Make sure that the strainer is properly submerged.
Check all bare shaft pump and belt guard mounting bolts are not
Mounting Bolts
loose or missing. Retighten or replace bolts as necessary.
Ensure the gland is adjusted to the correct position required to
Gland Adjustment
pump.

Table.2.1. Daily Pre-Start Checks

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2.4.2 STARTING PROCEDURES

The code to unlock Battery Isolator key is 123.

CAT C9 ACERT - Control Panel

Engine

Fuel Filler

Fuel Cell

Fuel Gauge

Fig.2.2 CF - 48H Pump Unit

 Inspect the engine for potential hazards.
 Before starting the engine, ensure that all protective guards and all protective covers
are installed to help prevent an accident that is caused by parts in rotation, work
around the parts carefully.
 Do not bypass or disable the automatic shutoff circuits. The circuits are provided in
order to help prevent personal injury. The circuits are also provided in order to help
prevent engine damage.
 Complete the prestart checks.
 Check all applicable suction and discharge valves are open.
 Turn master disconnect switch, battery isolator to ON.
 Pull out the Emergency Stop.
 The start system has three positions: OFF, RUN, and START. When the start Switch is
turned clockwise to the RUN position, the lamps will flash for five seconds during the
system test. The lamps will then shut off. In the RUN position the ECM and electronic
systems are powered up.
 Allow to idle by operating Idle Speed Switch (750-800RPM) for 2 Min. - When the
switch is in the up position, the engine speed increases to HIGH IDLE. When the
switch is in the down position, the engine speed decrease to LOW IDLE.
 Increase the RPM to 1000 until the wet end primes (approximately –20 to –40) on the
vacuum gauge).Wait for the Pump to Prime.
 Gradually Ramp the engine to the intended duty.
 During Operation Check for Oil or Water Leaks etc. around the engine.
 Check that water is flowing from the discharge pipe.
 To find the maximum duty, which includes suction pressure lift, & discharge pressure,
bring the revs up until the discharge pressure gauge reaches its highest reading.

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 Increase the engine RPM until the pump starts to cavitate. The pump will vibrate and
a crackling sound will be heard at the pump volute.
 Check for Gland packing leakage and adjust as required.
 Decrease the RPM slowly until the pump stops cavitating completely.
 The vibration and crackling sound will go away.
 This is the correct engine operating speed for this application.

Digital display area - The Messenger system shows information on the digital display
area.
 Previous button (16) - Use the previous button to return to information that was
previously shown on the digital display area.
 Scroll up/left button - This button is used to scroll up through information that is
shown on the display area. The button can also be used to scroll to the left through
information that is shown on the display area.
 Scroll down/right button - This button is used to scroll down through information that
is shown on the display area. The button can also be used to scroll to the right
through information that is shown on the display area.
 OK button - Use this button to confirm selections that you have made with the scroll
up/left button and the scroll down/right button.
Maintenance Lamp:
 The ECM records data that is related to equipment maintenance. The ECM will
activate the maintenance indicator lamp when scheduled maintenance is due. The
maintenance indicator lamp can be reset by actuating the maintenance clear switch.
The maintenance interval may be based on operating hours or fuel consumption. The
ECM provides information that pertains to maintenance intervals and the last
maintenance that was performed.
 Maintenance Clear Switch:
 The maintenance clear switch is required to reset the maintenance lamp after
maintenance on the engine is performed.

It is recommended that the unit be monitored for at least 6 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 protection system is set.
4. The vacuum prime light will go out when the vacuum pump starts pumping.
2.4.3 OPTIMUM 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.

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.

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2.4.4 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.2.3 Result of cavitation

2.4.5 NORMAL OPERATION
Please refer to site procedures.
2.4.6 SHUTDOWN PROCEDURE
 Decrease engine RPM slowly to idle.
 Disengage the transmission at idle RPM.
 Allow the engine to idle for 2 - 3 minutes before shutting down. (Turbo charged models
only).
 Stop the engine. Use the engine shutdown switch in order to stop the engine. Push the
shutdown switch in order to put the switch in the OFF position. This will stop the engine.
After the engine stops, turn the knob clockwise. This will reset the engine shutdown
switch to the ON position.
 Turn the Master Switch (Start Switch) key to the ‘OFF’ position.
 Drain down the pump if it has been used for pumping slurry.
 Push up the Battery Isolator.

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 Use the Emergency Stop Button ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal Engine stopping. After an Emergency stop, DO NOT
start the engine until the problem that caused the emergency stop has been corrected.
2.4.7 PUMP SHUTDOWN SYSTEM
The bare shaft pump protection system consists of heavy duty flow sensor fitted on the
Vacuum tank that senses low flow and sends out the signal required to activate the pump
shutdown system. The low flow switch is fitted to the CAT panel through a remote
technology module with an inbuilt dampener.
When the ignition is turned ON, the Relay R1 starts the Timer T1 which overrules the
Shutdown Relay R2 from shutting down the Engine for a set period of time, i.e. six minutes.
This allows the unit to prime, which closes the low Flow Switch initially during priming. The
low flow switch after the Timer has run out holds the Shutdown Relay closed, which keeps
the unit running.
If there is a lack of water the low flow switch is in the OPEN mode, the timer will start a six
minute countdown to shut down the pump unit. If the low flow switch senses water in that
duration then the system will reset and continue pumping.
The unit will not start automatically once it has timed out and it needs to be restarted.
It is the user’s responsibility to complete all the pre start checks and make sure there is
adequate amount of water before restarting the pump unit.
.

Refer to “CF - 48H Wiring Circuit Caterpillar C9 ACERT” in the Appendices section of this
manual for further information.

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2.5 DESCRIPTION OF MAJOR COMPONENTS

2.5.1 DIESEL ENGINE - CAT C9 ACERT
The Caterpillar C9 ACERT diesel engine generates 168 kW @ 2000 RPM and drives the bare
shaft pump and is the main source of power for other auxiliary items like vacuum pump, etc.
The engine is fitted with a water jacket heater specifically for cold weather operations.

For further information, refer to “Caterpillar C9 ACERT Manual" supplied.

2.5.2 BARE SHAFT PUMP

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 pump discharge can be orientated in
almost any position through 360° depending on mounting.
The impellers are specially designed to obtain high efficiencies without requiring close
clearances between impeller and casing, and still maintain the ability to pass reasonable
sized solids. The long wearing materials the bare shaft pump is cast from have been
developed for abrasion and corrosion resistance and to give a long life in slurry pumping
applications.

Fig.2.4 Bare Shaft pump CF-48H

Refer to “CF - 48H Bare Shaft Pump IOM” in the accompanying manuals section of this
manual for further information on bare shaft pump operation.

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2.5.3 VACUUM PUMP - MODEL 39

38 C.F.M. air cooled twin reciprocating piston type fully sealed unit - self-contained oil
lubricated unit. Operating at 600 rpm, it is driven by two Vee belts from the pump input
shaft.

Fig.2.5 Vacuum Pump

2.5.4 VACUUM TANK
The high lift vacuum tank is manufactured from 6 mm mild steel incorporating a vacuum and
air separator chamber designed to give maximum air separation and allowing an
uninterrupted capacity flow to the bare shaft pump. The vacuum tank is also complete with
a vacuum water trap and houses the “Ball Float Assembly” that helps in priming the pump.

Ball Float
Water Trap
Assembly
Vacuum
Vacuum Tank
Gauge

Hose

Fig.2.6 Vacuum Tank Components

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2.5.5 CF - 48H MECHANICAL PRIMING SYSTEM

The Vacuum Prime System consists of a Ball Valve Float system fitted into the vacuum tank.
Vacuum primed pumps need not be filled with water prior to starting up and is belt driven
from the main shaft.
The Ball float system uses a ball on a pivot to open and close 2 valves. 1 is open to vacuum,
when there is no water and the other is open to atmosphere when there is water.
The Assembly is connected to a vacuum pump. The float arm is designed to pivot
downwards while in priming mode, without the need for a spring loaded valve system, this
opens the vacuum valve at the same time as closing the atmosphere valve, allowing a
vacuum to be created in the priming tank.
The fluid to be pumped is then pulled into the priming tank. As the fluid level rises, it reaches
a pre-designed level, set to ensure pump priming. This causes the float ball to float upwards,
rotating the pivot arm, closing the vacuum valve, and opening the atmosphere valve. This
prevents any more fluid being drawn into the tank; ensuring fluid is not pulled into the
vacuum pump. The fluid is then pumped away causing the fluid level in the tank to drop, the
float ball will then move with the water level allowing the float arm to pivot downwards,
opening the vacuum valve, and closing the atmosphere valve re-establishing the preset fluid
level in the priming tank. The water level in vacuum tanks drops mostly because the tank
loses vacuum (air gets into the tank via atmosphere valve).This process ensures a constant
flow of fluid from the pump while there is fluid in the catchment area.

Fig.2.7 Ball Valve Float Assembly

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Atmospheric Valve

Vacuum Valve

To Vacuum Pump
Fig.2.8 Ball Float Operation
Valve
2.5.6 VACUUM GAUGE
A vacuum gauge which is mounted in the vacuum tank indicates, while the pump unit is
operating, dynamic head loss in the suction system. The normal operating range depicted by
the gauge should be within -80 kPa to -20 kPa.

Fig.2.9 Vacuum Gauge

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2.5.7 NON RETURN VALVE (VOOOM)

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.
 On starting up, the vacuum pump expels the air from the suction hoses and the
priming tank, and pulls the non-return valve, sealing the discharge side.
 When the air in the system has been completely replaced by water, the pump is fully
primed.
 When the water reaches the impeller and is discharged, the non-return valve is
pushed off its seat and allows the water to pass.
 This whole process happens automatically within a few seconds from start up.
Benefits
 Non Return Valve can be opened completely, hence less friction losses in the flow of
fluid.
 Also Non Return Valve can be used in vertical position.

Fig.2.10 NRV Operation

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2.5.8 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 including the flow control valve, pilot line float valve, and breather and
mounting hardware.
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 of this manual.

2.5.9 ENGINE MONITORING SYSTEM (EMS)

Caterpillar Engine Monitoring System – Please refer to the CAT C9 ACERT manual
supplied.

2.5.10 WORK LIGHT TIMER

The optional work lights are fitted with a time adjustable push button that can be set
between 60 seconds and 60 minutes. The work lights are directly wired through the battery
isolator to the batteries and therefore will remain operational even when the engine is not
operating.
2.5.11 DRIVE COUPLING
The CF range is fitted with a torsionally soft disc type coupling. This allows quick and easy
setup of the pump and eliminates the possibility of pump misalignment.

Fig.2.11 Drive Coupling

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 CF - 48H

PART III
MAINTENANCE

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3 MAINTENANCE
3.1 NORMAL MAINTENANCE PROCEDURES
3.1.1 SAFETY NOTES - MAINTENANCE
Bare shaft pump and all fluids may be at extremely high temperatures when the
pump unit is stopped and may cause serious burns. Ensure pump unit has cooled
down before any checks or maintenance is carried out.
It must be checked that the intake and discharge openings are totally isolated
from all potentially pressurized connections and that they are and can only be
exposed to atmospheric pressure.
The pump unit is tagged with appropriate safety stickers. The user must refer the
“Introduction & Safety” section of this manual to understand the safety and risks.
It is the user’s responsibility to understand all the inherent risks and consequences
involved during maintenance procedures and take necessary precautions against
such risks.
All maintenance procedures MUST be performed complying with the technical
data and content mentioned in this manual. User MUST not perform any
procedures that are not specified in the technical manual.
Ensure that there is at least one metre free space around the unit before
performing any maintenance procedures.
It is the user’s responsibility to provide the necessary training required to perform
maintenance procedures on the Pump Unit.
Belt Guards, Top and Bottom Guards for pump are provided as protective devices.
Pump unit to be locked out and tagged out before any maintenance or service is
performed.
Observe for unusual gauge leaks and general condition of the unit. If condition
exists, determine the cause and have necessary repairs made.

Personal protective equipment must be worn when operating or servicing this

unit.

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3.1.2 SAFETY NOTES - BARE SHAFT 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. Appropriate lifting apparatus must be used to lift.
the pump
When unit have
pumps or anybeen
individual pump components.
dismantled for complete overhaul, all parts should be closely
inspected and new parts checked for correct identification.
Used parts being replaced should be thoroughly cleaned and repainted where required.

Mating faces and spigots should be free of rust, dirt and burrs and given a coat of grease
before they are fitted together to assist future overhaul.
Names and basic part numbers are used in assembly instructions in this manual. Full part
numbers are given in the drawings in the spare parts section of this manual. Full part
numbers should be used upon ordering spare parts.
It is preferable to renew small bolts and set screws during overhaul and all threads should
be coated with graphite grease before assembly. It is also recommended that all rubber
seals should be replaced during major overhauls as rubber tends to harden and seals lose
their effectiveness.
Vibration from transport and operation can cause the loosening of some fasteners. Check
and tighten.
Procedure and diagrams is a guide only and should be followed in conjunction with the
attached Pump Supplements 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.
Oil level must be checked before operating the vacuum pump. Running the vacuum
pump without oil will cause damage.

To eliminate the possibility of brinelling of the pump and bearings, shaft locking devices
may be employed. These should be removed and the free rotation at the pump should be
checked before use.

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3.2 CAT C9 ACERT ENGINE

Refer to the CAT manual supplied for maintenance procedures of the CAT C9 ACERT
Engine.

3.3 MAINTENANCE - BARE SHAFT PUMP

Refer to “CF - 48H Bare Shaft Pump IOM” in the accompanying manuals section of this
manual for further information on bare shaft pump safety and maintenance procedures.

3.4 HYDRAU-FLO

For further information on Hydrau-flo® fuel filling valve components, refer to “Hydrau -
flo® IOM” in accompanying manuals section of this manual.

3.5 FLOW SWITCH

Refer to “Wire Flow Switches” in the accompanying manuals section for further
information.

3.6 MAINTENANCE & SERVICE GUIDE

If the pump is operating continually, it should be checked about twice a day (Every 10
hours).

3.6.1 EVERY 10 ENGINE HOURS OR DAILY

SCHEDULE MAINTENANCE
Maintain oil level between “add” and “full” marks on the dipstick.
Engine Oil Use SAE15W40 or refer to Lube List. (Refer also to the Engine
Manual).
Maintain level between “high” and “low” marks on the dipstick. Use
Vacuum Pump Oil
SAE15W40 or refer to Lube List.
Inspect and adjust Gland if necessary.
Gland Packed BSP
Grease Gland or check Oil Tank.
Coolant Level
Maintain level in range above baffle plate and filler neck.
(Engine Stopped and Cold)
Fuel Tank Fill as required.
Battery Maintain level range above plates and filler bridge.

Drive Belts Check condition and tension if required.

Water Trap Drain and clean bowl.

Observe for unusual gauge leaks & general condition of the unit. If condition exists,
determine the cause and have necessary repairs made.

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3.6.2 EVERY 250 ENGINE HOURS (PERFORM IN ADDITION TO DAILY SCHEDULE ITEMS)
SCHEDULE MAINTENANCE
Change the oil and filters.
Engine Oil & Filters
(Refer to Engine Manual)
Change Filters.
Engine Fuel Filters
(Refer to Engine Manual)
Non Return Valve Inspect condition. Repair if necessary.
Change the Oil.
Vacuum Pump
Use SAE15W40 or refer to Lube List.
Inspect condition.
Drive Coupling
Re-tension bolts and grub screws if required.
Engine Air Cleaner Element Inspect condition. Replace if necessary.
Check all bolts on Engine, Bare Shaft Pump and Vacuum Pump.
Mounting Bolts
Tighten if necessary.
3.6.3 EVERY 1000 ENGINE HOURS (PERFORM IN ADDITION TO 250 HOURS SERVICE ITEMS)
SCHEDULE MAINTENANCE
Condition/Adjustment.
Bare shaft pump
Inspection of impeller, wear plate(s), volute, and packing.
1. Clean core finning.
Radiator
2. Inspect condition of radiator hoses.
1. Test shutdown operation.
Auto shutdown system 2. Inspect condition of wiring, hoses etc.
(Refer to Caterpillar Manual)
3.6.4 EVERY 2000 ENGINE HOURS (PERFORM IN ADDITION TO 1000 HOUR SERVICE ITEMS)
SCHEDULE MAINTENANCE
Bare shaft pump Check condition of bare shaft pump bearings for moisture inclusion.
Engine Check operation and performance.

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3.7 TROUBLESHOOTING
3.7.1 FINDING AND DIAGNOSTIC GUIDE
3.7.1.1 PUMP UNIT TROUBLESHOOTING
SYMPTOMS POSSIBLE CAUSES REMEDIES
Check: Water trap Gaskets Lid seal
Vacuum leaks on the suction side of
fittings Suction hose strainer is
the pump.
sucking air.
Put a piece of soft rubber or plastic
over the valve opening, if the
pressure on the gauge drops the
Atmosphere valve leaking.
valve is faulty. Remove the lid and
check the condition of the valve and
the setting.
Check each end of the hose is tight.
Remove the gauge from the tee,
remove the hose from the tee, fit the
Vacuum hose between pump and
gauge to the hose and test, if the
tank loose or leaking.
gauge still reads low the gauge is
faulty or there is a leak or blockage
Pump won’t prime. closer to the vacuum pump.
(vacuum pressure low) Same as above only fit the gauge to
Brass NRV in vacuum hose blocked.
the brass NRV on the vacuum pump.
Deteriorating vacuum pump Same as above only fit the gauge
condition. direct to the vacuum pump inlet.
Check belt tension, replace if
Loose/broken vacuum pump belts.
necessary.
Change gland packing if worn or
Check gland packing condition.
hard.
Tighten if required to show small
Check the gland follower isn’t loose.
visual leak.
Check suction side of the pump for
Repair if required.
vacuum leaks.
NRV seat or flap may be damaged (if Remove inspection lid from NRV
the discharge is still primed the flap inspect the seat and/or flap and
and seat are ok). replace if damaged.
Pump unit not
Emergency stop switch activated. Reset emergency stop switch.
starting.
Check the probe condition. Replace if damaged.
Check the suction strainer isn’t in the
Remove from mud if required.
mud.
Pump keeps shutting
Check the operation of the flow Ensure continuity between common
down on water loss.
switch. and normally closed terminals.
Check the water loss module (M2) in
Adjust if required.
the control box has the LED on.
Check the suction line for blockage. Clear blockage if required.
Prime light won’t go
out. Check the float in the krundimendt
Replace valve if required.
valve isn’t shut.

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Check the plug at the switch under Check plug is correctly inserted in
Low fuel light is on the vacuum tank. switch.
with the engine shut
Remove the float from the tank and
down (presuming Replace float if damaged.
there is enough fuel). see if the float floats.
Check the switch for operation. Check switch.
Remove the strainer from the water
and remove mud and rocks.
Blocked strainer. Reposition the strainer away from
thick mud and loose rocks. Or dig the
sump deeper.
Refer NPSHR in the pump curve for
the application and calculation of
Suction lift too high. NPSHA. If the NPSHA is greater than
NPSHR the pump will not fully prime
Pump wont prime or will cavitate when primed.
vacuum pressure high.
Remove float ball lid and inspect the
Vacuum valve stuck shut valve and seat wear, obstruction and
adjustment, replace if required.
Remove the hose and inspect the
Suction hose liner collapsed or kinked.
liner, replace as required.
Remove the lid of the vacuum tank
and suction hose, wash out all mud
Vacuum tank bogged.
and loose rock from the tank and the
hose.
Dynamic head is too high for the Lower the discharge, increase the
pump. pipe diameter, and lower the NPSH.
Pump primes but has Check impeller wear and
Pump condition.
no flow at discharge of adjustment.
pipe. Leaks in discharge pipe. Find and repair leaks.
Check engine load at CAT
Low engine power.
messenger.
Dynamic head is too high for the Lower the discharge height, increase
pump. pipe diameter.
Lubricate and adjust gland leakage,
Excessive gland leakage.
Pump primes but has replace packing as required.
low flow Check impeller wear and
Pump condition.
adjustment.
Check engine load at CAT
Low engine power.
messenger.
Check the flow rate is enough to
Low flow.
operate the flow switch.
Check flow switch operation and
Flow switch faulty.
Pump primes, has flow trailing wire condition.
but shuts down after 6
minutes. If the flow switch is ok check the
Flow switch timer faulty.
timer operation.

Check the CAT messenger (where

Engine fault.
fitted) for fault codes and warnings.

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Vacuum leaks. Find and repair leaks.

Pump has difficulty Insufficient water supply. Increase the water supply.
maintaining prime. Lower the pump speed.
Float ball lid valve adjustment. Inspect and adjust valves as per the
maintenance manual.
Failing vacuum pump. Service or replace the pump.
Water temperature. Empty water trap more frequently.
Check that the float ball isn’t full of
Failed float ball.
water.
The water trap fills
Atmosphere valve stuck shut or Inspect the valve and seat clean,
with water.
blocked. readjust or replace as required.
Inspect valve and seat for damage or
Vacuum valve leaking.
obstruction.
Pump running on the left hand side
of the curve, reduce the total head.
(Pump volute will be hot).
Pump primes pumps Low Flow. Increase pump speed.
then shuts down after Refer to the pump performance
6 minutes (Models curve for maximum head and flow
fitted with flow information.
switches). Refer to the electrical trouble
Faulty flow switch.
shooting guide.
Refer to the electrical trouble
Engine Fault.
shooting guide.
Pump primes pumps
then shuts down after
Refer to the electrical trouble
6 minutes (Models not Engine Fault.
shooting guide.
fitted with flow
switches).
Pump regularly shuts Increase the water supply.
Low water supply.
down after a few Slow the pump speed down.
hours (models fitted Refer to the electrical trouble
with flow switches). Engine fault.
shooting guide.

Pump regularly shuts

down after a few
Refer to the electrical trouble
hours (models not Engine fault.
shooting guide.
fitted with flow
switches).
Lower the head height.
Increase the pipe size.
Total head too high (hot volute).
Increase the pump speed within
Low or no discharge recommended limits.
flow. Check for damaged or flattened
Blocked discharge (hot volute).
pipes under haul roads and culverts.
Excessive leakage along pipe route Inspect and repair the discharge pipe
(ambient water temperature volute). for leakage.

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Decrease the engine speed within

Pump cavitates Pump is operating on the right hand recommended limits.
excessively. side of the curve. Fit an orifice plate or throttle valve
to the discharge.
Excessive gland Loose gland. Tighten gland.
leakage. No gland adjustment. Replace packing.
Excessive gland Excessive head pressure (may occur
Lower the total head.
leakage, Gland tight when the pump has dead headed).
but there is still
adjustment between
Overheated packing. Replace the packing.
the follower and the
stuffing box.
Notes:
1. When replacing float ball lid valves or seats it is advisable to replace them as a set (both seats
and both valves).
2. When replacing gland packing replace all rows with fresh packing, refer to the manual for
instructions.
3. 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.
Remove the R5 relay and run the
engine
Engine shuts down
If the fault is now gone, the Multiflo Refer to the CAT manual or contact
with no diagnostic
side of the electrics has the fault. a CAT representative.
lights on.
If the fault is still there, the problem is
in the CAT side of the electrics.
3.7.1.2 LINK-BELT TROUBLESHOOTING
SYMPTOMS POSSIBLE CAUSES REMEDIES
Generally caused by shortage of belt
Small cracks on Belt Avoid belt contamination during
tension but excessive heat and/or
side and base operation and storage.
chemical fumes can also give cause.
Caused by excessive contamination
Belt swelling or
by oil, certain cutting fluids or rubber
softening
solvent.
If a slightly higher (or lower)
Usually caused by incorrect tension does not cure the problem
Whipping during tensioning, principally on long center there may be a critical vibration
running drives. frequency in the system which
requires re-design or a Banded belt.

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3.7.1.3 HYDRAU-FLO VALVE

Pump unit fuel system may contain diesel fuel. Pump unit fuel system should be isolated
and drained prior to any work on the fuel system being undertaken.

SYMPTOM POSSIBLE CAUSES REMEDIES

Nozzle or receiver spring setting too Check condition and rating of
low. spring, replace if necessary.
Ensure there is no excessive
Back pressure in filler pipe too high. restriction in the flow of fuel from
Fuel nozzle shutting off the Hydrau-Flo to the tank
prematurely. Check and clean or replace if
Breather blocked.
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 ensuring it
does not hit internal walls of fuel
Float valve not closing capillary line. tank.
Check valve seat for damage or
obstruction.
Fuel nozzle not shutting Check piston operation is smooth
off. Piston stuck open.
and unrestricted.
Check line and fittings for leaks or
Leakage in capillary line.
damage.
Lower float lever below height of
Float lever set above breather height.
breather.
Fuel weeping from Float level set too high, not allowing
Lower float level setting.
breather after tank has enough air space for fuel expansion
been filled. due to rise in temperature.
Table.3.1 Troubleshooting guide – Hydrau-Flo

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3.8 VACUUM GAUGE READINGS

SYMPTOMS POSSIBLE CAUSES REMEDIES
Static suction lift too high. Lower suction lift.
Obstruction in suction hose or Remove obstruction from hose
High Vacuum Reading
strainer. and/or strainer.
(-80 and above).
Suction hose kinked or collapsed. Unkink or Replace suction hose.
Suction hose stuck low into the mud. Remove suction hose from mud.
Low or No Reading (-20 Air leak in the suction line. Repair suction line.
and below) If Vacuum Discharge reflux valve not sealing. Replace seal.
Pump is operating with Air leak in vacuum line from tank. Repair vacuum line.
air being exhausted. Leaking gland packing. Adjust gland packing.
If Vacuum Pump is Non-return valve sticking. Clean or replace valve ball.
operating with no air Check and seal.
being Exhausted. Vacuum pump faulty.
Repair vacuum pump.
Check the gauge for accuracy. Replace gauge if faulty.
Check gaskets at the vacuum tank
inlet, pump suction and pump
discharge.
Check the float ball lid gasket,
Vacuum leaks. check the lid for flatness.
Check the vacuum hose between
the vacuum tank and the vacuum
pump.
Check the suction hose for damage.
Tighten gland.
If the gland is tight and there is still
excessive leakage, replace the
Loose Gland.
packing.
Pump takes excessive If the follower is hard against the
amounts of time to stuffing box replace the packing.
prime, vacuum gauge If belts are excessively worn,
reading low. replace them. Check the alignment
Loose Belts. if the wear is uneven.
Re-tention the belts.
Remove the triangle covers (with
the fittings) loosen or remove the
Unloader valves stuck shut in the
brass unloader valves. (The vacuum
vacuum pump.
pump will work effectively without
the unloader valves).
Remove the float ball lid and
inspect the atmosphere valve,
Atmosphere valve on the float ball lid readjust or replace as required. (If
is damaged or incorrectly adjusted. the finish on either of the valve is
not smooth the operation will be
compromised).
Remove and inspect, replace as
Brass NRV faulty.
required.
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Pump takes excessive Dilute the slurry.

amounts of time to Put the pump closer to the water.
prime, vacuum gauge Specific gravity of slurry too thick.
reading low. Select another pump.
(Continued).
Consult the pump performance
Pump too far from the water. curve for recommended NPSH
requirements.
Blocked strainer. Unblock the strainer.
Remove the suction hose, inspect,
Blocked or delaminated suction hose.
Pump takes excessive clean or replace as required.
amounts of time to Remove the tank lid and suction
prime, vacuum gauge Vacuum tank full of mud.
hose and clean the tank.
reading high. Remove the float ball lid, inspect
the valves, clean if blocked, replace
Vacuum valve in the float ball lid if damaged, and readjust if out of
faulty, stuck or blocked. tolerance. (If the finish on either
valve is not smooth the operation
will be compromised).
Pump takes excessive amounts of Pump takes excessive amounts of
time to prime, vacuum gauge reading time to prime, vacuum gauge
low. reading low.
Check operation service or replace
Vacuum pump failed.
as required.
Pump wont prime Lower the strainer low enough so
vacuum gauge reading there is no visible vortex on the
Strainer not submerged far enough
low. water. If the water source is too
into the water.
shallow, dig a sump or wait until
there is enough water.
Water trap seal worn or missing. Replace the seal.
No grease in lantern ring. Grease the gland.
Vacuum pump exhaust blocked. Check the exhaust for obstructions.
Pump wont prime Pump takes excessive amounts of Pump takes excessive amounts of
vacuum gauge reading time to prime, vacuum gauge reading time to prime, vacuum gauge
high. high. reading high.
Table.3.2 Troubleshooting guide – Vacuum Gauge Readings

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High Reading Low Reading Normal Reading

Fig.3.1 Vacuum Gauge Readings

A low reading indicates:
 An air leak in the vacuum tank.
 An air leak in the bare shaft pump.
 Leaking gland packing.
 Faulty vacuum pump.
3.8.1 FAULTY VACUUM PUMP
 Blocked Exhaust Pipe
 Broken Belts
3.8.2 PUMP PRIMES BUT FAILS TO DELIVER AT A REDUCED RATE
 Foreign materials lodged in the impeller.
 Low bare shaft pump RPM (1800 RPM maximum).
 Obstruction in discharge hose.
 Partial obstruction in suction hose, strainer or vacuum tank.
 Obstruction in non-return valve.
 Air leak in suction system.
 Worn pump components.
 Collapsed suction hose.
 Pump located too high above water being pumped.
3.8.3 PUMP OVERLOADS ENGINE
 Speed too high.
 Specific gravity and viscosity of pump fluid different from pump rating.
 Mechanical defects.
 Total dynamic head lower than pump rating-pumping too much water.
3.9 TORQUE SETTINGS
Cylinder Head 35Nm + 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

Table.3.3 Torque Settings for Vacuum Pump

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3.10 LUBRICATION SCHEDULE

3.10.1 GRADES AND FREQUENCY OF LUBRICATION

Lock the pump unit and tag the same before any maintenance or service is performed.

Personal Protective Equipment must be worn when operating or servicing the unit.

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

Grades and Frequency of Lubrication

Item Recommended Lubricant Frequency Maximum Capacity
Mobil Delvac MX 15W40
Engine Oil Checked Daily 32 litres
Shell Rimula 15W40
Mobil Delvac MX 15W40
Vacuum Pump Oil Checked Daily 2.2 litres
SAE15W40
Multiflo Pump Grease-
Gland Packing and 1 Shot & 2 Shots-48
Shell Alvania RL2 Grease, Before Start up
Labyrinth hours respectively
SKF LGMT2
Vacuum Pump Capacity

Model - 39 1.5 litres

Table.3.4 Lubrication Grades and Frequency

3.10.2 RE STARTING THE PUMP UNIT AFTER AN INTERVENTION
In case the pump unit ceases to operate due to any of the above mentioned conditions
or due to an emergency shutdown, the user must rectify the problem that caused the
shutdown.
After rectifying such problems, the Pump Unit can be restarted using the same
procedures as explained in the section “2.4.2 Starting Procedures” of this manual.

Refer to section “2.4.2. Starting Procedures” of this manual.

3.11 PISTON & RE-RINGING INSTRUCTIONS

It is advisable that the ridge be removed from the top of worn cylinders prior to
removing the piston. Failure to do so may result in cracked or broken piston ring lands.
The ring sets are designed to bed in on both new bores and worn bores. Honing is not
essential but it is recommended to give the optimum result. However, it is essential if
one of the following conditions is present:
 Excessive wear
 Bore distortion
 Polishing or Glazing
 Scuffing
 Scratching

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When boring to oversize, allow sufficient honing allowance to completely remove boring
marks (0.06 is usually needed).
Aim for a high cross hatch angle (30 - 60 included) and an even cut in both directions.
Machine hone if possible as hand honing is harder to achieve the desired result.
Always replace scuffed, cracked, worn or otherwise damaged pistons.
Always check the gap clearance of new rings in the lower unworn portion. The gap
should not be less that 0.003 mm per mm of cylinder diameter.
Maximum gap condition is not especially critical but should not exceed 0.01 mm per mm
for compression rings while gap on oil ring rails may be up to 1.75 mm regardless of
bore size.
Poor cleaning after honing accounts for most of today’s worn out / oil consumption
problems. Petrol and kerosene are not suitable. Soap and hot water with a nylon
scrubbing brush are best. Check with a clean white cloth which should not come out
grey. Finally, swab with light engine oil to prevent corrosion.
Ensure piston rings and pins are thoroughly clean and then lubricate rings, skirt, pin
bores and bearings with engine oil. Use a good quality ring compressor held firm
against the engine block at the time of entry of the rings into the cylinder.

3.11.1 ASSEMBLY OF 3-PIECE OIL RING ASSEMBLY

1. Wind on Expander

2. Hold the expander end in place with thumb. Wind on

lower rail then wind on upper rail.

3. Both ends of the expander should be visible and not

over lapped.

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4. Align all gaps as per the picture (gaps must

not be lined up). Check the assembly can
rotate in the groove.

5. When fitting the compression rings, make sure they are fitted the correct way up as
per the diagram below.

Table.3.5 Correct Fit of Piston Rings

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

X
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7. Use a ring expander or expand with

the thumbs before placing in piston
grooves.

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

9. Correct running in of rings is essential, especially

on un-honed bores. Firstly, avoid prolonged
idling and vary the engine speed and load. The
load provides the build-up of pressure behind
the compression rings and helps them to bed in.

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3.12 MAINTENANCE - DRIVE COMPONENTS

i. Drive Belt Tensioning

Pump unit to be locked and tagged before any maintenance or service is

performed.

Personal Protective Equipment must be worn when operating or servicing this

unit.

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

Fig.3.2 Belt Tension Indicator Applied to Mid Span

 Calculate the deflection distance in mm on a basis of 16 mm (5/8”) per meter
(yard) of span. Center Distance (m) x 16 = Deflection (mm).
 Set the lower marker ring at the deflection distance required in mm on the lower
scale.
Set the upper marker ring against the bottom edge of the top tube. Place the belt
tension indicator on top of the belt at the center of span, and apply a force at
right angles to the belt deflecting it to the point where the lower marker ring is
level with the top of the adjacent belt.

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For single belt drives a straight edge should be placed across the two pulleys to act as a
datum for measuring the amount of deflection. If the measured force falls within the
values given, the drive should be satisfactory. A measured force below the lower value
indicates under-tensioning. A new drive should be tensioned to the higher value to allow
for the normal drop in tension during the running-in period. After the drive has been
running for 30 minutes, the tension should be checked and re-adjusted to the higher
value, if necessary.

 Read off the force value indicated by the top edge of the upper marker ring.
 Compare this force to the kgf value shown in the attached table.
 If a Belt Tension Indicator is not available, a spring balance and rule will suffice.

Fig.3.3 Belt Tensioning Indicator

ii. Belt Tensioning Forces
Force Required to Deflect Belt 16 mm per Meter of Span
BELT SECTION
Small Pulley Diameter (mm) Newton (N) Kilogram Force (kgf)

SPA 125 10 to 125 1.0 to 1.5

Table.3.6 Belt Tensioning Forces

iii. Installation & Operation of Link Belt Drives
1. Pulley Installation
Before assembling the drive, check the pulley grooves are free from scores or
sharp edges and all dimensions conform to the relevant standard. The taperlock
bush is the starting point when it comes to assembly and installation. Drive
installation is a straight forward job with taperlock, but the stages set out on the
installation leaflet provided with every taperlock bush should be followed closely.
2. Alignment
Good alignment of pulleys prior to belt installation is important to avoid belt flank
wear. The diagram below shows some of the common alignment faults. You
should only be satisfied if the conditions in Fig.3.4 prevail.

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 CF - 48H

Fig.3.4 Belt Alignment

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

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 CF - 48H

PART IV
PARTS LIST

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 CF - 48H

CF - 48H MAJOR COMPONENTS

3
8
7
5
6
2

NO. DESCRIPTION SECTION

1 PUMP UNIT PUMP
2 HIGH LIFT SKID ANCILLARY
3 C9 ACERT CAT ENGINE CAT MANUAL
4 VACUUM TANK PRIMING
5 BARE SHAFT PUMP PUMP
6 WINCH DISCHARGE
7 BATTERY BOX DRIVE
8 ISOLATORS SUCTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

CF - 48H MAJOR COMPONENTS

5

6
4

1
2

NO. DESCRIPTION SECTION

1 SERVICE POINT LUBRICATION
2 CONTROL PANEL CAT MANUAL
3 NON RETURN VALVE DISCHARGE
4 VACUUM PUMP DRIVE
5 MUFFLER CAT MANUAL
6 BEACON ELECTRICAL
7 EXTINGUISHER ANCILLARY

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1 DRIVE SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.1 CF - 48H DRIVE MAIN COMPONENTS

1 3

2
4

NO. DESCRIPTION PART NUMBER QTY

1 C9 ACERT CAT ENGINE CAC9 1
2 BARE SHAFT PUMP BS0048Z0003 1
3 MUFFLER REFER CAT MANUAL 1
4 VACUUM PUMP VP0039Z0001 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.2 MODEL 39 VACUUM PUMP

NO. DESCRIPTION PART NUMBER QTY

1 COMPLETE VACUUM PUMP ASSEMBLY VP0039Z0001 1
2 EXHAUST ASSEMBLY HO0048Z0004 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.3 MODEL 39 VACUUM PUMP

5

1
2
3 11 10
12

13

14
4 3

6
7

NO. DESCRIPTION PART NUMBER QTY

1 BOLT BLTM0802008 8
2 SEAL 100040 1
3 BEARING 100009 2
4 BOLT BLTM06020 8
5 BOLT 100556 2
6 OIL DRAIN 100063 1
7 STUD 100012 1
8 NUT 100011 1
9 BOLT 100557 4
10 GASKET 100039 1
11 STUD 100032 6
12 NUT BLTMN10 6
13 WASHER BLTSW10 6
14 BEARING SUPPORT 100010 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.4 MODEL 39 VACUUM PUMP (CONTINUED)

3
4 5

1
14

13 7

12
6

11
7

8 9
10

NO. DESCRIPTION PART NUMBER QTY

1 CYLINDER BLOCK 100005 1
2 CYLINDER HEAD ASSEMBLY 100004 1
3 GASKET 100038 1
4 HOUSING, TAIL END 100060 1
5 GASKET 100041 1
6 GASKET 100007 2
7 INSPECTION PLATE 100006 2
8 CRANK CASE 100046 1
9 SIGHT GLASS 100008 1
10 HOUSING, TAIL END 100042 1
11 O’ RING 100045 1
12 OIL CAP VP0000Z0001 1
13 CRANK SHAFT 100043 1
14 KEY 100044 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.5 MODEL 39 VACUUM PUMP (CONTINUED)

1
2
3
2
3

6 4

8
7

10

NO. DESCRIPTION PART NUMBER QTY

1 PISTON RING 100014 2
2 PISTON RING 100015 2
3 PISTON RING 100016 2
4 GUDGEON PIN 100018 2
5 CIRCLIP 100019 4
6 PISTON 100017 2
7 CONNECTING ROD ASSEMBLY 100020 2
8 BUSH 100021 2
9 SLIPPER 100022 2
10 SPLASHER 100023 2
PISTON RING SET 100013

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.6 MODEL 39 VACUUM PUMP

11

2 2

3
15
4
14
5

6 13

7
12
8
11
9
10
10

NO. DESCRIPTION PART NUMBER QTY

1 PIPE 100061 2
2 BOLT BLTM08030 2
3 CAP NUT 100031 100031 2
4 PUSH BOLT P 100030 2
5 GASKET 100029 2
6 COVER EXHAUST 100028 2
7 GASKET 100027 2
8 PUSH CAGE 100026 2
9 VALVE 100025 2
10 GASKET 100024 4
11 VALVE 100033 2
12 O-RING 100034 2
13 TRIANGLE INLET 100035 2
14 UNLOADER PISTON 100036 2
15 INLET COVER 100037 2

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.7 CF - 48H VACUUM PUMP ASSEMBLY

6
1
8

NO. DESCRIPTION PART NUMBER QTY

1 GUARD MECHANICAL DRIVE GU0048Z0004 1
2 BELT GUARD BOLTS BLTM08020G4.6 4
3 PULLEY, GROOVE VP0036Z0001 1
4 PULLEY, GROOVE DC0048Z0002 1
5 BELT, V, ADJUSTABLE LINK - 5.7 M VBPTA01 2
6 STUD BLTMTR10-0125 4
7 WASHER BLTW10G 16
8 NUT BLTMN10G 16
9 MOUNTING PLATE 203134 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

1.8 CF - 48H DRIVE COUPLING

NO. DESCRIPTION PART NUMBER QTY

1 COUPLING CM-280CA4-0-50-14 DC0048Z0001 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2 PUMP SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.1 CF - 48H BARE SHAFT PUMP

NO. DESCRIPTION PART NUMBER QTY

1 BARE SHAFT PUMP ASSEMBLY BS0048Z0003 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.2 CF - 48H WET END PARTS

4
2

6
5

NO. DESCRIPTION PART NUMBER QTY

1 VOLUTE 380-67 SS 1
2 BOLT BLTC20050 8
3 IMPELLER 380-69 1
4 WEAR PLATE 380-72 SS 1
5 O-RING 380-73 1
6 SHIM 0.5MM THICK 380-55 A/R
SHIM 0.9MM THICK 380-56 A/R
7 SUCTION COVER PLATE 380-70 SS 1
8 O-RING 380-74 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.3 CF - 48H DRIVE END PARTS

5 2
4

8 13

12
3
6

7
9

10
11

NO. DESCRIPTION PART NUMBER QTY

1 BOLT HEX 3/4” UNC BLTC20050 4
2 WEARING SLEEVE, SHAFT CF0048Z0001 1
3 O-RING BS238 6A-29 2
4 NUT, GLAND BOLTS 6A-34 SS 2
5 ISO METRIC SCREWS AS1111 M12x110 2
6 STUD 5/8” UNC 6A-34ST 2
7 RETAINER PACKING - BRASS 6A-32 SS 1
8 PACKING KIT, FLUROGRAF CF0048Z0002 1
9 LANTERN RING 6A-36 SS 1
10 STUFFING BOX 6A-30 SS 1
11 O-RING BS261 6A-31 1
12 GUARD, GLAND GU0048Z0001 2
13 GUARD, INSPECTION GU0048Z0002 2

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.4 CF - 48H DRIVE END PARTS

9
8

7
5

10

4
3

NO. DESCRIPTION PART NUMBER QTY

1 BOLT, BEARING CAPS BLTC16042 12
2 LOCK TAB WASHER 6A-20 6
3 BEARING CAP, COUPLING END 6A-04A 1
4 GASKET 1.5MM 6A-21 2
5 SEAL, BEARING CAP LIP 6A-05 1
6 LOCK NUT 6A-08 1
7 O-RING BS258 6A-06 2
8 BEARING SET, COUPLING END 6A-10A 2
9 RETAINER, BEARING LUBRICANT BH0048Z0002 1
10 GRUB SCREW FA0306Z1006 4

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.5 CF - 48H DRIVE END PARTS (CONTINUED)

7
3
8

2 1

NO. DESCRIPTION PART NUMBER QTY

1 KEY, COUPLING CF0048Z0004 1
2 SHAFT CF0048Z0003 1
3 BEARING HOUSING BH0048Z0001 1
4 SLINGER 6A-16 1
5 BEARING CAP, IMPELLER END 6A-14A 1
6 GREASE NIPPLE 5AA-07 3
7 SEAL, BEARING CAP LIP 6A-15 1
8 BEARING, METAL CAGE CLEARANCE 6A-13 1
9 RETAINER, BEARING LUBRICANT BH0048Z0002 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.6 CF - 48H BEARING HOUSING

1
2

3
1

NO. DESCRIPTION PART NUMBER QTY

1 SIDE BELT GUARD GU0048Z0002 2
2 SIDE BELT GUARD BOLTS BLTM08020G4.6 4
3 SIDE GLAND GUARD GU0048Z0001 2
4 SIDE GLAND GUARD BOLTS BLTM10030G4.6 4
5 VACUUM PUMP MOUNT CF4348Z0001 1
VACUUM PUMP AND AIR CLEANER MOUNT
6 BLTM10030G4.6 4
BOLTS

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

2.7 CF - 48H PUMP UNIT

1 3

5
4
6
7 8

NO. DESCRIPTION PART NUMBER QTY

1 CANOPY LEG L.H. CA0048W0001 1
2 CANOPY LEG R.H CA0048W0002 1
3 ROOF CA0048P0006 1
4 CENTRE LIFT FRAME LI0048W0001 1
5 SCREW PLUG DIN 910-G2A 2
6 BASE 205612 1
7 VACUUM TANK MOUNT VT0048Z0002 1
8 BARE SHAFT PUMP MOUNT BS0048Z0002 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

3 SUCTION SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

3.1 CF - 48H SUCTION ASSEMBLY

1
2
10

3 9

5 8

NO. DESCRIPTION PART NUMBER QTY

1 SUCTION BOOM 4 M MFB4-1 1
2 BOOM PULLEY ASSEMBLY MFBP1 1
3 HAMMER LOCK PLATED HL13 4
4 CHAIN 205608 1
5 CHAIN WELDED 205617 2
6 WIRE ROPE WR8-16SASA 1
7 D’ SHACKLE DS-S-13 1
8 SPREADER BAR 102333 1
9 HOSE 100230 1
10 STRAINER SU0200Z0001 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

4 DISCHARGE SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

4.1 CF - 48H NON RETURN VALVE

14

6 13

11 3

4
10
7

12

2
8
9
1

NO. DESCRIPTION PART NUMBER QTY

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

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

4.2 CF - 48H SUCTION WINCH ASSEMBLY

NO. DESCRIPTION PART NUMBER QTY

1 WINCH MFW0600 1
2 WINCH POST 209532 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

5 PRIMING SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

5.1 CF - 48H VACUUM TANK

NO. DESCRIPTION PART NUMBER QTY

1 LID VALVE ASSEMBLY CF0000A0002 1
2 200 MM VAC TANK 200082 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

5.2 CF - 48H VACUUM TANK LID COMPONENTS

1
3
4

2
5

6
5
6
7
9
7 7
4
10 12
4 7

12
8

12
7
11

NO. DESCRIPTION PART NUMBER QTY

1 TOP LID (BARE) 200113 1
2 LID GASKET CF0000Z0002 1
3 LID BOLT 102347 8
4 WASHER BLTW10SS6 10
5 VALVE INSERT 200110 2
6 VALVE 200109 2
7 HALF NUT FA0110Z1000 4
8 ROCKER ARM 200098 1
9 ROCKER ARM PIVOT BOLT BLTM10080SS6 1
10 ROCKER ARM BUSH CF0000Z0010 1
11 FLOAT BALL 200105 1
12 NYLOC NUT BLTMNN10SS6 4

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

5.3 CF - 48H VACUUM TANK LID COMPONENTS

2
1

3
4
5
6
7
15 8
16

9
10
14 11
4
13

12

NO. DESCRIPTION PART NUMBER QTY

COMPLETE LID VALVE ASSEMBLY 200115 1
1 VALVE LID 10M000008 1
2 SCREW 01B005157 4
3 NUT 01B006922 1
4 ROUND 10M000003 2
5 VALVE BODY 10M000001 1
6 GASKET 10M000006 1
7 EYE BOLT 07B000053 1
8 SCREW 01B006575 8
9 WASHER 01B006829 8
10 PLATE 10M000005 1
11 SHEET 10M000007 1
12 BALL FLOAT 03B004319 1
13 PIPE 10M000004 1
14 HEXAGONAL 10M000008 1
15 EXTENSION 01B005157 1
16 NIPPLE 01B006922 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

5.4 CF - 48H PRIMING SYSTEM

4
5

NO. DESCRIPTION PART NUMBER QTY

1 WATER TRAP 200-0345 1
2 NIPPLE HFS27-1212 1
3 TEE HFS48-121212 1
4 REDUCING BUSH HFS24-1204 1
5 HYDRAULIC FITTING HFS27-1212 1
6 HOSE 102225 1
7 VACUUM GAUGE 200-0365 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6 ELECTRICAL SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.1 CF - 48H EMERGENCY STOP

NO. DESCRIPTION PART NUMBER QTY

1 EMERGENCY STOP ES-03-01 1
NC CONTACT (IF REQUIRED) ES-03-02 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.2 CF - 48H LED BEACON AND WORK LIGHT

NO. DESCRIPTION PART NUMBER QTY

1 LED BEACON 105571 1
2 LED WORK LIGHT 105076 6

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.3 CF - 48H BATTERY BOX

NO. DESCRIPTION PART NUMBER QTY

1 BATTERY BOX RWB662 2

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.4 CF - 48H LOW FLOW SWITCH

NO. DESCRIPTION PART NUMBER QTY

1 LOW FLOW SWITCH TWS26SS-140 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.5 CF - 48H OIL PRESSURE SWITCH

NO. DESCRIPTION PART NUMBER QTY

1 OIL PRESSURE SWITCH 101495 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

6.6 CF - 48H BATTERY ISOLATOR

1
2

NO. DESCRIPTION PART NUMBER QTY

1 BATTERY LOCKOUT LS11003-01 1
2 STARTER LOCKOUT LS11003-02 1
3 ISOLATOR 341003004 2

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

7 LUBRICATION SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

7.1 CF - 48H HYDRAU - FLO FLOAT

NO. DESCRIPTION PART NUMBER QTY

1 ADAPTOR PLATE HF1012Z0002 1
2 O’RING HF1012Z0004 1
3 NUT HF1014Z0003 1
4 FLOAT ASSEMBLY HF1007Z0001 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

7.2 CF - 48H SERVICE POINT

4 1 2 3 5
3

NO. DESCRIPTION PART NUMBER QTY

1 RECEIVER HF1113Z0003 1
2 VALVE HF1105Z0003 1
3 HOSE HF1215Z0002 1
4 FUEL GAUGE 62200 - A - 150 1
5 FLOAT VALVE ASSEMBLY HF1017Z0001 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

7.3 CF - 48H FUEL FILLER

NO. DESCRIPTION PART NUMBER QTY

1 DUST COVER KL50-DC 1
2 KAMLOCK KL50-A 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

7.4 CF - 48H FUEL AND VACUUM TANK HOSES

NO. DESCRIPTION PART NUMBER QTY

1 FUEL TANK TO FUEL FILTER HOSE HO0048Z0001 1
2 FUEL COOLER TO FUEL TANK HOSE HO0048Z0002 1
3 VACUUM TANK TO VACUUM PUMP HOSE HO0048Z0003 1
4 VACUUM TANK EXHAUST HOSE HO0048Z0004 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

8 ANCILLARY SECTION

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

8.1 FIRE EXTINGUISHER

NO. DESCRIPTION PART NUMBER QTY

1 MOUNTING PLATE FEP-1 1
2 FIRE EXTINGUISHER 201713 1
3 MOUNTING BRACKET FEHDVMBC9KG 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

8.2 CF - 48H HIGH LIFT SKID

NO. DESCRIPTION PART NUMBER QTY

1 HIGH LIFT SKID 208412 1

(Always quote model and serial number of pump when ordering spare parts)
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 CF - 48H

PART V
APPENDICES

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 TORQUE SETTINGS

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
(eg: for Hot-Dip Gal M12 Class 8.8, final torque required will be 77 x 2.1 Nm = 161.7 Nm, etc)

Bremick Pty Ltd

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CF - 48H

PART VI
ACCOMPANYING MANUALS
 CF - 48H BSP

1.1 BARE SHAFT PUMP SAFETY

THE WARMAN PUMP IS BOTH A PRESSURISED COMPONENT AND A PIECE OF ROTATING
EQUIPMENT. ALL STANDARD SAFETY PRECAUTIONS FOR SUCH EQUIPMENT SHOULD 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 Warman Parts are for lifting
individual parts only.

To eliminate the possibility of brinelling of the pump and, shaft locking devices may be
employed. These should be removed and the free rotation at the pump should be checked
before use.

1.2 BRIEF DESCRIPTION

The type of bare shaft pump used on Multiflo® CF Unit is of the centrifugal design.
This Pump will not operate until initially filled with water (primed). An automatic priming
system is used to initially prime and maintain the prime as long as fluid is available.
1.3 CF - 48 BARE SHAFT PUMP DISASSEMBLY PROCEDURE
Procedure to suit new bearing assembly:
A. Step 1
Remove SUCTION COVER PLATE.

B. Step 2
Remove WEAR PLATE from VOLUTE and discard 'O' RINGS.

Fig.1.1 Wet End Assembly

 CF - 48H BSP

C. Step 3
Remove KEY from SHAFT. Using Impeller Locking Tool (Figure 3 in tools and clearance
section) to lock IMPELLER, remove the IMPELLER by turning the SHAFT with the Shaft
Spanner (Figure 1 in tools and clearance section).

Fig.1.2 Removal of Impeller

D. Step 4
Remove BLANK DUST CAPS/GUARD PLATE from BEARING HOUSING and use ¾ UNC BOLTS
through DUST CAP holes to separate VOLUTE from BEARING HOUSING. Remove VOLUTE
from BEARING HOUSING.
E. Step 5
Remove STUFFING BOX from VOLUTE and discard PACKING & 'O' RING.

Volute

Volute Bolts

Fig.1.3 Volute Bolts

Blank Dust Caps/Guard Plate
 CF - 48H BSP

F. Step 6
Remove SHAFT SLEEVE and discard 'O' RINGS. Withdraw GRUB SCREWS from LABYRINTH
SLINGER and remove from SHAFT SLEEVE Discard 'O' RING.

Shaft Sleeve

Shaft Sleeve O-ring

Grub Screw

O-ring

Slinger

Fig.1.4 Shaft Sleeve and Slinger

G. Step 7
Remove BEARING CAPS. Discard 'O' RING and SEALS.
Bearing Cap Impeller End

Bearing Cap Drive End

Fig.1.5 Bearing Caps

 CF - 48H BSP

H. Step 8
Remove SHAFT LOCK NUT from SHAFT.

I. Step 9
Press SHAFT from BEARING HOUSING out through Impeller End.

J. Step 10
Remove GREASE RETAINER RING and BEARINGS from both DRIVE END and WET END side of
BEARING HOUSING.

Shaft
Grease Retainer Ring Drive End

Bearing Drive End

Bearing Impeller End

Grease Retainer Ring

Lock Nut Impeller End

Fig.1.6 Bearing & Shaft Assembly onto Bearing Housing

It is recommended that all Bearings, Gaskets, 'O' Rings, Bushes and Nyloc Nuts be
replaced when rebuilding Pump Bare Shaft Assembly.
 CF - 48H BSP

1.4 CF - 48 BARE SHAFT PUMP ASSEMBLY PROCEDURE

A. Step 1
Fit the Grease Retainer Ring onto the Shaft. Fit 1st Drive End Bearing onto Drive End of the
Shaft. Use an Induction Heater or similar to heat Bearing to 100°C to 120°C.
Grease Retainer Ring Drive End
1st Drive End Bearing

Shaft

Fig.1.7 Drive End Bearing onto Shaft

Bearing is an interference fit onto shaft and transition fit into Housing.

B. Step 2
Fit the 2nd Bearing in the same way next to the 1st Bearing.
Shaft

2nd Drive End Bearing

Fig.1.8 Shaft and Bearing Assembly

 Oil between BEARING and SHAFT LOCK NUT.
 Over torqueing BOLTS will cause a heat increase.
 Tool ‘B’ acts as a press bed.
C. Step3
Fit the Shaft - Drive End Bearing Assembly onto the Bearing Housing.

Bearing Housing

Shaft - Drive End Bearing Assembly

Fig.1.9 Shaft Assembly onto Bearing Housing

 CF - 48H BSP

D. Step 4
Fit Shaft Lock Nut with Loctite 271 & tighten to torque specifications. Raised face against
bearing.
Turn BEARING HOUSING 180°. Pre-load BEARINGS 30% to 50% with ALVANIA RL2 Grease. Fit
Grease Retainer and then pre-greased BEARING. Press into place using Tools ‘C’ & ‘D’.

Lock Nut

Fig.1.10 Lock Nut

Impeller End Bearing

Grease Retainer Ring

Impeller End

Fig.1.11 Impeller End Bearing onto Shaft

 CF - 48H BSP

E. Step 5 Fit Lip Seal, O-ring & Bearing Cap gasket onto Bearing Cap Assembly.
Lock Bolts

O-Ring

Lip Seal

Bolt Lock Tabs

Drive End Bearing Cap

Bearing Cap Gasket

Fig.1.12 Bearing Cap Assembly
F. Step 6
Close both Drive End & Impeller End with the Bearing Cap assembly and Fit BOLT LOCKING
PLATES and BEARING CAP BOLTS and torque BEARING CAP BOLTS to 95 Nm (70 ftlbs). Lock
BOLTS with LOCKING PLATES.

Fig.1.13 Bearing Cap

 CF - 48H BSP

1.5 CF - 48 BARE SHAFT PUMP – WETTED PARTS ASSEMBLY

A. Step 1
Fit ‘O’ Ring into the Shaft sleeve. Install Shaft Sleeve to Shaft.

Shaft Sleeve

Shaft Sleeve O-ring

Fig.1.14 Shaft Sleeve

Once assembled, do not fix with GRUB SCREWS onto the Shaft Sleeve.

Shaft Sleeve

Fig.1.15 Shaft Sleeve onto Shaft

 CF - 48H BSP

B. Step 2 Fit ‘O’ Ring to Slinger and then to the Shaft.

Grub Screw O-ring

Slinger

Fig.1.16 Slinger

Shaft Sleeve

Slinger

Fig.1.17 Slinger onto Shaft Sleeve

 CF - 48H BSP

C. Step 3
Fit 2 rows of Packing Rings in Stuffing Box, Alternating joints of individual Packing Rings at 180°
intervals, fit Lantern Ring, fit 2 rows of Packing Ring and fit the Stuffing Box Studs.

2nd set Gland Packing

Lantern Ring
1st set Gland Packing
Fig.1.18 Gland Assembly
D. Step 4
Fit Gland follower Halves and Assembly onto Shaft Sleeve.

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.

E. Step 5
Install the GLAND STUDS into STUFFING BOX and install 'O' RING onto STUFFING BOX. Fit
GLAND PACKING. Alternate joints of individual Packing Rings at 180° intervals. Then fit
STUFFING BOX with BOLTS into VOLUTE with the GLAND OIL FEED HOLE to the top.

Use oil on SHAFT and PACKING to assist in assembly of STUFFING BOX.

Stuffing Box Assembly

Gland Follower
Fig.1.19 Stuffing Box Assembly
 CF - 48H BSP

F. Step 6
Fit VOLUTE to BEARING HOUSING using BOLTS. Be careful not to cause damage to SHAFT when
fitting. Tension as per bolt specifications. Use anti-seize between all bolts and bolted surfaces
for ease of future disassembly.

Volute

Fig.1.20 Stuffing Box onto Volute

Fig.1.21 Volute Fasteners

 CF - 48H BSP

G. Step 7
Apply anti-seize to shaft thread then fit IMPELLER on to SHAFT using Shaft Spanner (Figure 1) to
prevent shaft from turning. SPIN THE IMPELLER AND ENSURE IT IS NOT FOULING.

Impeller
Fig.1.22 Impeller onto Volute
H. Step 8
Insert STUDS using Loctite 620 into face of VOLUTE.
I. Step 9
Without 'O' RING, fit WEAR PLATE to VOLUTE to determine clearance between WEAR PLATE
and IMPELLER. Use a combination of SHIMS to ensure a clearance of 1 mm between WEAR
PLATE & IMPELLER when SUCTION COVER PLATE is installed. Fit 'O' RING to WEAR PLATE and
install into VOLUTE.

O ring

Shim

Fig.1.23 Wear Plate onto Volute Wear Plate

 CF - 48H BSP

J. Step 10
Fit 'O' RING to recess at the back of WEAR PLATE then fit SUCTION COVER PLATE and secure
with VOLUTE NUTS. Grease all 'O' RINGS for ease of fitting.

Nuts

Wear Plate O Ring

Stud

Suction Cover Plate

Fig.1.24 Suction Cover Plate

CF - 48H BSP

2 OPERATION
2.1 SAFETY NOTES-OPERATION
The principle requirements for operation of bare shaft pumps are as follows:
 Gland sealing water is provided at adequate pressure and flow.
 Impellers adjusted to maintain minimum clearance with front liner.
 Wearing parts are replaced when performance falls below required operating pressure.
 Volute liner seal and stuffing box seal are maintained to prevent leakage.
 Grease purged labyrinths (where used) are lubricated regularly to prolong bearing life
by excluding dust and dirt from the bearing assembly.
2.2 SHAFT ALIGNMENT
The Coupling Design consists of a rubber disc, which has moulded teeth on its outside
diameter and engaged into an internally toothed aluminium ring that is driven by the diesel
engine fly wheel. The centre of the rubber disc is vulcanised to an inner driven hub, which is
mounted to the pump shaft. The bare shaft pump housing spigots directly connected to the
diesel engine flywheel housing. This allows for blind fittings of the pump to the motor, with
the rubber disc allowed to float axially in the outer ring.
2.3 SHAFT UNLOCKING
The bearings can be locked to prevent vibration and consequent damage during transport. It
is not critical to lock the bearings as small movements help to prevent false brinelling. The
following steps must be followed initially:
 The set screw must be removed to free the bearings
 The shaft should then be rotated by hand (clockwise) by means of the clamp to ensure
that the impeller turns freely within the pump.
 Adjust the impeller, if any scraping noises are issued from the pump.
 The shaft clamp must then be removed.
2.4 NORMAL PUMP-START UP
 Check that all bolts are tight and that the impeller turns freely.
 Ensure that the shaft seal is in order and that correct pressure of gland water is used.
Start up the pumps on water before introducing solids or slurry into the stream. On
shutting down it is also recommended that pumps should be allowed to pump water
only for a short period before shut down.
 Open intake valve (if any) and check that water is available at the inlet. Check drain
valve (if any) is closed. Ensure the suction is submerged in water.
 If a discharge valve is installed and NRV not present or not working properly, close the
discharge valve for start-up.
 Start pump and run up to speed, if pump is on suction lift execute priming procedure
for facilities provided. When the pump is primed, isolate prime facilities (if any).
 Open the discharge valve. Check intake and discharge pressures (if gauges have been
provided).
 Check flow rate by inspection of meters or pipe discharge.
 Check Gland leakage. If leakage is excessive, tighten the gland nuts until flow is reduced
to the required level. If leakage is insufficient and gland shows signs of heating, then try
loosening the gland nuts. If this is ineffective and the gland continues to heat up, the
pump should be stopped and the gland should be allowed to cool.
CF - 48H BSP

Gland nuts should not be loosened to such an extent that the gland follower is allowed
to disengage the stuffing box.

It is normal for the gland leakage water to be hotter than the supply because it conducts
away heat generated due to friction in the gland.
At low pressures (single stage operation) very little leakage is required and it is possible to
operate with only a small amount of water issuing from the gland. It is not essential to
stop the pump because of gland heating unless steam or smoke is produced.
This difficulty is normally only experienced on initial start-up. When initial heat up of the
gland is encountered, it is only necessary to start up -- stop -- cool and start the pump two
or three times before the gland operates satisfactorily.
It is preferable at start to have too much leakage than not enough. After the pump has run
for 8-10 hours, gland bolts can be adjusted to give optimum leakage. If heating of gland
persists, the packing should be removed and the gland should be repacked.

2.5 PUMP START-UP PROBLEMS

The following reasons can cause the pump not to prime:
BLOCKED INTAKE PIPE:
When the pump has not been operated for some time, it is possible for slurry to settle in or
around the intake pipe if operating from a pit and thereby prevent water rising to the pump
impeller. The pressure gauge on the intake side of the pump may be used to check the level
of water in the pump.
AIR ENTERING GLAND:
If one of the following conditions apply, air may be inducted into the pump through the
gland. This may prevent the pump "picking up" its prime or cause it to loss its prime during
operation.
 Sealing water pressure is too low.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
 Gland sealing water connection into the stuffing box is blocked.
 Inspection of the gland will reveal if above faults occur and remedial action is self-
evident.
CF - 48H BSP

3 MAINTENANCE
Bare shaft pump and all fluids may be at extremely high temperatures when
the pump unit is stopped and may cause serious burns. Ensure pump unit has
cooled down before any checks or maintenance is carried out.
It must be checked that the intake and discharge openings are totally isolated
from all potentially pressurized connections and that they are and can only be
exposed to atmospheric pressure.
Pump unit to be locked out and tagged out before any maintenance or service
is performed.
Observe for unusual gauge leaks and general condition of the unit. If condition
exists, determine the cause and have necessary repairs made.

Personal Protective Equipment must be worn when operating or servicing this

unit.

3.1 MAINTENANCE – BARE SHAFT PUMP

The areas of maintenance for the bare shaft pump are:
 Gland
 Lubrication
 Bearings
3.1.1 GLAND
The CF Gland system requires a shot of grease into the stuffing box before each start-up of
the pump. This system requires the use of "Flurograph 193" or equivalent packing, which
has been found, through experience, capable of providing excellent service under the harsh
conditions under which it may be called upon to operate.
The gland should be adjusted regularly to prevent excess leakage. The gland must not be
over tightened as this will lead to 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.
Each ring of packing should be inserted separately and pushed in place into the stuffing box.
The split opening of the successive packing rings is 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.
 CF - 48H BSP

3.1.2 GLAND PACKING REMOVAL

The gland packing must be replaced when packing has deteriorated to the point that no
further tightening of the gland will provide a seal or when the gland follower has reached
the end of its travel. All packing rings must be replaced, adding one or two new rings on top
of the old rings is not sufficient to provide a proper seal. Remove the two gland adjustment
nuts and withdraw the gland follower from the stuffing box. Remove the two gland follower
securing bolts then remove both halves of the follower from the shaft. Using the
appropriate packing removal tool, (PAK 1) remove all packing rings from stuffing box and
clean out any remaining residue.

Fig.3.1 Gland Packing Removal Tool

3.1.3 GLAND PACKING INSTALLATION
New packing rings must be installed one at a time by placing rings on the shaft and pressing
each ring all the way into the stuffing box, ensuring the ends are fitted neatly together.
Successive ring joints must be staggered around stuffing box. Pump models with Lantern
rings should have the lantern ring re-installed. Check with the pump manual for correct
positioning between the gland packing rings.
Fit gland follower to shaft and nip gland nuts up to pack gland packing. Ensure front face of
gland follower has entered the stuffing box housing. If after tightening the gland nuts the
packing has compressed enough to allow space for another ring, remove gland follower, fit
extra packing ring, re-assemble follower and nip gland nuts up again. Back nuts off and leave
finger tight until pump is started.
After pump has been started, the glands must be adjusted to provide reasonable leakage.
When water pressure is at a minimum the gland should leak slightly, therefore when this
pressure rises, leakage will necessarily be excessive.
If the gland is adjusted to provide optimum leakage at higher pump rpm (high pressure),
insufficient leakage will occur when the rpm falls or is less from the point of adjustment.
The gland sealing water should be as clean as possible, as large amounts of abrasive
material can quickly wear the gland components. Always maintain a very small amount of
water leakage along the shaft by regularly adjusting the gland. As well as lubricating and
cooling the gland, the water escaping from the gland also prevents the ingress of air when
the pressure at the shaft falls below atmospheric.
E.g. when a vacuum is required.
CF - 48H BSP

If one of the following conditions apply, air may be inducted into the pump through the
gland. This may prevent the pump “picking up” its prime or cause it to lose its prime during
operation.
 Packing has insufficient tension.
 Packing is excessively worn.
 Shaft sleeve is excessively worn.
 Inspection of the gland will reveal if any of the above faults are occurring.
3.1.4 GLAND PACKING ADJUSTMENT
After pump has started, the glands must be adjusted to provide reasonable leakage. When
water pressure is at a minimum the gland should leak slightly, therefore when this pressure
rises, leakage will be excessive. If the gland is adjusted to provide optimum leakage at
higher pump rpm (high pressure), insufficient leakage will occur when the rpm falls or is less
from the point of adjustment.
The gland sealing water should be as clean as possible, as large amounts of abrasive
material can quickly wear the gland components. Always maintain a very small amount of
water leakage along the shaft by regularly adjusting the gland.
As well as lubricating and cooling the gland, the water escaping from the gland also
prevents the ingress of air when the pressure at the shaft falls below atmospheric.
E.g.: when a vacuum is required.
If one of the following conditions applies, air may be inducted into the pump through the
gland. This may prevent the pump “picking up” its prime or cause it to lose its prime during
operation.
Packing has insufficient tension.
Packing is excessively worn.
Shaft sleeve is excessively worn.
3.1.5 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, stop the pump as per site
procedures and isolate.
4. Once unit is isolated, 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, stop the pump and tighten the
gland nuts by one turn at a time to ensure that only a constant drip is achieved.
 CF - 48H BSP

3.2 LUBRICATION
A correctly assembled and pre-greased 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 shots are from a standard hand operated grease gun (approximately 1 cc). The grease
used for both bearings and labyrinths should be a lithium complex soap thickener grease with
EP additives and oxidant inhibitors. If the bearing assemblies run at above 85°C, then high
temperature grease should be used.
Bearing housings must be opened at regular intervals (no longer than twelve months) for
inspecting bearings and grease. If re-greasing is required the bearing assembly grease plug
can be temporary replaced with grease nipples at the time of greasing. Bearings must never
be over greased. Use only recommended, clean grease. Refer the Table Recommended
Lubrication/Grease for the recommended greasing/lubrication.

Impeller End

Drive End

Fig.3.2 Bare Shaft Pump Impeller and Drive End

3.2.1 RECOMMENDED LUBRICATION/GREASE FOR PEDESTAL
TYPICAL PROPERTIES
 Lithium base (not containing Molybdenum or EP additives).
 Base oil Viscosity of 75 cSt to 120 cSt @ 40 degrees Celsius.
 NLGI consistency of 2 (a consistency of 3 can also be used, however it may not be
suitable for Automatic Greasing Pump Units.
Examples of this type of grease are:
 SHELL ALVANIA RL2.
 SKF LGMT 2.
Drive end bearing Impeller end bearing Labyrinth Stuffing box

1 Shot- 48 Hours 2 Shot- 48 Hours 2 Shots -48 Hours 2 Shots before starting up
Use Talcor Multiflo Red Grease Shell Alvania Rl2 Grease or equivalent
CF - 48H BSP

3.3 OVERHAUL MAINTENANCE

3.3.1 GENERAL
When the pump has worn to such an extent that the performance obtained no longer is
satisfactory then the pump should be dismantled for inspection and/or replacement of
wearing parts (impeller and liners).
If the bearing assembly requires maintenance, then the pump wet end must be dismantled
before the bearing assembly can be removed from the pump.

Bearing assemblies should only be reconditioned in a workshop preferably in a specific

area set aside for the work. A clean environment is essential.

3.3.2 PUMP DISMANTLING

Isolate the pump from the system and wash down as much as possible. Remove drive items
as necessary after noting alignment of drive. Dismantling can be done if suitable lifting
facilities and working space are available. Otherwise the complete pump should be moved
to a maintenance workshop.
 It is recommended that bearing assemblies should only be dismantled and overhauled
in the workshop.
 When bearing components are removed from a pump, they should be identified with
suitable tags so that if they are reused they may be replaced in the same position in the
pump with their correct mating parts.
 Bearing components which are an interference fit on the shaft should be removed only
if replacement is necessary.
 The procedure for removing the pump or bearing assembly is simply a reversal of the
assembly procedure as set out in the relevant Instruction Supplements for the pump
and bearing assembly. Note that the pump must be dismantled before the bearing
assembly can be removed for reconditioning.
3.4 INSPECTION AND REMOVAL OF BEARINGS
Since greasing requirements vary with operating conditions and environment the following
general recommendations should be used as a guide. When new bearings are fitted or re-
assembled after overhaul they should be correctly packed with grease. It is then
recommended that a systematic program of investigation be instituted in order to ascertain
the following:
 Whether the grease addition is required between overhauls.
 How frequently grease addition is required?
 What quantity of grease addition is required?
A suggested program of investigation is briefly described below for the case of a number of
the same pumps operating on similar or the same duties (i.e. the pumps have identical
bearings).
 Start with two pumps with bearings correctly packed with grease.
 After a set number of hours (depending on the duty and environment) dismantle the
bearing assemblies of one pump and inspect condition and disposition of the grease.
 From inspection assess whether grease addition is required at this interval and if grease
addition is not required assess whether the second pump can safely run to twice the
set number of hours without greasing.
CF - 48H BSP

 By repeating this procedure on the remaining pumps in turn, the maximum time
interval before re-greasing may be determined and it may be found possible to run
pumps for the life of the wearing parts without re-greasing bearings.
3.4.1 WHEN TO REMOVE BEARINGS
Bearings should be renewed when any of the following faults are observed:
 Face of race is worn to such an extent that a detectable shoulder is evident at the edge
of the rolling track.
 Cage is worn to such an extent that there is excessive slackness or burrs.
 Any roughness or pitting of rollers or rolling track.
The rolling track will often be slightly darker than the unused portion of the race. This does
not mean that the bearing has reached the end of its useful life provided no other
symptoms are present.
3.4.2 REMOVING BEARINGS
Care should be exercised during dismantling. When driving bearing cups out of the assembly
with shaft and rollers, the shaft should be held hard in the direction of driving so that rollers
are seated hard up against the face of the cup and the effects of impact on the bearing faces
are thereby minimized.
If inspection of bearings shows that they require replacement then a press or suitable puller
should be set up to bear on the end of the shaft and on the bearings. When bearing
components are removed from an assembly, they should be identified with suitable tags so
that if they are reused they may be replaced in the same position in the assembly with their
correct mating parts.
If any portion of a bearing required replacing then the bearing should be replaced in its
entirety. Worn parts must not be mixed with new parts. A complete new bearing at one end
of a bearing assembly may be installed with a used bearing at the other if required however,
if one bearing requires replacement, economics usual favour renewing the pair.
3.5 COMMISSIONING OF PUMPS
In addition to the procedures and safety instructions necessary at start up the following
checks should be performed at Commissioning:
 Impeller clearance is pre-set to give optimum efficiency but this should be checked and
adjusted. Refer to the section on impeller adjustment in this supplement.
 Grease the labyrinths until grease emerges at the outside.
 Bolts and nuts may become loose during transport and they have to be rechecked.
CF - 48H BSP

3.6 STORAGE OF PUMPS

Pumps must always be kept clean. Pumps taken out of service should be flushed with water
and dried before storage.
Indoor storage is recommended especially for elastomer pumps. Too much heat can
artificially age elastomer and render it unserviceable. For outside stored pumps it is
recommended to cover the unit(s) with a tarpaulin rather than plastic so that air can
circulate.
It is best to cover flanges. Remove transport clamps and loosen gland to release pressure on
the packing. Turn the shaft of the pump a quarter of a turn by hand once per week. In this
way all the bearing rollers in turn are made to carry static loads and external vibrations.
Ensure that the rust preventing coat of the shaft drive end is maintained.
3.7 OPERATING FAULTS
Overloading can occur when the pump is discharging into an empty system when the delivery
head will be temporarily lower and the throughput in excess of that for which the pump is
designed. Careful regulation of the delivery valve until the system is fully charged will prevent
this.
3.7.1 LOW PIT LEVEL
Pumps may lose their prime if air is induced through the gland. Pumps may also lose their
prime if the water level in the pit falls sufficiently low to allow air to be inducted into the
pump intake by vortex action. In order to obtain the best possible pump operation, sump
(or hopper) makeup water controls should be arranged to maintain as high a level in the
sump (or hopper) as runback requirements will allow and should be arranged to maintain
this level within as close limits as is practical.
3.7.2 BLOCKED INTAKE PIPE
It is possible during operation of pump for a piece of foreign material to be drawn across
the bottom of the intake pipe and thereby cause a partial obstruction. Such an obstruction
may not be sufficient to stop operation completely but will result in a reduced output from
the pump. It will also cause a drop in discharge pressure and ampere, and will increase the
vacuum reading on the pump intake. Rough running and vibration of the pump may also
occur due to the high induced suction causing cavitation within the pump.
3.7.3 BLOCKED IMPELLER
Impellers are capable of passing a certain size particle. If a particle larger in size enters the
intake pipe it may become lodged in the eye of the impeller thereby restricting the output
of the pump. Such an obstruction will usually result in a drop of ampere and a drop in both
discharge pressure and intake vacuum readings. Pump vibrations will also occur due to the
out of balance effects.

Before applying manual torque to the pump shaft ensure that the intake and discharge
lines are isolated and that the engine is disconnected.

3.7.4 BLOCKED DISCHARGE PIPE

Blocked discharge pipe may be caused by abnormally high concentration of coarse particles
in the pump discharge pipe or by the velocity in the discharge pipe being too low to
adequately transport the solids. Such a blockage will be shown up by a rise in discharge
pressure and a drop in ampere and intake vacuum readings.
CF - 48H BSP

3.8 CF-48 TOOLS AND CLEARANCE

FIGURE 1
Shaft Spanner

FIGURE 2
Impeller Clearance
CF - 48H BSP

FIGURE 3
Impeller Locking Tool

FIGURE 4
Angular Contact Ball
Bearing Arrangement

(Face to Face)
CF - 48H BSP
 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‐FO®HARDWAE......................................................................................................................................12

 
 
 
 
 
 
 
 
 
   Mechanical and Non‐Pressurised  
  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 
Mechanical and Non-Pressurised
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.

SYMBOLS DEFINITIONS CONSEQUENCES

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.

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

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.

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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.

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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.

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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.

© Copyright Weir Minerals Australia Ltd

   Mechanical and Non‐Pressurised  
  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. 
 

© Copyright Weir Minerals Australia Ltd 
   Mechanical and Non‐Pressurised  
  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. 

© Copyright Weir Minerals Australia Ltd 
Mechanical and Non-Pressurised
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

© Copyright Weir Minerals Australia Ltd

 Mechanical and Non-Pressurised
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

© Copyright Weir Minerals Australia Ltd

 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
 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.

6
MF - 420 EX
MF - 420 EX
WEIR Minerals Multiflo

Head Office Tel: +61 7 5449 3000

15 Dacmar Road Fax: +61 7 5446 4304
Coolum Beach E-mail: [email protected]
QLD 4573 [email protected]
Australia