WMM CF-48 IOM & Parts Manual, October 2010

Weir Minerals Multiflo
MULTIFLO MODEL CF-48H

DIESEL POWERED SKID
PUMP UNIT
INSTALLATION, OPERATION,
MAINTENANCE AND PARTS MANUAL
WITH ACCOMPANYING MANUALS
Copyright (C) 2010, Weir Minerals Australia Ltd trading as Weir Minerals Multiflo. All rights reserved.
MULTIFLO, VACTRONIC and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd.
This document contains information which is confidential to Weir Minerals Australia Ltd. It should not
be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir Minerals Australia Ltd authorized personnel.
June 2010
CF Pump Unit
Master Index
Index
List of Figure References
ISO Certifications:-
Quality Management System (QMS) AS/NZS ISO 9001:2008
Environmental Management System (EMS) AS/NZS ISO 14001:2004
Occupational Health & Safety System (OHS) AS/NZS 4801:2001
Introduction
O.E.M. Introduction
O.E.M Contact Details
General Safety
Shaft Lock Removal
Weir Minerals Australia General Conditions of Sale (April 2009)
Part 1 Installation and Commissioning

Part Page
Recommended Lubricants I
Performance Curve - Pump Model CF-48H I
Electrical Wiring Diagram for Standard CF-48H I
Section 1.1 Pump Unit Delivery I 1
Section 1.2 Safety Warnings I 1
1.2.1 Bare Shaft Pump Safety I 2
1.2.2 Vacuum Pump Safety I 2
Section 1.3 Unit Lifting Points (Total Unit Mass) I 3
Section 1.4 Installation & Removal Sequences I 4
1.4.1 Moving & Locating the Pump Unit I 4
1.4.2 Assembly of Pump and Skid (If Fitted) I 4
1
CF-48H Pump – Master Index
(Always quote Model and Serial Number of Unit when Ordering Parts)
CF Pump Unit
Part 2 Operation
Part Page
Section 2.1 Introduction II 1
2.1.1 General Information & Safety II 1
2.1.2 General Safety Recommendations II 2
Section 2.2 Normal Operating Procedures II 3
2.2.1 Daily Pre-Start Checks II 4
2.2.1.1 Engine Oil II 4
2.2.1.2 Vacuum Pump Oil II 4
2.2.1.3 Gland Oil Tank II 4
2.2.1.4 Coolant Level II 4
2.2.1.5 Fuel Tank II 4
2.2.1.6 Battery II 4
2.2.1.7 Drive Belts II 4
2.2.1.8 Water Trap II 4
2.2.1.9 Air Cleaner Indicator II 4
2.2.1.10 Suction Strainer II 4
2.2.2 Starting Procedures II 5
2.2.2.1 Start Up Procedure II 5
2.2.2.2 Operating Speed II 5
2.2.3 Shutdown Procedure II 5
2.2.4 Shutdown Protection II 6
2.2.4.1 Waterloss Shutdown System II 6
2.2.5 First Out Indication Panel II 7
2.2.6 Engine Monitoring System (EMS) II 7
Section 2.3 Electrical II 8
2.3.1 Unit Schematic Wiring Diagram II 8
2
CF Pump Unit
Part 3 Maintenance
Part Page
Section 3.1 Normal Maintenance Procedures III 1
3.1.1 Safety Procedures III 1
3.1.2 Maintenance – Vacuum Pump III 2
3.1.2.1 Vacuum Pump Piston & Re-Ringing Instructions III 2
3.1.2.2 Assembly of 3 Piece Oil Ring Assembly III 3
3.1.3 Maintenance – Bare Shaft Pump III 7
3.1.3.1 Gland III 7
3.1.3.2 Impeller III 9
3.1.3.3 Lubrication III 9
3.1.4 Maintenance – Drive Components III 11
3.1.4.1 Drive Belt Tensioning III 11
3.1.4.2 Installation & Operation of Link Belt Drives III 13
3.1.4.3 Drive Coupling III 16
3.1.5 Frequency of Routine General Maintenance III 17
3.1.5.1 Every 10 Engine Hours or Daily III 17
3.1.5.2 Every 250 Engine Hours III 18
Section 3.2 Troubleshooting III 20
3.2.1 Finding & Diagnostic Guide (Including Details of III 20
Normal Readings)
3.2.1.1 Pump Unit Troubleshooting III 20
3.2.1.2 Link Belt Troubleshooting III 24
3.2.1.3 Hydrau-Flo Valve Troubleshooting III 24
Section 3.3 Lubrication Schedule III 26
3.3.1 Grades/Recommended Lubricants & Frequency III 26
3
CF Pump Unit
Part 4 Spare Parts
Part Page
CF-48H Wetted Parts Assembly IV 1
CF-48H Bearing Housing Part A IV 2-3
CF-48H Bearing Housing Part B IV 4
CF-48H Bearing Housing Part C IV 5
CF-48H Gland Seal IV 6
CF-32M 43H 48H Vacuum Tank IV 7
CF Vacuum Tank Lid Components IV 8
CF-48H Vacuum Pump Assembly IV 9
Model 39 Vacuum Pump IV 10-14
CF Priming System IV 15
CF-28M 32M 43H 48H Drive Coupling IV 16
CF Fuel Filler IV 17
CF Fuel Gauge IV 18
CF-43H & CF-48H Fuel & Vacuum Tank Hoses IV 19
CF Strainers IV 20
CF-48H Canopy IV 21
CF Suction Hoses (Optional) IV 22
CF-43 & CF-48 Hydrau-Flo Kit (Optional) IV 23
Trailer Assembly (Optional) IV 24
Suction Assembly (Optional) IV 25
Pressure Gauge (Optional) IV 26
Work Light (Optional) IV 27
Part 5 List of Accompanying Manuals
WMM Gland Packed Bare Shaft Pump Manual V
4
CF Pump Unit
List of Figures
Figure
Ref No Description Part Page
Part 1 - Installation & Commissioning

1 Unit Lifting Points I 3
2 Installing Pump onto Skid Chassis I 5
Part 2 - Operation
3 “First Out” Indication Panel II 7
Part 3 - Maintenance
4 Vacuum Pump Winding on Piston Oil Ring Expander III 3
5 Vacuum Pump Upper & Lower Rail of Expander III 4
6 Vacuum Pump Upper & Lower Rail Gap III 4
7 Vacuum Pump Correct Fitment of Compression Rings III 5
8 Vacuum Pump Incorrect Fitment of Compression Rings III 5
9 Vacuum Pump Correct Expansion Method for Compression Rings III 6
10 Vacuum Pump Correct Ring Back Clearance III 6
11 Bare Shaft Pump - Packing Removal Tool III 8
12 Manual Greasing Guide for Bare Shaft Pump III 10
13 Belt Tensioning Indicator Operation III 11
14 Belt Tensioning Indicator III 12
15 Belt Alignment III 14
16 Drive Coupling III 16
17 Vacuum Gauge – High Reading III 20
18 Vacuum Gauge – Low Reading III 21
19 Vacuum Gauge – Normal Operating Range III 22
1
CF-48 Pump – List of Figures
ISO CERTIFICATIONS
Introduction
Introduction
The purpose of this Manual is to advise and instruct installers, operators and repairers of Weir Minerals
Multiflo Model Pump Units in the recommended installation, operation and maintenance of this equipment.
You have purchased a quality product which has been manufactured with utmost care and the finest
materials, reflecting many years of engineering knowledge and design.
The following information will aid you in the installation, operation and maintenance of your new Weir
Minerals Multiflo Model Pump Unit. To ensure long life and trouble-free operation, you should read and
understand these instructions and provide regular, periodic maintenance.
The Weir Minerals Multiflo Pump Unit is of a robust construction and is designed to be used as a mine
dewatering pump in accordance with the pump performance data contained in this manual. When they correctly
installed and operated, will give long, and trouble free service with a minimum amount of maintenance. To
achieve the consistent high performance which Multiflo pumps are designed for, it is imperative that the
instructions contained in these manuals are read, understood and carried out by all users of this product.
WEIR MINERALS MULTIFLO PUMPS

• EXCELLENCE THROUGH DESIGN
• EXCELLENCE THROUGH ENGINEERING
• EXCELLENCE THROUGH PERFORMANCE
Introduction
In Australia:-
In Queensland:- In Western Australia:- In New South Wales:-
Head Office Kimberley, Pilbara, Mid-West, Hunter Valley Authorised Service

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

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

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

Fax: 62 542 746099 62 511 4772357
Fax: 62 511 4773583
O.E.M. Contact Details

Safety
The Weir Minerals Multiflo Model pump unit is designed to be used as a mine dewatering pump in
accordance with the pump performance data contained in this manual.
It is the user’s responsibility to be aware of and comply with all federal and state occupational health and
safety requirements.
The Weir Minerals Multiflo pump unit has been designed to provide a safe working environment for
operators, maintenance personnel and others.
Improper operation, installation, maintenance or repair of this equipment could result in injury or death.
Do not operate or perform any operation, installation, maintenance or repair on this product, until you have
read and understood the operation, installation, maintenance and repair information contained in the
supplied documentation.
Personal Protective Equipment (PPE) must be used when installing, operating, servicing, maintaining and
repairing this equipment.
Safety warnings and precautions are provided in the supplied documentation.

Failure to heed these warnings and precautions may result in personal injury and/or death to yourself and/or
others. Failure to heed these warnings and precautions may also result in equipment and environmental
damage.
Safety Symbols
The accompanying documentation supplied with the Weir Minerals Multiflo pump unit utilizes the following
safety symbols to highlight potentially harmful situations to personnel and the environment.
SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES
Imminent risk of Fatal or crippling injuries

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

crippling injuries possible
Possibility
CAUTION ! Persons Minor or slight injuries
of a harmful
possible
situation
Possibility Property Damage possible to the

ATTENTION ! of a harmful and or the product or the Environment
situation Environment
Application
INFORMATION ! Hints and other Nil Nil
useful Information
Weir Minerals Multiflo – Safety & Safety Management Plan

Safety Management Plan for Installation Work

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

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

WARNING!
REMOVE SHAFT LOCKS

(IF FITTED)
FROM BARE SHAFT PUMP
AND/OR
ELECTRIC MOTOR BEFORE
START-UP
Shaft Lock Removal
WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802
GENERAL CONDITIONS OF SALE

1. APPLICATION 6.2 Any times quoted for delivery are to be treated as best estimates
Until such time as Weir Minerals Australia Ltd ABN 69 009 701 802 or a only, not involving any contractual obligation, unless Weir has
related company of Weir Minerals Australia Ltd which applies these General specifically agreed in writing to negate this Clause 6.2 and to give a
Conditions of Sale to its sales (“Weir”) notifies a customer (“Purchaser”) of contractually binding commitment that dispatch or delivery will be
replacement General Conditions of Sale, these General Conditions of Sale within a specified time or on or by a specified date.
shall form part of any contract for the sale of goods (“Goods”) or supply of
6.3 Any contractually binding commitment by Weir to deliver on or by a
services (“Services”) by Weir to Purchaser, except as varied by written
specific date is subject to the provisions of Clause 18.3 below and
agreement between Weir and Purchaser. Conditions or terms of contract
also subject to Weir not being delayed by instructions or lack of
submitted by Purchaser in or with a purchase order or request for quotation
instructions from the Purchaser. The times quoted shall be
or other document or communication do not form part of any contract with
increased by the duration of any event of force majeure and by the
Weir unless and to the extent agreed to by Weir in writing.
period or periods of any such delay and any consequences of the
2. QUOTATIONS delay.
A quotation by Weir may be withdrawn or varied at any time, prior to
6.4 Weir may make delivery of and invoice any order either as a whole
acceptance by Weir of an order, and ceases to have any effect after 30
or progressively and effect delivery at any time within the period
days from the date of the quotation unless extended in writing by Weir.
advised by it for delivery of the order. If the Purchaser requests
Prices quoted are subject to variation in accordance with clause 5.
Weir to delay delivery or fails to give Weir adequate delivery
3. ACCEPTANCE OF ORDERS instructions, Weir may invoice the Purchaser and store the goods at
Weir is not bound by any order from Purchaser until and unless Weir the Purchaser’s expense.
notifies Purchaser in writing of its acceptance of that order.
7. RISK & INSURANCE
4. TERMS OF PAYMENT Insurance cover is the responsibility of the Purchaser and all Goods will be
4.1 Unless other terms of payment are expressly provided for by Weir, at the Purchaser’s risk from the point of delivery as defined in Clause 6.
invoices are payable strictly net within 30 days from the invoice date Weir will not be responsible for any loss or damage occurring after the time
or the date on which Purchaser is notified that the Goods are ready of delivery or deemed delivery and will only arrange insurance upon written
for dispatch, whichever is the earlier. instructions from the Purchaser and at the cost of the Purchaser.
\
4.2 The due date for payment shall not be postponed on account of 8. AMENDMENT AND CANCELLATION
damage, non delivery or additions, alterations, minor omissions or The Purchaser shall not, after acceptance of order, cancel or amend it in
defects to, from or in the Goods which do not substantially affect the any way without the written approval of Weir. Weir may, on consenting to
commercial use of the Goods. Payments must be made without an amendment, revise its price and delivery schedule and amend the terms
setoffs, counter-claim or deduction. and conditions to reflect such change. In the event of an amendment or
cancellation, the Purchaser shall reimburse Weir for all costs and expenses
5. PRICES & TAXES
already incurred by Weir or for which Weir has or will become liable, and for
5.1 GST All prices quoted are exclusive of GST. In addition to the
any additional costs and expenses resulting from the amendment or
payment of the prices quoted, Purchaser must pay to Weir an
cancellation.
amount equal to any GST imposed on Taxable Supplies made by
Weir to the Purchaser. Weir must give the Purchaser a Tax Invoice The specification by Weir of any particular personnel, in any quotation or
in respect of each such Taxable Supply. “Taxable Supply”, “GST” tender, is subject to availability of those personnel and Weir reserves the
and “Tax Invoice” have the same meanings as in the A New Tax right to substitute any nominated personnel at any time.
System (Goods and Services Tax) Act 1999. If the Purchaser
9. DEFAULT
intends to export the Goods, so that Weir will be exempt from GST
If the Purchaser makes default in payment or fails to carry out any part of
in respect of its supply of the Goods, it must provide Weir with
any contract of which these General Conditions of Sale form part or shall
copies of the shipping documents, and such other documentation as
become bankrupt or commit any act of bankruptcy or compound with its
Weir may reasonably require, within 60 days after the date of Weir’s
creditors or have judgment entered against it in any court or, being a
invoice, otherwise an amount equal to the GST will be payable by
company, have a provisional liquidator, receiver or manager appointed or
the Purchaser to Weir.
enter into any other form of insolvency administration, Weir may at its option
5.2 Unless otherwise specified in writing by Weir, all prices quoted are and without prejudice to any of its rights and remedies under the contract,
ex works (the location specified by Weir in its tender or quotation), suspend or terminate the contract or require payment in cash before or on
unpacked, and all costs of freight and delivery from Weir works, and delivery notwithstanding any other terms of payment specified in the
packing, will be to the Purchaser’s account. contract. If Weir terminates the contract pursuant to this clause, all amounts
payable for work performed up to the date of termination, whether or not
5.3 Where Goods or raw materials or components for Goods are to be
otherwise then due for payment, will become immediately due and payable.
imported:
Weir will not be liable to the Purchaser for any loss or damage the
(a) the quoted prices for those Goods are based on the foreign
Purchaser suffers because Weir has exercised its rights under this clause.
currency rate of exchange disclosed in Weir’s quotation and if
no rate of exchange is disclosed, are based on the 10. RETURN OF GOODS
Commonwealth Bank of Australia Foreign Exchange Rates, Weir may, at its absolute discretion, agree to accept the return of any of
published on the date of the quotation. Goods which have not been made or purchased specifically for the
Purchaser and credit the Purchaser with the invoice value of the Goods
(b) unless otherwise specified in writing by Weir, the quoted prices
provided the Goods is returned in “as purchased” condition and the prior
shall be adjusted upwards or downwards as the case may be
written approval of Weir has been obtained by the Purchaser for the return
to reflect the difference between the base rate of exchange
of the Goods. Weir reserves the right to charge a restocking fee for the
referred to in (a) and the actual rate of exchange prevailing on
return of Goods to stock.
the day Weir remits the foreign currency amount for the Goods
or raw materials or components, or if Weir hedges the order for 11. WARRANTIES
the Goods or raw materials or components, the rate hedged by 11.1 New Goods If within a period of 12 months from the date of delivery
Weir and advised to the Purchaser in writing prior to Weir’s (or in the case of diesel-operated pumps, within the first 1,000 hours
remitting the foreign exchange currency amount. of operation, whichever first expires) (“warranty period”) any new
Goods sold by Weir (other than purchased equipment as referred to
5.4 Any increases in the rate of GST, any increases in customs duty on
in Clause 11.4) are found to be defective in materials or
imported Goods or raw materials or components for Goods (whether
workmanship, or do not conform to any applicable drawings and
because of a change in the Customs Tariff Classification and/or
specifications approved in writing by Weir, or (in the case of Goods
rate), and any new carbon trading or emissions trading or other
which are Weir-manufactured pumps) do not perform in accordance
levies, imposts, duties or taxes, applicable to or impacting on the
with the current applicable water performance curves supplied as
cost to Weir of the Goods or Services, between the date of Weir’s
part of the Weir quotation or published by Weir as at the date of the
tender or quotation and the date of invoice, will be to Purchaser’s
quotation (within the tolerances specified in applicable Australian
account, and will be payable by Purchaser within 30 days from the
Standards), then Weir will, at its option, either repair or provide
date of Weir’s invoice.
replacement parts or Goods provided that:
6. DELIVERY & STORAGE (a) the Purchaser has given written notice to Weir of any alleged
6.1 Delivery shall be deemed to occur when the Purchaser is informed defect within the warranty period;
by Weir that the Goods are ready for collection at Weir’s works. (b) the Purchaser has provided Weir a reasonable opportunity to
perform all appropriate tests on the Goods;
April 2009 Page 1 of 3
ABN 69 009 701 802

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

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

Recommended Maximum
Item Lubricant Frequency Capacity
Engine Oil Mobil Delvac MX 15W40

Checked Daily See Below
Shell Rimula 15W40
Mobil Delvac MX 15W40

Vacuum Pump Oil Checked Daily See Below
SAE15W40
Refer Pump
Greasing
Bare Shaft Pump Multiflo Pump Grease
Table
Bearing Assembly Shell Alvania RL2 Grease Checked Daily
(Maintenance
SKF LGMT2
Manual,
Page 10)
Multiflo Pump Grease

Gland Packing Shell Alvania RL2 Grease Before Startup 1 Shot
SKF LGMT2
Vacuum Pump Capacity

CF-48H – CF-43H 1.5 Litres
CF-32M – CF-28M – CF-22L 1 Litres
Engine Capacity
C2.2 (NA) (CF22) 10.6 Litres
3054NA (CF28) 11 Litres
C4.4 ACERT (CF32) 11 Litres
C7 ACERT (CF43) 28 Litres
Recommended Lubricants – CF Pump Unit
PART 1
INSTALLATION
1.1 Pump Unit Delivery
Each order or shipment is double checked before leaving the factory. All parts,
pieces and components are listed item by item on our packing list, which
accompanies each order. The number and description of each item, package,
container, skid, etc., is listed on the bill of lading. IN SIGNING THE BILL OF
LADING, THE CARRIER ASSUMES FULL RESPONSIBILITY FOR SAFE
DELIVERY OF ALL GOODS TO DESTINATION. In the event of damage or
shortage, have the transportation company note the same on the freight bill.
You will find a packing list attached to one of the items in the shipment. Check each
item against the list. Check by description, specification, quantity, count, etc. Should
there be any discrepancies, notify Multiflo immediately. Small parts and items such
as bolts, washers, bushings and keys are just as important to an installation as the
larger parts. Make sure these are located and checked before disposing of any
containers or packing. We cannot be responsible for loss of items that are listed and
included on our packing list.
1.2 Warnings
(Regarding Installation & Pre-
Operational Procedures)
Pump unit to be locked and tagged before
DANGER ! any maintenance or service is performed.
Weir Minerals Multiflo CF-48 Pump Unit – Installation Manual 1

1.2.1 Bare Shaft Pump Safety
It must be checked that the intake and

WARNING ! discharge openings are totally isolated from
all potentially pressurized connections and
that they are and can only be exposed to
atmospheric pressure.
The following instructions relate to the

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

Prior to initial operation the vacuum pump oil level must be
checked before operating the vacuum pump. Running the
vacuum pump without oil will cause damage.
If installing the vacuum pump, the direction of rotation should

be checked.

1.3 Unit Lifting Points

WARNING! any maintenance or service is performed.
Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.
FIGURE 1
PUMP UNIT LIFTING
Total Unit Mass: 3,457kgs (Dry). POINT

1.4 Installation & Removal Sequences

1.4.1 Moving and Locating the Pump Unit
Pump unit to be moved by experienced
WARNING ! personnel only.

Pump unit moving and locating

instructions are intended as a guide only.
INFORMATION ! Site preparation and positioning to be
undertaken with regard to site conditions
and procedures.
Due to its lightweight design the CF pump can not be towed and must only be lifted
from its central lift eye in a vertical lift.
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 Assembly of Pump and Skid (If Fitted)

Lifting of the pump unit should be

WARNING! undertaken by experienced personnel only.
Refer to site procedures for lifting,
personnel and equipment requirements.
Do not stand under suspended load.

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

1. Using suitable lifting equipment, lift pump base over high lift skid.
2. Make sure the skid is clean of all rocks and debris.
3. When pump base is suspended over skid, gently lower base into skid.
4. Make sure the pump is sitting flat in the skid.
5. When base is sitting on skid frame, fit the bolts and tighten them.
Do not attempt to insert bolts until pump

WARNING! base is sitting on skid frame and is not
suspended by lifting equipment.
FIGURE 2
INSTALLING PUMP ONTO
SKID CHASSIS

PART 2
Operation
PART 2
OPERATION
2.1 Introduction
2.1.1 General Information (& Safety)
It is the user’s responsibility to be aware of and comply with all federal
and state occupational health and safety requirements.
The Weir Minerals Multiflo CF Pump Unit has been designed to provide a
safe working environment for operators, maintenance personnel and
others.
Improper operation, installation, maintenance or repair of this equipment

could result in injury or death.
Do not operate or perform any operation, installation, maintenance or

repair on this product, until you have read and understood the operation,
installation, maintenance and repair information contained in the
supplied documentation.
Personal Protective Equipment (PPE) must be used when installing,

operating, servicing, maintaining and repairing this equipment.
SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THE

SUPPLIED DOCUMENTATION. FAILURE TO HEED THESE WARNINGS
AND PRECAUTIONS MAY RESULT IN PERSONAL INJURY AND/OR
DEATH TO YOURSELF AND/OR OTHERS. FAILURE TO HEED THESE
WARNINGS MAY ALSO RESULT IN EQUIPMENT AND ENVIRONMENTAL
DAMAGE.
Weir Minerals Multiflo CF-48 Pump Unit – Operation Manual 1

2.1.2 General Safety Recommendations

The accompanying documentation supplied with the Weir Minerals
Multiflo CF utilises the following safety symbols to highlight potentially
harmful situations to personnel and the environment.
SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES
DANGER ! Imminent risk of Persons Fatal or crippling

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

crippling injuries injuries possible
CAUTION ! Possibility Persons Minor or slight

of a harmful injuries possible
situation
ATTENTION ! Possibility Property Damage possible

of a harmful and or the to the product or
situation Environment the Environment
INFORMATION ! Application Nil Nil

Hints and other
useful
Information

2.2 Normal Operating Procedures

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

Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.

2.2.1 Daily Pre-Start Checks

2.2.1.1 Engine Oil

Maintain oil level between ‘add’ and ‘full’ marks on the dipstick.
2.2.1.2 Vacuum Pump Oil

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

Fill to 10mm below the filler pipe opening.
2.2.1.4 Coolant Level

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

Fill as required. Use dipstick.
2.2.1.6 Battery
Maintain level in range above plates and filler bridge.
2.2.1.7 Drive Belts (Fan / Generator / Vacuum Pump)

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

Drain and clean the bowl.
2.2.1.9 Air Cleaner Indicator (If Fitted)

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

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

2.2.2 Starting Procedures
Pump unit to be operated by experienced

WARNING ! personnel only.
2.2.2.1 Start Up Procedure
1. Turn Battery Isolator switch to the ON position.

2. Turn START/STOP switch to start engine, allow engine to idle.
3. Wait for the pump to prime.
4. When primed set operating speed (as described below).
5. Check for oil or water leaks etc, around the engine.
6. Check that water is flowing from the discharge pipe.
2.2.2.2 Operating Speed
(To Set the Operating Speed)
1. Increase the engine RPM until the pump starts to cavitate. The pump
will vibrate and a crackling sound will be heard at the pump volute.
2. Decrease the RPM slowly until the pump stops cavitating completely.
The vibration and crackling sound will go away.
This is the correct engine operating speed for this application.
2.2.3 To Shutdown
1. Decrease engine RPM slowly to idle.
2. Stop engine with start/stop switch.
3. Drain pump volute (if pumping slurry).
4. Use emergency stop only if necessary.

2.2.4 Shutdown Protection

2.2.4.1 Waterloss Shutdown System
One of the safety features provided to protect the Multiflo pump during
operations is a “water loss” wet end shutdown system. A probe situated in the
discharge pipework detects the rate of flow from the pump. Once the rate of
flow becomes too low to keep the switch activated the pump will begin the
shutdown timer. If this water loss situation remains for six minutes, the engine
will be automatically shut down. This is designed to minimize unnecessary
operation of seals (gland) and bearings.
When or if there is sufficient water available within the six minute period, the
shutdown system automatically resets.

2.2.5 First Out Indication Panel

THIS SECTION FOR MODELS CF-22 AND CF-28 ONLY
The “First Out” Indication panel has been specifically designed to allow for
simple pump unit shutdown diagnosis. This panel will allow the unit operator
to determine what has caused the unit to shutdown at a glance.
The power light on the left of the panel indicates when the unit is running.
When the unit stops for any reason a light corresponding to a specific fault
(indicated down the right side of the panel) will then illuminate indicating to the
operator what has caused the unit to cease functioning.
The fault light will allow maintenance personnel to rectify the problem in the
system indicated by the light.
The light corresponding to the fault will remain on until the unit ignition is re-
set.
FIGURE 3
“FIRST OUT”
INDICATION PANEL
2.2.6 Engine Monitoring System (EMS)

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

2.3 Electrical
2.3.1 Unit Schematic Wiring Diagram

WARNING ! any maintenance or service is performed.
Pump unit power supply to be isolated

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

Refer to the data in the Accompanying

Manuals Section (Information as supplied
INFORMATION ! by Caterpillar - Engine Monitoring
System) for the Schematic Wiring
Diagram.
For more information regarding unit

INFORMATION ! schematic wiring diagram, please refer to
a drawing provided at the beginning of
the Installation Section.
2.3.2 Work Light Timer (If Fitted)

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, provided the
battery isolator is set to the on position.

PART 3
Maintenance
PART 3
MAINTENANCE
3.1 Normal Maintenance Procedures
3.1.1 Safety Procedures


Observe for unusual gauge leaks and

general condition of the unit. If condition
INFORMATION ! exists, determine the cause and have
necessary repairs made.
Multiflo Model CF-48 Pump Unit – Maintenance Manual 1

3.1.2 Maintenance - Vacuum Pump


Heavy Components – appropriate lifting

WARNING ! techniques to be used.
Oil level must be checked before

INFORMATION ! operating the vacuum pump. Running
the vacuum pump without oil will cause
damage.
3.1.2.1 Vacuum Pump Piston & Re-Ringing Instructions
It is advisable that the ridge be removed from the top of worn cylinders prior to
removing the piston. Failure to do so may result in cracked or broken piston
ring lands.
The ring sets are designed to bed in on both new bores and worn bores.
Honing is not essential but it is recommended to give the optimum result.
However, it is essential if one of the following conditions are present:-
Excessive wear.
Bore distortion.
Polishing or Glazing.
Scuffing.
Scratching.
When boring to oversize, allow sufficient honing allowance to completely

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

result.

Poor cleaning after honing accounts for most of today’s wear out / oil
consumption problems. Petrol and kerosene are not suitable. Soap and hot
water with a nylon scrubbing brush are best. Check with a clean white cloth
which should not come out grey. Finally, swab with a light engine oil to
prevent corrosion.
Always replace scuffed, cracked, worn or otherwise damaged pistons.
Always check the gap clearance of new rings in the lower unworn portion.
The gap should not be less that 0.003mm per mm of cylinder diameter.
Maximum gap condition is not especially

INFORMATION ! critical but should not exceed 0.01mm
per mm for compression rings while gap
on oil ring rails may be up to 1.75mm
regardless of bore size.
Ensure piston rings and pin are thoroughly clean and then lubricate rings,
skirt, pin bores and bearings with engine oil. Use a good quality ring
compressor held firm against the engine block at the time of entry of the rings
into the cylinder.
3.1.2.2 Assembly of a 3 Piece Oil Ring Assembly
• Wind on expander.
FIGURE 4
WINDING ON PISTON OIL
RING EXPANDER
• Hold the expander end in place with thumb. Wind on lower rail then wind
on upper rail.

FIGURE 5
UPPER & LOWER RAIL
OF EXPANDER
• Both ends of the expander should be visible and not over lapped.
FIGURE 6
UPPER
&
LOWER
RAIL GAP
• Align all gaps as per the diagram above (gaps must not be lined up).
Check the assembly can rotate in the groove.

• When fitting the compression rings, make sure they are fitted the correct
way up as per the diagram below.
FIGURE 7
CORRECT FITMENT OF
COMPRESSION RINGS
• To avoid breakage, do not wind on the compression rings.
X FIGURE 8
INCORRECT FITMENT OF
COMPRESSION RINGS

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

FIGURE 9
CORRECT EXPANSION
METHOD FOR
COMPRESSION RINGS
• All rings must have clearance between the back of the ring and the back
of the groove. To check this, push the rings against the bottom of the
groove on the thrust side of the piston, then place a straight edge against
the skirt of the piston. The minimum clearance between rings and edge
should be 0.3mm for compression rings and 0.15mm fir oil rings.
FIGURE 10
CORRECT RING
BACK CLEARANCE
Correct running in of rings is essential, especially on un-honed bores. Firstly,

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

3.1.3 Maintenance – Bare Shaft Pump

These pump units are of robust construction and when correctly installed and
operated, will give long trouble free service with a minimum amount of
maintenance. There are only four areas of maintenance for the bare shaft
pump and these are:
Gland.
Impeller.
Lubrication.
Bolts.
3.1.3.1 Gland
The CF Gland system requires a shot of grease into the stuffing box before
each startup 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 over heating of the gland area
and short life of the sealing components.
The pumps will require repacking when the gland follower is tight against the
stuffing box. It is imperative that all packing rings are replaced when
repacking. Replacement of only the first few sets of packing will lead to
premature wear of the shaft and priming difficulties.
Each ring of packing should be inserted separately and pushed in place into
the stuffing box. The split opening of the successive packing rings are to be
positioned at 180° intervals. A slight leak is des irable from the newly packed
gland to allow the packing time to bed in. Excessive tightening at this period
will result in burning of the packing and scoring of the shaft.

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.
FIGURE 11
PACKING REMOVAL TOOL
Gland Packing Installation:

New packing rings must be installed one at a time by placing rings on the shaft and
pressing each ring all the way into the stuffing box, ensuring the ends are fitted neatly
together. Successive ring joints must be staggered around stuffing box. Pump
models with Lantern rings should have the lantern ring re-installed. Check with the
pump manual for correct positioning between the gland packing rings.
Fit gland follower to shaft and nip gland nuts up to pack gland packing. Ensure front
face of gland follower has entered the stuffing box housing. If after tightening the
gland nuts the packing has compressed enough to allow space for another ring,
remove gland follower, fit extra packing ring, re-assemble follower and nip gland nuts
up again. Back nuts off and leave finger tight until pump is started.
After pump has been started, the glands must be adjusted to provide reasonable
leakage. When water pressure is at a minimum the gland should leak slightly,
therefore when this pressure rises, leakage will necessarily be excessive. If the
gland is adjusted to provide optimum leakage at higher pump rpm (high pressure),
insufficient leakage will occur when the rpm falls or is less from the point of
adjustment.

The gland sealing water should be as clean as possible, as large amounts of

abrasive material can quickly wear the gland components. Always maintain a very
small amount of water leakage along the shaft by regularly adjusting the gland.
As well as lubricating and cooling the gland, the water escaping from the gland also
prevents the ingress of air when the pressure at the shaft falls below atmospheric.
E.g. when a vacuum is required.
If one of the following conditions apply, air may be induced into the pump through the
gland. This may prevent the pump “picking up” its prime or cause it to loose its prime
during operation.
Packing has insufficient tension.
Packing is excessively worn.
Shaft sleeve is excessively worn.
Inspection of the gland will reveal if any of the above faults are occurring.
3.1.3.2 Impeller
The performance of the pump can change with excessive clearance between the
impeller and the front wear plate/door. For best performance it may be necessary to
occasionally stop the pump and move the impeller forward. This adjustment can be
carried our in a few minutes without any dismantling.
3.1.3.3 Lubrication
A correctly assembled and pre-greased bearing assembly will have a long trouble
free life, provided it is protected against ingress of water or other foreign matter and
that it is adequately maintained. The bearing assembly should be opened at regular
intervals (no longer than 12 months) to inspect the bearing and grease.
The shots are from a standard hand operated grease gun (approximately 1cc). The
grease used for both bearings and labyrinths should be a lithium complex soap
thickener grease with EP additives and oxidant inhibitors. If the bearing assemblies
run at above 85°C, then a high temperature grease s hould be used.

IMPELLER END
DRIVE END
FIGURE 12
MANUAL GREASING
GUIDE FOR BARE
SHAFT PUMP
RECOMMENDED GREASE FOR PEDESTAL

TYPICAL PROPERTIES
Lithium base (not containing Molybdenum or EP additives).
Base oil Viscosity of 75 cST to 120 cST @ 40 degrees Celcius.
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.
CF-48H / CF-43H CF-32M / CF-28M CF-22L
IMPELLER END 1 SHOT / 24 HRS 1 SHOT / 200 HRS 2 SHOTS / 24 HOURS
DRIVE END 1 SHOT / 24 HRS 1 SHOT / 200 HRS 2 SHOTS / 24 HOURS

3.1.4 Maintenance - Drive Components

3.1.4.1 Drive Belt Tensioning


Put the belts around the pulleys, set them to the appropriate tension value
stated in the "Tensioning Forces" Table (using the Belt Tension Indicator as
shown), run the drive under load for 30 minutes, stop the drive, check the
tension, re-setting to catalogue value if necessary. On a properly designed
drive for the application there will be no need for any further attention during
the life of the drive.
Belt Tension Indicator applied to mid span
FIGURE 13
BELT TENSIONING
INDICATOR OPERATION

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

metre (yard) of span. Centre Distance (m) x 16 = Deflection (mm).
2. Set the lower marker ring at the deflection distance required in mm on the
lower scale.
3. Set the upper marker ring against the bottom edge of the top tube. Place
the belt tension indicator on top of the belt at the centre of span, and apply
a force at right angles to the belt deflecting it to the point where the lower
marker ring is level with the top of the adjacent belt.
For single belt drives a straight edge

INFORMATION ! should be placed across the two pulleys
to act as a datum for measuring the
amount of deflection. If the measured
force falls within the values given, the
drive should be satisfactory. A measured
force below the lower value indicates
under-tensioning. A new drive should be
tensioned to the higher value to allow for
the normal drop in tension during the
running-in period. After the drive has
been running for 30 minutes, the tension
should be checked and re-adjusted to the
higher value, if necessary.
4. Read off the force value indicated by the top edge of the upper marker ring.
5. Compare this force to the kgf value shown in the attached table.
6. If a Fenner Belt Tension Indicator is not available, a spring balance and rule
will suffice.
FIGURE 14
BELT TENSIONING
INDICATOR

Belt Tensioning Forces


Force required to deflect belt 16mm per metre of span

BELT SECTION Small Pulley Newton (N) Kilogram Force (kgf)
Diameter (mm)
SPA 125 10 to 15 1.0 to 1.5
3.1.4.2 Installation & Operation of Link Belt Drives


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.

Alignment

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

flank wear. The diagram below shows some of the common alignment faults.
You should only be satisfied if the conditions in sketch 4 prevail.
A. B. C. D.
Figure A. Figure B. Figure C. Figure D.
Shafts are not Shafts are not Shafts are Correct

parallel to one in correct parallel and in installation both
another. alignment alignment but shafts and
although they pulleys are not pulleys are
appear parallel in alignment. parallel and in
when seen from alignment.
above.
FIGURE 15
BELT ALIGNMENT

Belts


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

3.1.4.3 Drive Coupling
The CF range is fitted with a Torsionally soft disc type coupling. This allows
quick and easy set up of the pump and eliminates the possibility of pump
misalignment.

3.1.5 Frequency of Routine General

Maintenance


3.1.5.1 Every 10 Engine Hours or Daily
EVERY 10 ENGINE HOURS OR DAILY

SCHEDULE MAINTENANCE
Engine Oil Maintain oil level between “add” and “full” marks on the
dipstick. Use SAE15W40 or refer to Lube List.
(Refer also to the Engine Manual)
Vacuum Pump Oil Maintain level between “high” and “low” marks on the
dipstick. Use SAE15W40 or refer to Lube List.
Gland Oil Tank Fill to 10mm (3/8”) below filler pipe opening.
(If Fitted) Use SAE15W40 or refer to Lube List.
Gland Packed BSP / Inspect and adjust Gland if necessary.
Mechanical Seal 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 and

INFORMATION ! general condition of the unit. If condition
exists, determine the cause and have
necessary repairs made.
3.1.5.2 Every 250 Engine Hours
EVERY 250 ENGINE HOURS

Perform in addition to Daily Schedule Items
Engine Oil & Filters Change the oil and filters.
(Refer to Engine Manual)
Engine Fuel Filters Change Filters.
(Refer to Engine Manual)
Vacuum Pump Change the Oil.
Use SAE15W40 or refer to Lube List.
Non Return Valve Inspect condition. Repair if necessary.
Drive Coupling Inspect condition.

Re-tension bolts and grub screws if required.
Engine Air Cleaner Inspect condition. Replace if necessary.

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

Perform in addition to 250 Hours Service Items
Bare Shaft Pump Condition/Adjustment.
Inspection of impeller, wear plate(s), volute, and packing.
Radiator 1. Clean core finning.

2. Inspect condition of radiator hoses.
Auto Shutdown System 1. Test shutdown operation.

2. Inspect condition of wiring, hoses etc.
(Refer to Caterpillar Manual)
Non Return Valve Replace Flap if Required.


Perform in addition to 1000 Hour Service Items
Bare Shaft Pump Check condition of Bare Shaft Pump Bearings for moisture
inclusion.
Engine Check operation and performance.
Non Return Valve Replace Valve Seat if required.

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


The engine must not be run when

ATTENTION ! disconnected from the battery!!
Doing so may damage the Vactronic Module
Failure to Prime
Check Vacuum Gauge Reading.
FIGURE 17
VACUUM GAUGE –
HIGH READING

SYMPTOM CAUSE REMEDY
1. Static suction lift too high. Lower suction lift.

Obstruction in suction hose Remove obstruction from
High Vacuum Gauge or strainer. hose and/or strainer.
Reading Suction hose kinked or Unkink suction hose.
collapsed.
(-80 and above) Suction hose collapsed Replace suction hose.
internally.
Suction hose stuck low into Remove suction hose from
the mud. mud.
2.
Low or No Reading Air leak in the suction line. Repair suction line.
Discharge reflux valve not Replace seal.
(-20 and below) sealing.
Air leak in vacuum line from Repair vacuum line.
If Vacuum Pump is tank.
Operating with Air Leaking gland packing. Adjust gland packing.
Being Exhausted
FIGURE 18
VACUUM GAUGE –
LOW READING

3.
If Vacuum Pump is Non-return valve sticking. Clean or replace valve ball.

Operating with no
Air Being Exhausted Vacuum pump faulty. Check and seal.
Repair vacuum pump.
If the pump fails to prime after all the above conditions have been checked,
remove the suction hose from the vacuum tank inlet and the delivery hose
from the pump discharge. Seal the vacuum tank inlet and the pump
discharge. Start the engine and check the vacuum gauge reading. The
reading should be within 80 KPA to 100 KPA.
A low reading indicates:

1. An air leak in the vacuum tank.
2. An air leak in the bare shaft pump.
3. Leaking gland packing.
4. Faulty vacuum pump.
Normal Operating Range
FIGURE 19
VACUUM GAUGE
NORMAL OPERATING
RANGE

Faulty Vacuum Pump

1. Blocked exhaust pipe.
2. Broken belts.
Pump Primes But Fails to Deliver Water or Delivers at a Reduced Rate

1. Foreign materials lodged in the impeller.
2. Low bare shaft pump RPM (1800 RPM maximum).
3. Obstruction in discharge hose.
4. Partial obstruction in suction hose, strainer or vacuum tank.
5. Obstruction in non-return valve.
6. Air leak in suction system.
7. Worn pump components.
8. Collapsed suction hose.
9. Pump located too high above water being pumped.
Pump Overloads Engine

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

3.2.1.2 Link Belt Troubleshooting


Symptom Remedy
Small cracks on Belt Generally caused by shortage of belt tension
side and base but excessive heat and/or chemical fumes can
also give same failure.
Belt swelling or Caused by excessive contamination by oil,

softening certain cutting fluids or rubber solvent.
Whipping during Usually caused by incorrect tensioning,

running principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires re-
design or a Banded belt.
3.2.1.3 Hydrau-Flo Valve Troubleshooting (if fitted)
Pump unit fuel system may contain diesel

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



Symptom Cause Remedy

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

tank.
Restriction in capillary line. Check line for damage,

kinks, or crushing.
Replace if necessary.
Fuel nozzle not Float valve not closing Check operation of float
shutting off capillary line. ensuring it does not hit
internal walls of fuel tank.
Check valve seat for
damage or obstruction.
Piston stuck open. Check piston operation is
smooth and unrestricted.
Leakage in capillary line. Check line and fittings for
leaks or damage.
Float lever set above Lower float lever below

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

3.3 Lubrication Schedule

3.3.1 Grades & Frequency of Lubrication
Engine, bare shaft pump and transmission
DANGER ! parts and all fluids may be at extremely high


Grades and Frequency of Lubrication

Recommended Maximum
Item Lubricant Frequency Capacity
Engine Oil Mobil Delvac MX 15W40

Checked Daily See Below
Shell Rimula 15W40
Mobil Delvac MX 15W40

Vacuum Pump Oil Checked Daily See Below
SAE15W40
Refer Pump
Greasing
Bare Shaft Pump Multiflo Pump Grease Table
Bearing Assembly Shell Alvania RL2 Grease Checked Daily (Maintenance
SKF LGMT2 manual,
page 10)
Multiflo Pump Grease

Gland Packing Shell Alvania RL2 Grease Before Startup 1 Shot
SKF LGMT2

Vacuum Pump Capacity

CF-48H – CF-43H 1.5 Litres
CF-32M – CF-28M – CF-22L 1 Litres
Engine Capacity
C2.2 (NA) (CF22) 10.6 Litres
3054NA (CF28) 11 Litres
C4.4 ACERT (CF32) 11 Litres

PART 4
Spare Parts
1
2
6
5
CF-48H WETTED PARTS ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY
1 VOLUTE 380-67 1
2 BOLT BLTC20050 8
3 IMPELLER 380-69 1
4 WEAR PLATE 380-72 1
5 O'RING 380-73 * 1
6 SHIM (.5MM) 380-55 * A/R
SHIM (1MM) 380-56 * A/R
7 SUCTION COVER PLATE 380-70 1
8 O'RING 380-74 * 1
CF-48 PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS 1
2
IMPELLER END
1 8 9
5 4
10
6
4
4
7
4 3
5
1
DRIVE END 10
2
CF-48H BEARING HOUSING PART A
1 BOLTS BLTC16042 12
2 LOCKING PLATE 6A-20 * 6
3 GREASE RETAINER BH0048Z0002 2
4 SET SCREW FA0306Z1006 4
5 O-RING 6A-06 * 2
6 BEARING 6A-13 1
7 BEARING 6A-10A 2
8 DEFLECTOR (C/W O-RING - 6A-17) * 6A-16 1
9 CAP, BEARING HOUSING (IMPELLER END) 6A-14A 1
10 GREASE NIPPLE 5AA-07 3
IMPELLER END
3 2
4
DRIVE END
CF-48H BEARING HOUSING PART A (CONTINUED)
1 SEAL 6A-15 * 1
2 CAP, BEARING HOUSING (DRIVE END) 6A-04A 1
3 LOCK NUT 6A-08 * 1
4 GASKET 6A-21 * 2
5 SEAL 6A-05 * 1
CF-48H BEARING HOUSING PART B

1 SHAFT CF0048Z0003 1
2 KEY CF0048Z0004 1
3 BEARING HOUSING BH0048Z0001 1
2 1
CF-48H BEARING HOUSE PART C

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
6 VACUUM PUMP AND AIR CLEANER MOUNT BOLTS BLTM10030G4.6 4
COMPLETE BARE SHAFT PUMP BS0048Z0001
10
6
8
11 3
2 9
7
5
2 4
1
CF-48H GLAND SEAL

1 STUFFING BOX 6A-30 1
2 PACKING KIT CF0048Z0002 * 1
3 RING, LANTERN 6A-36 1
4 GLAND FOLLOWER 6A-32 1
5 STUD 6A-34ST 2
6 BOLT 6A-32B 2
7 NUT 6A-32N 2
8 O-RING 6A-29 * 2
9 SLEEVE, WEARING, SHAFT CF0048Z0001 1
10 BOLT BLTC20050 4
11 O-RING 6A-31 * 1
GASKET AND SEAL KIT 100468 A/R
* DENOTES PARTS INCLUDED IN GASKET KIT
CF-32M 43H 48H VACUUM TANK

1 BALL FLOAT LID CF0000A0002 1
2 VACUUM TANK 200 (MILD STEEL) CF0200Z0001 A/R
OPTIONAL - VACUUM TANK 200 (STAINLESS STEEL) CF0200Z0001-U A/R
1 3
5 2
5
6 9
6
7
7 4
7
12
12
4 7
10 8
12
12
11
CF VACUUM TANK LID COMPONENTS

1 TOP LID (BARE) CF0000Z0001 1
2 LID GASKET CF0000Z0002 1
3 LID BOLT BLTMSS10025 8
4 WASHER BLTW10SS6 10
5 VALVE INSERT CF0000Z0007 2
6 VALVE CF0000Z0003 2
7 HALF NUT FA0110Z1000 4
8 ROCKER ARM CF0000Z0006 1
9 ROCKER ARM PIVOT BOLT BLTM10080SS6 1
10 ROCKER ARM BUSH CF0000Z0005 1
11 FLOAT BALL CF0000Z0004 1
12 NYLOC NUT BLTMNN10SS6 4
COMPLETE LID VALVE ASSEMBLY CF0000A0002
8 1
2
4
5
CF-48H VACUUM PUMP ASSEMBLY

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 VBPTA01 5.7MT
6 STUD BLTMTR10-0125 4
7 WASHER BLTW10G 16
8 NUT BLTMN10G 16
9 COMPLETE VACUUM PUMP VP0039Z0001 1
4
1
5
14
13
6 7
12
7
11
8 9
10
MODEL 39 VACUUM PUMP

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
2
3 12
10
11 13
3
4 14
6
7
MODEL 39 VACUUM PUMP (CONTINUED)

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
1
2
5
3
4
6
5
7
10

1 PISTON RING 100014 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
2
2
4
5

1 PIPE 100061 1
2 BOLT BLTM08030 6
3 CAP NUT 100031 2
4 PUSH BOLT 100030 2
5 GASKET 100029 2
6 COVER, EXHAUST 100028 2
7 GASKET 100027 2
8 PUSH CAGE 100026 2
9 VALVE 100025 2
1 1

1 GASKET 100024 4
2 VALVE 100033 2
3 O-RING 100034 2
4 TRIANGLE INLET 100035 2
5 UNLOADER PISTON 100036 2
6 INLET COVER 100037 2
3
4 2
CF PRIMING SYSTEM
1 WATER TRAP 200-0345 1
2 HYDRAULIC FITTING HFS27-1212 1
6 HOSE HO0048Z0003 1
7 GAUGE 200-0365 1
CF-28M 32M 43H 48H DRIVE COUPLING

1 DRIVE COUPLING SUIT CF-28M / CF-32M DC0032Z0001 1
DRIVE COUPLING SUIT CF-43H / CF-48H DC0048Z0001 1
CF FUEL FILLER
1 DUST COVER KL50-DC 1
2 CAMLOCK KL50-A 1
CF FUEL GAUGE
1 FUEL GAUGE 62200-A-150 1
ALL HOSES ARE COMPLETE WITH FITTINGS
FUEL & VACUUM TANK HOSES

(CF-43H & CF-48H)
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
CF STRAINERS
1 CF STRAINER 200 FOR 32M 43H 48H SU0048Z0001 A/R
2 CF STRAINER 150 FOR 28M SU0028Z0001 A/R
3 CF STRAINER 100 FOR 22L SU0022Z0001 A/R
STAINLESS STEEL OPTIONS

1 STRAINER, SUCTION CF-48H/43H/32MSS SU0048Z0002 A/R
2 STRAINER, SUCTION CF-28MSS SU0028Z0002 A/R
3 STRAINER, SUCTION CF-22LSS SU0022Z0002 A/R
7
1
3
2
CF-48H CANOPY
1 LIFT FRAME LI0048Z0001 1
2 BOLT SET 100555 6
3 LEG RIGHT CA0048Z0002 1
4 LEG LEFT CA0048Z0001 1
5 BOLT SET 100554 4
6 BOLT SET 100553 4
7 ROOF CA0048Z0003 1
8 BOLT SET 100552 8
9 BATTERY BOX 13200043 2
CF SUCTION HOSES (OPTIONAL)

1 SUCTION HOSE 200mm (CF-32M, 43H & 48H) 100230 1
SUCTION HOSE 150mm (CF-28M) 100231 1
SUCTION HOSE 100mm (CF-22L) 100232 1
13
1
12
11
4 3
10
9 7
HYDRAU-FLO KIT (OPTIONAL)

(CF-43 & CF-48)
1 RECIEVER HF1113Z0003 1
2 HYDRAU-FLO VALVE HF1105Z0003 1
3 FITTING HFS49-0804 1
4 FITTING HF8012-0808 1
5 HOSE HF1215Z0002 MTRS
7 ADAPTOR PLATE HF1012Z0002 1
8 FLOAT VALVE HF1017Z0001 1
9 FITTING FBS-58 1
10 HOSE 100993 1
11 MOUNTING BRACKET HF1014Z0002 1
13 BREATHER USCAB7101 1
4
1
3
6
12
7
10
5
8
9 2
13
11
TRAILER ASSEMBLY(Optional)
1 DRAINBAR 200690 1
2 CHASIS 200681 1
3 LEVER 100399 1
4 COUPLING 101853 1
5 CHAIN 101874 2
6 HAMMER LOCK HL13 2
7 D SHACKLE DS-S-13 2
8 AXLE BRAKED 205645 1
9 AXLE NO BRAKES 205643 1
10 WHEEL CHOCKS WC-245 2
11 WHEEL 205644 4
12 MUDGUARD LEFT 205560 1
13 MUDGUARD RIGHT 205559 1
2
1
11
3 10
5 9
SUCTION ASSEMBLY(Optional)
1 BOOM C/W PULLEY MFB4 1
2 PULLEY ASSEMBLY MFBP1 1
3 HAMMER LOCK HL13 4
4 CHAIN 205608 1
5 CHAIN 205617 2
6 WINCH (NOT SHOWN) MFW0600 1
7 WIRE ROPE SLING WR8-16SASA 1
8 D SHACKLE (NOT SHOWN) DS-S-13 1
9 SPREADER BAR 102333 1
10 HOSE 100230 1
11 STRAINER( MILD STEEL) SU0200Z0001 A/R
STRAINER( 316SS) SU0200Z0002 A/R
PRESSURE GAUGE (Optional)

1 PRESSURE GAUGE 102606 1
2 BALL VALVE 102608 1
3 NIPPLE SS2703 1
WORK LIGHT (Optional)

1 WORK LIGHT 101843 2
2 TIMER RELAY (NOT SHOWN) 102628 1
3 PUSH BUTTON (NOT SHOWN) 102629 1
PART 5
Accompanying
Manuals
WEIR MINERALS MULTIFLO

MODEL CF-48
(GLAND PACKED BARE SHAFT PUMP)
ASSEMBLY & DISASSEMBLY MANUAL

OCTOBER 2009
Multiflo Model CF-48

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

CAUTION ! worn when operating or servicing this
equipment.
Names and basic part numbers are used

in assembly instructions in this manual.
INFORMATION ! Full part numbers should be used upon
ordering spare parts.
When pumps have been dismantled for

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

thoroughly cleaned and repainted where
INFORMATION ! required.
Mating faces and spigots should be free

of rust, dirt and burrs and given a coat of
INFORMATION ! grease before they are fitted together to
assist future overhaul.
October 2009 Page 1

Weir Minerals Multiflo Model CF-48 Bare Shaft Pump
It is preferable to renew small bolts and

set screws during overhaul and all
INFORMATION ! threads should be coated with graphite
grease before assembly. It is also
recommended that all rubber seals
should be replaced during major
overhauls as rubber tends to harden and
seals lose their effectiveness.
October 2009 Page 2

CF-48 Bare Shaft Pump Disassembly Procedure

To Suit New Bearing Assembly
1. Securely mount PUMP UNIT to anchored work bench.
2. Remove ACCESS COVER (31).
3. Remove LINER (32) from VOLUTE (29) and discard 'O' RINGS (34) and (33).
4. Remove KEY (17) from SHAFT (2). Using Impeller Locking Tool (Fig 3) to lock
IMPELLER (30), remove the IMPELLER by turning the SHAFT with the Shaft
Spanner (Fig 1).
5. Remove BLANK DUST CAPS (38) from PEDESTAL (1) and use ¾ UNC BOLTS
(28) through DUST CAP holes to separate VOLUTE (29) from PEDESTAL (1).
Remove VOLUTE (29) from BEARING HOUSING (1).
6. Remove STUFFING BOX (20) from VOLUTE (29) and discard PACKING (23).and
'O' RING (21).
7. Remove SHAFT SLEEVE (18) and discard 'O' RINGS (19). Withdraw GRUB
SCREWS from LABYRINTH SLINGER (15) and remove from SHAFT SLEEVE (18).
Discard 'O' RING (16).
8. Remove BEARING CAPS (13) and (4). Discard 'O' RING (6) and SEALS (14 and
(5).
9. Remove SHAFT LOCK NUT (8) from SHAFT (2).
10. Press SHAFT (2) from BEARING HOUSING (1) out through Impeller End.
11. Remove BEARINGS (9) from Coupling End of PEDESTAL (1) along with LIP SEAL
GREASE RETAINERS (10).
12. Remove CARB BEARING (12) from SHAFT (2).
13. Thoroughly clean and inspect all parts of pump. Pay particular attention to SHAFT
and IMPELLER. If there is any doubt about serviceability, replace suspect parts.
It is recommended that all Bearings,

INFORMATION ! Gaskets, 'O' Rings, Bushes and Nyloc
Nuts be replaced when rebuilding Pump
Bare Shaft Assembly.
October 2009 Page 3

CF-48 Bare Shaft Pump Assembly Procedure

1. Fit BEARING (12) to SHAFT (2) Impeller End.
Use an Induction Heater or similar to heat Bearing (12) to 120°C.
INFORMATION ! NOTE: Bearing is an interference fit onto

shaft and transitional fit into pedestal.
2. Fit LIP SEALS (10) inside PEDESTAL (1).

NOTE: Lip Seals have a 1/16” diameter
INFORMATION ! hole in face to allow journal to breathe
and release any pressure build up.
Fit FRONT SEAL (10) (Impeller End) with lip facing outwards and with the 1/16”
diameter hole to top.
Fit REAR LIP SEAL (10) with lip facing outwards and with the 1/16” hole to top.
INFORMATION ! NOTE: Use CRC 5.56 for ease of fitting

the SHAFT ASSEMBLY to PEDESTAL.
3. Fit SHAFT ASSEMBLY into PEDESTAL (1) from Impeller End, using Tool ‘A’ in
front of CARB BEARING (12) to keep it in line. PEDESTAL (1) should be secured
safely in the vertical position. Lower SHAFT ASSEMBLY carefully into PEDESTAL
(1) taking care not to turn LIP SEAL (10) at Impeller End.
4. Once SHAFT ASSEMBLY is in place, remove Tool ‘A’ and grease CARB BEARING
(12) 30% to 50% full with ALVANIA RL2 Grease. Fit END CAP TOOL, Tool ‘B’.
INFORMATION ! NOTE: Tool ‘B’ acts as a press bed.
Turn PEDESTAL (1) 180°. Pre-load BEARINGS (9) 30% to 50% with ALVANIA RL2
Grease. Fit pre-greased BEARINGS (9) as per Bearing Diagram (Fig 4). Press into
place using Tools ‘C’ & ‘D’.
October 2009 Page 4

INFORMATION ! NOTE: SHAFT is an interference fit and

PEDESTAL is a transitional fit.
5. Once BEARINGS (9) are in place, fit SHAFT LOCK NUT (8) to SHAFT (2) with
Loctite 271 and tighten to torque specifications. Raised face against bearing.
INFORMATION ! NOTE: Oil between BEARING (9) and

SHAFT LOCK NUT (8).
6. Fit SEALS (5) & (14) to BEARING CAPS (4) & (13).
7. Fit CORK GASKET (37) to BEARING CAP (4). Using Tool ‘E’ to avoid damaging
LIP SEAL (10), fit BEARING CAP (4) to BEARING HOUSING (1).
8. Fit BOLT LOCKING PLATES (36) and BEARING CAP BOLTS (3) to BEARING CAP
(4) and torque BEARING CAP BOLTS (3) to 95Nm (70 ftlbs). Lock BOLTS (3) with
LOCKING PLATES (36).
INFORMATION ! NOTE: Over torquing BOLTS (3) will

cause a heat increase.
9. Rotate PEDESTAL 180° and remove Tool ‘B’. Fit CORK GASKET (37) to
BEARING CAP (13) and fit BEARING CAP to PEDESTAL.
10. Fit BOLT LOCK TABS (36) and BEARING CAP BOLTS (3) to BEARING CAP (13).
Fit BEARING CAP to BEARING HOUSING and torque BEARING CAP BOLTS to
95Nm (70 ftlbs).
INFORMATION ! NOTE: Over torquing BOLTS (3) will

cause a heat increase.
11. Fit SHAFT SLEEVE (18) with 'O' RINGS (19). Apply anti seize to inside of SHAFT
SLEEVE (18) and fit to SHAFT (2). Fit ‘O’ RING (16) to LABYRINTH DEFLECTOR
(15).
October 2009 Page 5

NOTE: Fit LABYRINTH SLINGER (15) to

INFORMATION ! BEARING CAP END of SLEEVE before
assembly of SLEEVE as it is much easier.
Once assembled, set LABYRINTH
SLINGER (15) and fix with GRUB
SCREWS.
Clearance between LABYRINTH DEFLECTOR (15) and BEARING CAP (13) is 1 +/-
0.5mm.
12. Bearings to be RUN IN at 1800 RPM for ½ hour. At 10 minute intervals temperature
reading to be taken. In a workshop test run TEMPERATURE NOT ALLOWED TO
EXCEED 70°C. Above 70°C strip pedestal to find cause of over heating then RE-
RUN. TEMP RECOMMENDED front and back 60°C +/- 5°C.
Too much grease will cause the bearings to

CAUTION ! run hot, i.e. above the recommended
temperature.
Multiflo Model CF-48 Gland Packed Bare Shaft Pump
October 2009 Page 6

CF-48 Bare Shaft Pump – Wetted Parts

1. Assemble PACKING RETAINER (22) onto SHAFT (2) of BEARING HOUSING.
2. Install the GLAND STUDS (24) into STUFFING BOX (20) AND INSTALL 'O' RING
(21) onto STUFFING BOX (20). Fit GLAND PACKING (23). Alternate joints of
individual Packing Rings at 180° intervals.
INFORMATION ! NOTE: Use oil on SHAFT and PACKING

to assist in assembly of STUFFING BOX.
Then fit STUFFING BOX (20) with BOLTS (25) into VOLUTE (29) with the GLAND
OIL FEED HOLE to the top.
3. Fit VOLUTE (29) to BEARING HOUSING (1) using BOLTS (28). Being careful not
to cause damage to SHAFT when fitting. Tension as per bolt specifications. Use
anti-seize between all bolts and bolted surfaces for ease of future disassembly.
4. Apply anti-seize to shaft thread then fit IMPELLER (30) on to SHAFT (2) using Shaft
Spanner (Fig 1) to prevent shaft from turning. SPIN IMPELLER HARD HOME AND
ENSURE IT IS NOT FOULING.
5. Insert STUDS (35) using Loctite 620 into face of VOLUTE (29).
6. Without 'O' RING (34), fit LINER (32) to VOLUTE (29) to determine clearance
between LINER (32) and IMPELLER (30). Use a combination of SHIMS (27) to
ensure a clearance of 1mm between LINER (32) AND IMPELLER (30) when
ACCESS COVER (31) is installed (Fig 2).
Fit 'O' RING (34) to LINER (32) and install into VOLUTE (29).
7. Fit 'O' RING (33) to recess in the back of LINER (32) then fit ACCESS COVER
PLATE (31) and secure with VOLUTE NUTS (35). Grease all 'O' RINGS for ease of
fitting.
8. Install GLAND NUTS (24). DO NOT OVERTIGHTEN INITIALLY.
9. Install Key (17) to SHAFT (2).

NOTE: When first running up, loosen
INFORMATION ! gland nuts to allow the shaft to position
the packing. Allow water to pass through
the packing with the engine running at
idle rpm. Tighten the gland nuts until a
small controlled trickle of water is visible.
All new gland packing should be
adjusted in this manner.
October 2009 Page 7
CF-48 Bolt Tension Settings

B - Bearing Cap - 95Nm ( 70ft lb)
D - Volute Mounting Bolts - 270Nm (200ft lb)
H - Volute Studs - 270Nm (200ft lb)
J - Shaft Lock Nut - Tap Up Tight – Use Loctite
Shaft Lock Nut Grub Screw - 15Nm (11ft lb) – Use Loctite
K - Stuffing Box Bolts - 270Nm (200ft lb)
K
D
October 2009 Page 8

CF-48 Parts List

ILLUS NO PART NUMBER DESCRIPTION QTY
BS0048Z0001 Complete Bare Shaft Pump

1. BH0048Z0001 Housing, Bearing 1
2. CF0048Z0003 Shaft 1
3. BLTC16042 Bolts (Bearing Caps) 12
4. 6A-04A Cap, Bearing Housing 1
* 5. 6A-05 Seal 1
* 6. 6A-06 'O' Ring 2
7. 6A-07 Fitting, Lubrication 3
* 8. 6A-08 Shaft Lock Nut 1
9. 6A-10A Bearing (Coupling End) 2
* 10 FA0036Z1006 Setscrews 2
12 6A-13A Bearing 1
13. 6A-14A Cap, Bearing Housing 1
* 14. 6A-15 Seal 1
15. 6A-16 Deflector c/w ‘O’Ring 1
* 16. 6A-17 'O' Ring 1
17. CF0048Z0004 Key (Coupling) 1
18. 6A-28 Sleeve, Wearing, Shaft 1
* 19. 6A-29 'O' Ring (Shaft Sleeve) 2
20. 6A-30 Stuffing Box 1
BLTC20050 Bolts 4
6A-31 'O' Ring (Stuffing Box) 1
22. 6A-32 Retainer, Packing 1
* 23. CF0048Z0002 Packing, Pre Formed 1
24. 6A-34 Stud & Nut Kit (Gland) 1
* 27. 380-55 Shim .5mm As Req'd
380-56 Shim .9mm As Req'd
October 2009 Page 9

CF-48 Parts List (continued)

ILLUS NO PART NUMBER DESCRIPTION QTY
28. BLTC20050 Bolts 4

29. 380-67 Volute 1
30. 380-69 Impeller 1
31. 380-70 Cover, Access 1
32. 380-72 Liner 1
* 33. 380-73 'O' Ring (Face) 1
* 34. 380-74 'O' Ring (Radial) 1
35. 380-75 Stud 8
BLTCN20 Nut 8
36. 6A-20 Locking Plate 6
37. 6A-21 Gasket 2
38. KP-FCR034IM Plug 2
39. BLTW20 Washer 8
40. BH0048Z0002 Retainer, Lubricant, Bearing 2
100468 Gasket and Seal Set

(* Denotes parts included in Gasket Kit)
October 2009 Page 10

CF-48 Parts Assembly

29
30
27
34
39
35
32
33
31
28
23
18
19
24
22
20

3 15
13 37
40
10 2 1
36 16
6 12
17
10 9
6
8 37
4
5
10 3
40
11

CF-48 Tools and Clearances
FIGURE 1
SHAFT SPANNER
FIGURE 2
IMPELLER
CLEARANCE

FIGURE 3
IMPELLER LOCKING
TOOL
FIGURE 4
ANGULAR CONTACT
BALL BEARING
ARRANGEMENT
(FACE TO FACE)

TOOL ‘A’
TOOL ‘B’

TOOL ‘C’
TOOL ‘D’

TOOL ‘E’


WMM CF-48 IOM & Parts Manual, October 2010

Uploaded by

Copyright:

Available Formats

WMM CF-48 IOM & Parts Manual, October 2010

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WMM CF-48 IOM & Parts Manual, October 2010

Uploaded by

Copyright:

Available Formats

Weir Minerals Multiflo

MULTIFLO MODEL CF-48H

Part 1 Installation and Commissioning

Part 5 List of Accompanying Manuals

WMM Gland Packed Bare Shaft Pump Manual V

Part 1 - Installation & Commissioning

WEIR MINERALS MULTIFLO PUMPS

In Queensland:- In Western Australia:- In New South Wales:-

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

Bowen Basin South West Region

Rockhampton Kalgoorlie & Goldfields Authorised

Ph: 62 542 746098 Ph: 62 511 4773027

O.E.M. Contact Details

Safety warnings and precautions are provided in the supplied documentation.

SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES

Imminent risk of Fatal or crippling injuries

WARNING ! Risk of fatal or Persons Fatal or crippling injuries

Possibility Property Damage possible to the

Weir Minerals Multiflo – Safety & Safety Management Plan

Safety Management Plan for Installation Work

Our Five Key Safety Values are:-

• My colleagues and my own safety are paramount;

Site Installation Responsibilities

Weir Minerals Multiflo – Safety & Safety Management Plan

REMOVE SHAFT LOCKS

Shaft Lock Removal

GENERAL CONDITIONS OF SALE

GENERAL CONDITIONS OF SALE

GENERAL CONDITIONS OF SALE

Grades and Frequency of Lubrication

Engine Oil Mobil Delvac MX 15W40

Mobil Delvac MX 15W40

Multiflo Pump Grease

Vacuum Pump Capacity

CF-32M – CF-28M – CF-22L 1 Litres

3054NA (CF28) 11 Litres

C4.4 ACERT (CF32) 11 Litres

C7 ACERT (CF43) 28 Litres

C9 ACERT (CF48) 32 Litres

Recommended Lubricants – CF Pump Unit

Weir Minerals Multiflo CF-48 Pump Unit – Installation Manual 1

1.2.1 Bare Shaft Pump Safety

It must be checked that the intake and

The following instructions relate to the

1.2.2 Vacuum Pump Safety

If installing the vacuum pump, the direction of rotation should

Weir Minerals Multiflo CF-48 Pump Unit – Installation Manual 2

1.3 Unit Lifting Points

Lifting of the pump unit should be

Weir Minerals Multiflo CF-48 Pump Unit – Installation Manual 3

1.4 Installation & Removal Sequences

Pump unit to be locked and tagged before

Pump unit moving and locating

1.4.2 Assembly of Pump and Skid (If Fitted)

Lifting of the pump unit should be

Do not stand under suspended load.

Weir Minerals Multiflo CF-48 Pump Unit – Installation Manual 4

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

4. Make sure the pump is sitting flat in the skid.

Do not attempt to insert bolts until pump