Multiflo Vaccum Pump 420
Multiflo Vaccum Pump 420
Multiflo Vaccum Pump 420
Vacuum Pump
MODEL 57
Assembly Supplement Manual
®
Copyright © 2015, 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.
Revision History
Revision Description Reviewed Authorised Date
Contact Details
Australia
Queensland (QLD):
Head Office Rockhampton
Weir Minerals Multiflo® Authorised Service Provider
15 Dacmar Road Weir Minerals Service Centre
Coolum Beach Qld 4573 80 McLaughlin Street
Ph: 07 5449 3032 North Rockhampton QLD 4701
Fax: 07 5446 4304 Ph: 07 4924 7700
Email: multifloparts@weirminerals.com Fax: 07 4924 7799
Email: australiansales@weirminerals.com
Indonesia
Table of Contents
Contact Details .................................................................................................................................................................. ii
Australia ............................................................................................................................................................................. ii
Indonesia ........................................................................................................................................................................... ii
Table of Contents.............................................................................................................................................................. v
List of Figures ................................................................................................................................................................. vii
List of Tables .................................................................................................................................................................. viii
1 Introduction ........................................................................................................................................................ 1-12
1.1 Scope of the Manual ...................................................................................................................................... 1-12
1.2 Intended Audience ......................................................................................................................................... 1-12
1.3 Disclaimer ...................................................................................................................................................... 1-12
1.4 Copyright ........................................................................................................................................................ 1-12
2 Safety .................................................................................................................................................................. 2-13
2.1 Safety Symbols .............................................................................................................................................. 2-14
2.2 Safety Symbols used on the Pump Unit ........................................................................................................ 2-15
3 Technical Data ................................................................................................................................................... 3-17
3.1 Vacuum Pump Technical Data ...................................................................................................................... 3-17
4 Transport and Storage ...................................................................................................................................... 4-18
4.1 Packing & Delivery ......................................................................................................................................... 4-18
4.1.1 Packing .................................................................................................................................................. 4-18
4.1.2 Loading and Unloading .......................................................................................................................... 4-18
4.1.3 Reporting Shipping Shortage ................................................................................................................. 4-18
4.1.4 Repacking .............................................................................................................................................. 4-18
4.2 Storage Procedures ....................................................................................................................................... 4-19
4.2.1 Long Term Storage (2 weeks or longer) ................................................................................................ 4-19
5 Assembly ............................................................................................................................................................ 5-20
5.1 Assembly Safety ............................................................................................................................................ 5-20
5.2 Pre-Installation and Assembly Checks .......................................................................................................... 5-20
5.3 Component List .............................................................................................................................................. 5-21
5.3.1 Vacuum Pump – Cylinder Block Group ................................................................................................. 5-21
5.3.2 Vacuum Pump – Crank Case Group ..................................................................................................... 5-22
5.3.3 Vacuum Pump – Cylinder Block Group ................................................................................................. 5-23
5.4 Vacuum Pump Assembly Procedure ............................................................................................................. 5-24
5.4.1 Assembly Procedure .............................................................................................................................. 5-24
6 Maintenance ....................................................................................................................................................... 6-38
6.1 Maintenance Safety ....................................................................................................................................... 6-38
6.2 Piston and Re-Ringing Instructions ............................................................................................................... 6-38
6.3 Assembly of 3-Piece Oil Ring ........................................................................................................................ 6-39
6.4 Leaks in Balance Tube .................................................................................................................................. 6-41
6.5 Vacuum Leaks in Crank Case ....................................................................................................................... 6-41
6.6 Worn Rings .................................................................................................................................................... 6-41
List of Figures
Figure 5-1: Vacuum Pump Cylinder Head Components ............................................................................................... 5-21
Figure 5-2: Vacuum Pump Crank Case Group Components ........................................................................................ 5-22
Figure 5-3: Vacuum Pump Cylinder Block Group Components .................................................................................... 5-23
Figure 5-4: Fitting the Oil Drain Plug to the Crank Case. .............................................................................................. 5-24
Figure 5-5: Fitting the Outer Bearing Brace to the Front Bearing Cover. ...................................................................... 5-24
Figure 5-6: Fitting the Oil Drain Plug to the Crank Case. .............................................................................................. 5-24
Figure 5-7: Fitting the Cover to the Crank Case Housing.............................................................................................. 5-25
Figure 5-8: Assembly of Rear Bearing Cover with Bearing Supporter and Outer Bearing Race. ................................. 5-25
Figure 5-9: Assembly of Rear Bearing Cover with Bearing Supporter and Outer Bearing Race. ................................. 5-25
Figure 5-10: Assembly of Outer Bearing Brace to the Rear Bearing Cover. ................................................................. 5-26
Figure 5-11: Assembly of Outer Bearing Brace to the Rear Bearing Cover. ................................................................. 5-26
Figure 5-12: Fitting the Bearings. .................................................................................................................................. 5-26
Figure 5-13: Preparing the Shaft Assembly for Installation into the Crank Case. ......................................................... 5-27
Figure 5-14: Installing the Crank Shaft into the Crank Case Housing. .......................................................................... 5-27
Figure 5-15: Installing the Grub Screw to the Rear Bearing Cover. .............................................................................. 5-27
Figure 5-16: Crank Shaft Adjustment. ........................................................................................................................... 5-28
Figure 5-17: Further Crank Shaft Adjustment. ............................................................................................................... 5-28
Figure 5-18: Further Crank Shaft Adjustment. ............................................................................................................... 5-28
Figure 5-19: Torqueing of Counter Weight Bolts. .......................................................................................................... 5-29
Figure 5-20: Piston Components ................................................................................................................................... 5-29
Figure 5-21: Piston Assembly ........................................................................................................................................ 5-29
Figure 5-22: Sequence of Installation of the Piston Rings............................................................................................. 5-30
Figure 5-23: Fitting the Piston Ring Expander. .............................................................................................................. 5-30
Figure 5-24: Fitting the Slipper Bearing Cap. ................................................................................................................ 5-30
Figure 5-25: Fitting the Piston into the Cylinder Block................................................................................................... 5-31
Figure 5-26: Fitting the Gasket to the Crank Case Assembly. ...................................................................................... 5-31
Figure 5-27: Fitting the Cylinder assembly to the Crank Case. ..................................................................................... 5-31
Figure 5-28: Fitting the End Caps. ................................................................................................................................. 5-31
Figure 5-29: Fitting the Cylinder Head. .......................................................................................................................... 5-32
Figure 5-30: Fitting the Block Nuts. ............................................................................................................................... 5-32
Figure 5-31: Fitting the Head Bolts and Blind Bolts. ...................................................................................................... 5-32
Figure 5-32: Fitting the Gasket Ring. ............................................................................................................................. 5-33
Figure 5-33: Fitting the Discharge Valve Assembly. ...................................................................................................... 5-33
Figure 5-34: Fitting the Discharge Valve Cage. ............................................................................................................. 5-33
Figure 5-35: Fitting the Discharge Triangle to the Head................................................................................................ 5-33
Figure 5-36: Tensioning the Securing Bolts of the Discharge Triangle. ........................................................................ 5-34
Figure 5-37: Fitting the Copper Gasket into the Recess on Discharge Triangle. .......................................................... 5-34
Figure 5-38: Fitting the Push Bolt to the Top of the Discharge Triangle. ...................................................................... 5-34
Figure 5-39: Fit the Cap Nut. ......................................................................................................................................... 5-35
Figure 5-40: Install Valve Assembly into the Cylinder Head.......................................................................................... 5-35
Figure 5-41: Install Valve Assembly into the Cylinder Head.......................................................................................... 5-35
Figure 5-42: Tension the Hold-Down Bolts. ................................................................................................................... 5-36
Figure 5-43: Inspection Plate Components. .................................................................................................................. 5-36
Figure 5-44: Fit Inspection Plate Securing Bolts and Fit the Dipstick. ........................................................................... 5-36
Figure 5-45: Fitting Vacuum Pump Balance Hose. ....................................................................................................... 5-37
Figure 6-1: Correct Replacement of Vacuum Pump Crank Seal ................................................................................... 6-41
List of Tables
Table 2-1: Safety Colours .............................................................................................................................................. 2-14
Table 2-2: Safety Symbols ............................................................................................................................................. 2-15
Table 2-3: Pump Unit Safety Symbols ........................................................................................................................... 2-16
Table 3-1: Vacuum PumpTechnical Data ...................................................................................................................... 3-17
Table 5-1: Vacuum Pump Cylinder Head Group Component List ................................................................................. 5-21
Table 5-2: Vacuum Pump Crank Case Group Component List..................................................................................... 5-22
Table 5-3: Vacuum Pump Cylinder Block Component List............................................................................................ 5-23
Table 6-1: Assembly Procedure for 3-Piece Oil Ring .................................................................................................... 6-39
Table 6-2: Correct Fit of Position Ring ........................................................................................................................... 6-40
Table 6-3: Torque Settings for Vacuum Pump .............................................................................................................. 6-42
1 Introduction
The purpose of this Manual is to advise and instruct installers, operators and repairers of Weir Minerals Multiflo®
Vacuum Pump - Model 57 in the recommended assembly 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®
Vacuum Pump - Model 57. To ensure long life and trouble-free operation, you should read and understand these
instructions and provide regular, periodic maintenance.
The Weir Minerals Multiflo® Vacuum Pump - Model 57 is of a robust construction and is designed to be used as a mine
dewatering component in accordance with the pump performance data contained in this manual. When correctly
assembled as per the recommended instructions, this unit will give a long and trouble-free service with minimum
maintenance. To achieve the consistent high performance which Weir Minerals Multiflo® Vacuum Pump - Model 57 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
CAUTION
PERSONNEL INJURY
The Vacuum Pump must be installed, operated and maintained only by personnel who are trained and
have sufficient knowledge about the hazards that may occur during operation.
1.3 Disclaimer
Despite of the care taken to compile all information and illustration in this document, neither the author nor the
publisher can be held liable for any consequential damages resulting from possible errors in this publication.
The English language was used to write the original manual. Any versions in other languages are a translation of the
original manual instructions. These translated versions may contain information that differs from the original due to
interpretation of the content and meaning of the original text. In the case of such discrepancies, the original English
language instructions will be considered the sole authentic source for the purpose of determining the content and
meaning of the text.
®
Weir Minerals Multiflo reserves the right to make changes to technical and design specifications at the any time
without prior notice.
1.4 Copyright
®
Weir Minerals Multiflo Pty Ltd 2015
This document is subject to copyright. Use or copying of this document in whole or part without the written permission
®
of Weir Minerals Multiflo constitutes an infringement of copyright.
2 Safety
The Weir Minerals Multiflo® Vacuum Pump - Model 57 is designed to be used as a mine dewatering pump component
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 Vacuum Pump Model 57 is designed to be used only in conjunction with Weir Minerals Multiflo® Dewatering Pump
Units. Weir Minerals Multiflo® is not responsible for any damage that may occur if the Vacuum Pump Model 57 is used
with other systems and applications than mentioned above.
The Weir Minerals Multiflo® Vacuum Pump - Model 57 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.
®
The documentation supplied with the Weir Minerals Multiflo Pump Unit utilises the following safety symbols listed in
Table 2-2 to highlight potential harmful situations to personnel, equipment and the environment as per ISO 9001:2008.
Table 2-2: Safety Symbols
Explosion warning
Possibility of a harmful
situation.
Fatal or crippling injuries likely to
Indicates Adjoining parts are result from any contact.
hot.
Fatal or crippling injuries likely to
Mandatory Personal result if not worn.
Protective Equipment to be
worn.
Mandatory Personal
Protective Equipment to be Damage to hearing likely to result
worn for protection against if not worn.
Noise.
3 Technical Data
3.1 Vacuum Pump Technical Data
Table 3-1: Vacuum PumpTechnical Data
Net Weight:
Speed: 800RPM
No. of Cylinders: 2
4.1.1 Packing
Each shipment is sent through approved transport companies. The Vacuum Pump is packed in a suitable wooden
crate and loaded onto truck or a container for local and overseas transport respectively. The Vacuum Pump is packed
in such a way so that the integrity of the components is not damaged during shipment. Suitable packing material such
as dunnage may be used in the crates. These crates can be left free standing or strapped to the vehicle floor as
required. The wooden crates are sealed using duct tape or nylon tape. The wood packing material heat treated.
4.1.4 Repacking
If the VACUUM PUMP has 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 damage the integrity of
the component.
Weir Minerals Multiflo® does not bear any responsibility for damage if the VACUUM PUMP is damaged during
repacking and transport.
CAUTION
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 VACUUM PUMP AND ANY ASSOCIATED
EQUIPMENT WHEN STORED, HANDLED AND TRANSPORTED ON-SITE.
5 Assembly
5.1 Assembly Safety
• Refer to site procedures for lifting, personnel and equipment requirements. Only use site
approved lifting equipment.
• Follow General Arrangement Drawings during Assembly and Installation.
IT IS THE USER'S RESPONSIBILTY TO ENSURE THAT NO COMPONENTS ARE DAMAGED
DURING ASSEMBLY AND INSTALLATION PROCEDURES.
NOTICE
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 with
this and pump unit.
Pictures used to illustrate are only suggestive and not actual.
Make sure to use Anti-seize on all bolt threads before tightening the bolts.
When bolts holes are aligned, insert bolts and tension.
WARNING
PPE must be worn all the time while moving, installing, operating or overhauling the unit.
CAUTION
Vacuum Pump Model 57 must be used only in conjunction with the Weir Minerals Multiflo® Pump
Units.
Refer to the main Installation, Operation and Maintenance manual of the Pump Unit for Spare
Parts list of the Vacuum Pump which includes a detail list of part numbers.
10 Stud 2
44 Conrod 2
46 Conrod Bolt 4
47 Oil Splasher 2
49 Piston 2
50 Pin 2
51 Circlip 4
52 Ring Set 2
Figure 5-4: Fitting the Oil Drain Plug to the Crank Case.
2. Fit the outer bearing brace (38) into the front bearing cover (53), using a Hydraulic Press or similar.
Figure 5-5: Fitting the Outer Bearing Brace to the Front Bearing Cover.
3. After fitting the outer bearing race, turn the end cover over and install the lip seal (54). Note: The lip of the seal
faces to the outside of the end cover. Use a press and drift to install the seal into the cover.
Figure 5-6: Fitting the Oil Drain Plug to the Crank Case.
4. Apply a thin layer of grease to gasket (33) and fit to the front bearing cover. Fit the cover onto the crank case
housing. Apply Loctite 567 or thread sealant to bolts. Install the bolts and tension to 25 ft lbs.
5. Assemble the rear bearing cover (32) with bearing supporter (34) and outer bearing race (38).
Figure 5-8: Assembly of Rear Bearing Cover with Bearing Supporter and Outer Bearing Race.
6. Bearing supported (34) is a loose fit into the bearing cap. NOTE: Install the bearing supporter with the concave
center facing into the bearing cover.
Figure 5-9: Assembly of Rear Bearing Cover with Bearing Supporter and Outer Bearing Race.
7. Now install the outer bearing bace into the rear bearing cover using a hydraulic press or similar. The bearing
race should fit below the level of the spigot and tight against the bearing supporter. The narrow edge of the race
taper faces to the inside of the crank case.
Figure 5-10: Assembly of Outer Bearing Brace to the Rear Bearing Cover.
8. Crankshaft (39) assembly is next. Both bearings (38) are the same size. The narrow edge of the taper faces to
the ends of the shaft.
Figure 5-11: Assembly of Outer Bearing Brace to the Rear Bearing Cover.
9. Use a hydraulic press or similar device to fit the bearings. A sleeve made to suit the inner diameter of the
bearing should be used to ease the bearings onto the shaft. The bearings must fit hard on the shoulders of the
crankshaft.
10. Apply a thin layer of grease to gasket (33) and ready the shaft assembly for installation into the vacuum pump
crank case.
Figure 5-13: Preparing the Shaft Assembly for Installation into the Crank Case.
11. Apply oil to the lip of the seal (54) in the front bearing end cap and carefully install the shaft. Hold the shaft in
place and fit the end cover onto the crank case housing. Apply Loctite 567 or thread sealant to bolts (37).
Install the bolts and tension to 25 ft lbs.
Figure 5-14: Installing the Crank Shaft into the Crank Case Housing.
12. Install the grub screw (35) into the back of the rear bearing cover.
Figure 5-15: Installing the Grub Screw to the Rear Bearing Cover.
13. The crank shaft will be loose in the bearing. To adjust the crank shaft end float, tighten the adjusting screw until
all end float is removed, then back off the grub screw (35) a 1/4 to 1/2 a turn.
14. Tap the crankshaft with a rubber/soft hammer. One sharp hit is all that is required. The shaft should now rotate
easily. If the rotation is restricted, gradually increase the adjustment by up to a 1/4 turn of the grub screw and
hit the shaft again. Don’t let the shaft go loose in the bearings. Once the end float is correct, lock the grub
screw with the locking cap (36)
15. Attach the two balance weights. NOTE: The green arrows on the photograph indicate the position in which the
balance weights are attached to the crank shaft. Use bolts (42) and lock tab (41) to secure the balance weights
to the crank shaft.
16. Once the balance weight is attached to the crank shaft, tighten the counter weight bolts to 25 ft lbs and bend
the corner of the lock tabs across the flat of the bolt head as shown here.
17. Piston (49), piston rings (52), conrod (44), gudgeon pin (50) and circlips (51) are displayed. The piston is fitted
to the conrod first.
18. The gudgeon pin is a clearance fit into the little end bearing. NOTE: First, fit a circlip into the recess provided.
Ensure that the clip is correctly located. Slide the gudgeon pin through the piston and conrod little end. Secure
the pin with the second circlip as shown.
19. Using “soft jaws”, the conrod should be gently held in a vice so that the piston rings may be installed easily. The
rings must be installed in the sequence shown.
20. Use a piston ring expander to correctly fit the piston rings into the piston ring grooves. Set the piston ring gaps
at intervals of 120 degrees
21. Undo the big end cap bolts and fit the slipper bearings (45) as shown. The big end slipper bearings have
bearing locator lugs as per conventional conrods. A. The conrod slipper bearing has an oil groove in the centre
of the inside of the bearing. B. The cap slipper bearing has no groove.
22. Using “soft jaws”, clamp the cylinder block (9) into a vice. Fit a piston ring compressor around the piston and
compress the rings. Prior to installation, the big end bolts (46) should be fitted to the conrod. Guide and
support the conrod big end into the bore of the cylinder block (9). Use a non-metallic device to push the piston
into the bore of the cylinder and out of the ring compressor.
23. Fit gasket (8) to the crank case assembly. Apply liberal amounts of oil to the conrod journals on the crank shaft.
24. Lift the pre-assembled cylinder into position over the crank case. Carefully lower the assembly so that the
conrod big end rests on the crank shaft journals. Align the cylinder with the crank case studs. When the
cylinder is sitting in position, push the pistons down so that the big ends are hard onto the crank shaft journals.
Check this visually through the inspection port.
25. Fit the big end caps (44) and tension the bolts to 25 ft lbs.
26. Apply a thin layer of grease to the cylinder head gasket (12). Fit the cylinder head (13).
27. Tension the block nuts (11) to approximately 20 ft lbs. (Access with a conventional tension wrench is not
possible on these nuts).
28. Install head bolts (14) and blind bolts (15) into the head (13). Tension these to 25 ft lbs in the tensioning
sequence shown in the figure below.
29. Fit gasket ring (16) to the two inlet and two exhaust ports as shown here. These rings locate into stepped
recesses in the head.
30. Insert the discharge valve assembly (27) as shown in this illustration. The valve seats in the same recess as the
gasket ring (16). Make sure that the valve assembly sits square in the recess.
31. Install the discharge valve cage (26). The valve cage fits into the shoulder on the back of the discharge valve
assembly (27). Check the parts diagram in figure 5-3 for reference.
32. Gasket (25) fits into a recess under discharge triangle (24) which creates a seal between the discharge triangle
and the head.
33. After installing both discharge triangles, tension the securing bolts (31) to 25 ft lbs. Do not over tension, as the
triangle may crack.
34. Copper gasket (29) fits into a recess on top of the discharge triangle (24).
Figure 5-37: Fitting the Copper Gasket into the Recess on Discharge Triangle.
35. Push bolt (28) screws into the top of the discharge triangle. The push bolt is tensioned to positively lock the
valve down.
Figure 5-38: Fitting the Push Bolt to the Top of the Discharge Triangle.
37. Install the inlet valve assembly (19) into the cylinder head in the same manner as shown here. Again, the valve
seats on the same recess as the gasket ring.
38. Fit ‘O’ ring (18) to the inlet triangle (17) and fit into the cylinder head. The assembly fits into a recess in the back
of the inlet valve assembly.
39. Tension the hold down bolts (31) to 25 ft lbs. Do not over tension as the triangle may crack.
40. The illustration here shows the inspection plate (4), inspection gasket (2) and the oil level dip stick (6).
41. Apply a thin layer of grease to gasket (2) to hold it in place on the crank case flange. Fit the inspection plate (4)
and tension the bolts (5). Fit the dipstick (6) into the port provided. The opposite side inspection plate (3) and
gasket (2) are fitted in the same manner, however, the plate has no dipstick. During rebuild operations, only
one inspection plate needs to be removed unless the situation requires that the plate be removed.
Figure 5-44: Fit Inspection Plate Securing Bolts and Fit the Dipstick.
42. Install the vacuum pump balance hose (63) and reducing bush (62) to the vacuum pump as shown here.
6 Maintenance
6.1 Maintenance Safety
CAUTION
Pump unit to be locked and tagged before any maintenance or service is performed.
Appropriate lifting techniques and lifting equipment to be used.
Oil level must be checked before operating the vacuum pump. Running the vacuum pump
without oil will cause damage.
WARNING
Personal Protective Equipment must be worn when operating or servicing the VACUUM PUMP.
NOTICE
• When boring to oversize, allow sufficient honing allowance to completely remove boring
marks (0.06 is usually needed).
•
o o
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 than 0.003mm per mm of cylinder diameter.
• Maximum gap condition is not especially critical but should not exceed 0.01mm per mm for
compression rings while gap on oil ring rails may be up to 1.75mm regardless of bore size.
• 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.
NOTICE
NOTICE
• To test valves, place upside down and fill with kerosene (diesel) for one (1) minute. Okay if
fluid does not disappear.
• When replacing a crankcase seal, it is to be inserted as per the diagram here.
Gaps should be fitted initially over the end of the gudgeon pin alternating sides, but they will tend to move around
during operation.
Cylinder Head 35 Nm + 3 25 ft lb + 2
Cylinder to Crankcase 30 Nm + 3 20 ft lb + 2
Bearing Cap 35 Nm + 3 25 ft lb + 2
Conrod Big Cap 35 Nm + 3 25 ft lb + 2
Valve Retainer Cap 35 Nm + 3 25 ft lb + 2
CAUTION
• It is the User’s responsibility to understand/identify all the inherent risks and consequences
involved during dismantling/ disposal procedures and take necessary precautions against
such risks.
• All disposal procedures MUST be carried out in accordance with the local laws. Only site
approved procedures MUST be used.
• Use only designated Lifting Points for Lifting Operations. Mass of the components must be
taken into consideration while selecting appropriate lifting equipment.
• The user must identify appropriate tools/equipment required to perform the dismantling
procedures.
• After Dismantling the components, ensure that proper storage measures are undertaken.
• Ensure that there is at least One (1) 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 any
dismantling and disposal procedures on the Pump Unit.
• Only approved recyclers/vendors to be used for disposal of components.
• All procedures to be carried out by Skilled Personnel only
WARNING
Personal Protective Equipment must be worn when operating or servicing the VACUUM PUMP.
7.3 Disposal
• Proper disposal of the Vacuum Pump Model 57 components becomes crucial after dismantling.
• All materials set aside for disposal must be disposed according to laws set forth by the local authorities. Proper
disposal becomes obligatory as toxic wastes can cause ill effect on the environment and life systems. For
example toxic wastes can seep into the ground contaminating water supplies and may cause diseases.
• Non – Toxic wastes causes pollution and has a negative impact on the Eco system. It is the user’s
responsibility to fully understand the laws set forth by the local authorities.
• Waste management methods might vary specific to different geographies and territories and the user MUST
understand these regulations.
• Domestic waste collection services are often provided by local government authorities, or by private companies
in the industry. The user must find out a list of approved vendors/recyclers and the components must be sent
only to such agents for disposal/recycling.
• Protective equipment such as Gloves and goggles should be used while handling chemical of toxic nature. It is
preferred that at least two persons should be present at all time while working with chemicals.
• Waste products and disposals must be discharged with proper neutralization. If the material to be disposed is
extremely toxic or poisonous, the material should be kept in closed container and sent to appropriate agency
for proper disposal.
• Steel must be sent to approved recyclers, steel to steel merchants, Al, Carbon steel, plastics, electrical wiring,
stainless steel, electric and electronic components, galvanized steel must be sent to approve recyclers for
disposal.
• Any waste oil present must be collected in approved seal containers and must be disposed via approved waste
management companies.
Refer to the main Installation, Operation and Maintenance manual of the Pump Unit for Spare
Parts list of the Vacuum Pump which includes a detail list of part numbers.
9 Appendices