Complete 420 Manual SIS Unit 89

Weir Minerals Multiflo
PT SAPTAINDRA SEJATI
(DIANLIA SETYAMUKTI)
MULTIFLO MODEL MFVC-420 PUMP UNIT
SERIAL No: MFVC-420-89-05.19
INSTALLATION, OPERATIONS,
MAINTENANCE AND
PARTS MANUAL
MFVC-
MFVC-420 Pump Unit
Master Index
Index
List of Figure References
Introduction
Contact Details for O.E.M.
O.E.M. Introduction
General Safety
Shaft Lock Removal
Weir Minerals Australia General Conditions of Sale
Caterpillar Warranty Conditions
Twin Disc Warranty Conditions
Part 1 Installation and Commissioning
Part Page
Pump Unit Data Sheet I
Mass Dimensions and Fuel Capacity I
Lubrication Table I
Model 420 Performance Curve I
List of Accompanying Manuals I
Section 1.1 Pump Unit Delivery & Storage Procedures I

1.1.1 Storage Procedures I 1
1.1.1.1 General Storage I 1
1.1.1.2 Transmission Storage I 2
1.1.1.3 Belt Storage I 3
Section 1.2 Safety Warnings I
1.2.1 Bare Shaft Pump Safety I 4
1.2.2 Vacuum Pump Safety I 5
1.2.3 Transmission Safety I 5
1
Multiflo Model 420 – Master Index Rev Dec 07
(Always quote Model and Serial Number of Unit when Ordering Parts)
MFVC-
MFVC-420 Pump Unit
Part 1 Installation and Commissioning
Part Page
Section 1.3 Unit Lifting Points (Total Unit Mass) I 7
Section 1.4 Installation & Removal Sequences I 8
1.4.1 Moving & Locating the Pump Unit I 8
1.4.1.1 Pump Site Preparation I 9
1.4.1.2 Moving the Pump Unit I 9
1.4.1.3 Preparation for Towing I 9
1.4.1.4 Procedures for Moving, Locating & Launching I 10
1.4.1.5 Procedure for Towing I 11
1.4.1.6 Positioning and Launching I 11
1.4.1.7 Incorrect Pump Unit Positioning I 14
1.4.1.8 Correct Pump Unit Positioning I 15
1.4.1.9 Pumping Operation Observations I 16
1.4.2 Installation Checks I 17
Part 2 Operation
Section 2.1 Introduction

2.1.1 General Information & Safety II 1
2.1.2 General Safety Recommendations II 2
2.1.3 General Description & Function of Equipment II 3
2.1.3.1 Operation II 3
2.1.4 Orientation of Major Unit Components II 4
Section 2.2 Normal Operating Procedures

2.2.1 Daily Pre-Start Checks II 5
2.2.1.1 Transmission II 5
2.2.1.2 Engine Oil II 6
2.2.1.3 Bare Shaft Pump Auto Lubrication System II 6
2.2.1.4 Vacuum Pump Oil II 6
2.2.1.5 Gland Oil Tank II 6
2
MFVC-
MFVC-420 Pump Unit
Part 2 Operation
Part Page
Section 2.2 Normal Operating Procedures (Continued)
2.2.1.6 Coolant Level II 6
2.2.1.7 Fuel Tank II 6
2.2.1.8 Battery II 6
2.2.1.9 Drive Belts II 7
2.2.1.10 Water Trap II 7
2.2.1.11 Air Cleaner Indicator II 7
2.2.1.12 Suction Strainer II 7
2.2.2 Starting Procedures II 7
2.2.2.1 Start Up Procedure II 7
2.2.2.2 Operating Speed II 8
2.2.2.3 Cavitation II 8
2.2.3 Shutdown Procedure II 9
2.2.4 Shutdown Protection II 10
2.2.4.1 Pump Shutdown System II 10
2.2.4.2 Waterloss Shutdown System II 10
Section 2.3 Detailed Description of Components II 11

2.3.1 Model 420 Bare Shaft Pump II 11
2.3.2 Model MG5202SC Transmission II 14
2.3.2.1 Oil Pump Drive II 14
2.3.2.2 Lubrication Features II 14
2.3.2.3 Suction Screen II 14
2.3.2.4 Heat Exchanger II 15
2.3.2.5 Identification Plate II 15
2.3.3 Model 57 Vacuum Pump II 16
2.3.3.1 Parts Identification II 17
2.3.3.2 Specifications & Torque Settings II 17
3
MFVC-
MFVC-420 Pump Unit
Part 2 Operation
Part Page
Section 2.3 Detailed Description of Components II 11
(Continued)
2.3.4 Vactronic Vacuum Tank II 18
2.3.5 Vacuum Gauge II 19
2.3.6 Non Return “Vooom” Valve II 20
2.3.7 Vactronic Vacuum Prime System II 23
2.3.8 Hydrau-Flo Fuel Pressure Control Valve II 25
2.3.9 Racor Fuel Filter / Water Separator II 29
2.3.9.1 Overview II 29
2.3.9.2 Installation Instructions II 30
2.3.9.3 Racor Fuel Hose Specs & Pressure Ratings II 33
2.3.9.4 Priming Instructions II 34
2.3.9.5 Specifications II 35
Section 2.4 Test & Performance Data II 36

2.4.1 Vactronic Module Tester II 36
2.4.2 Test of Operation of Vactronic & Waterloss II 37
Control Module Using Test Light
2.4.3 Design & Operating Limits II 39
Section 2.5 Electrical II 40

2.5.1 Electrical Drawings & Schematics II 40
Unit Schematic Wiring Diagram Attached
2.5.2 Monitoring Instruments II 41
2.5.2.1 Transmission Temperature Shutdown Gauge II 41
2.5.2.2 Coolant Level Detector II 43
4
MFVC-
MFVC-420 Pump Unit
Part 3 Maintenance
Part Page
Section 3.1 Normal Maintenance Procedures
3.1.1 Safety Procedures III 1
3.1.2 Disassembly & Assembly Procedures III 2
3.1.2.1 Model 420 Bare Shaft Pump III 3
Assembly Procedure
3.1.3 Maintenance – Bare Shaft Pump III 15
3.1.3.1 Bare Shaft Pump Gland III 15
3.1.3.2 Impeller III 18
3.1.3.3 Lubrication III 18
Manual Grease Guide III 19
Auto Grease Guide III 20
3.1.4 Maintenance – Model 57 Piston Vacuum Pump III 21
3.1.4.1 Vacuum Pump Piston & Re-Ringing Instruction III 21
3.4.4.2 Assembly of a 3 Piece Oil Ring Assembly III 22
3.1.5 Maintenance – Drive Components III 26
3.1.5.1 Drive Belt Tensioning III 26
3.1.5.2 Installation & Operation of Wedge & III 29
‘V’ Belt Drives
3.1.5.3 Taperlock Bushes III 32
3.1.5.4 Taperlock Flanges III 36
3.1.5.5 Tyre Couplings III 37
3.1.5.6 Maintenance - Model MG5202SC III 40
Transmission
General Maintenance III 41
Oil Level Setting Procedure III 41
Lubrication Points III 42
Filter and Oil Change III 43
Heat Exchanger III 44
Suction Strainer III 44
Flexible Input Coupling III 44
5
MFVC-
MFVC-420 Pump Unit
Part 3 Maintenance
Part Page
Section 3.1 Normal Maintenance Procedures (Continued)
3.1.5.7 Maintenance – 1000FH Fuel/ Water Separator III 45
Water Draining III 45
Element Replacement III 45
Parts Identification III 47
3.1.6 Frequency of Routine General Maintenance III 49
3.1.6.1 Every 10 Engine Hours or Daily III 50
3.1.6.2 After First 100 Engine Hours III 51
3.1.6.3 Every 250 Engine Hours III 51
Section 3.2 Troubleshooting 53

3.2.1 Finding & Diagnostic Guide (Including Details of III 53
Normal Readings)
3.2.1.1 Pump Unit Troubleshooting III 53
3.2.1.2 Vacuum Pump III 58
3.2.1.3 Vee Belt Troubleshooting III 60
3.2.1.4 Hydrau-Flo Troubleshooting III 60
3.2.1.5 1000FH Fuel/Water Separator Troubleshooting III 62
Section 3.3 Lubrication Schedule III 65

3.3.1 Grades/Recommended Lubricants & Frequency III 65
6
MFVC-
MFVC-420 Pump Unit
Part 4 Spare Parts (Rev Dec 07)
Part Page
Bare Shaft Pump
Bare Shaft Pump – Model 420 IV 1
Bearing Housing IV 2
Shaft Sleeve & Gland Packing IV 3
Tungsten Carbide Shaft Sleeve (Optional) IV 4
Wetted Parts IV 5
Gland Splash Guard IV 6
Priming System
Vacuum Pump – Model 57 Piston Type
Vacuum Pump IV 7
Crank Case Group IV 8/9
Cylinder Block Group IV 10
Cylinder Head Group IV 11/12
Vacuum Pump Electromagnetic Clutch 24 Volt IV 13
Vacuum Tank IV 14
Engine & Transmission
Transmission IV 15
Transmission Oil Cooler IV 16-18
Transmission Oil Drain IV 19/20
Engine Breather IV 21
Engine Oil Drain IV 22
Fuel / Water Separator Filter IV 24
Exhaust & Turbo Guard IV 25
Throttle Cable IV 26
Drive Coupling IV 27
Drive Guard IV 28
7
MFVC-
MFVC-420 Pump Unit
Part 4 Spare Parts
Part Page
Electrical
Battery Box IV 29
Battery Isolator & Isolator Box IV 30
Emergency Stop Button IV 31
Coolant Loss Sender & Detector IV 32
Monitoring Instruments IV 33
Control Box IV 34
Electrical Components IV 35/36
Accessories
Hydrau-Flo IV 37
Highwall Fuel Filler IV 38
Gland Oil Tank IV 39
Manual Fuel Filler IV 40
Auto Greasing Unit (Bare Shaft Pump) IV 41/42
Suction Strainer, Hose & Boom IV 43/44
Discharge Pipe Work IV 45/46
Fire Extinguisher IV 47
Washdown Hose IV 48
Worklights IV 49
Strobe Lights IV 50
Nordic Worklight IV 51
Crane IV 52
Discharge Pressure Gauge IV 53
Chassis (New Style) IV 54
Access Platforms IV 55
Chassis (Old Style) IV 56
Pontoon IV 57
High Lift Skid Chassis IV 58
Part 5 List of Accompanying Manuals
8
MFVC-
MFVC-420 Pump Unit
List of Figures
Figure
Ref No Description Part Page
Part 1 - Installation & Commissioning

1 Unit Lifting Points I 7
2 Blade Contact Point on Pump Pushbar I 12
3 Blade Contact Point on Pontoon Pushbar I 13
4 Incorrect Pump Position Examples I 14
5 Correct Pump Position Examples I 15
Part 2 - Operation
6 Pump Unit Orientation Guide II 4
7 Resulting Effects of Continuous Cavitation II 9
8 Vactronic Module Waterloss Shutdown II 10
9 Bare Shaft Pump Wetted Parts II 12
10 Bare Shaft Pump Bearing Housing II 12
11 Bare Shaft Pump Pedestal Assembly II 13
12 Transmission Identification Plate II 15
13 Model 57 Piston Vacuum Pump Major Components II 16
14 Vacuum Tank II 18
15 Vacuum Gauge II 19
16 Non Return “Vooom” Valve – Flap in Closed Position II 21
17 Non Return “Vooom” Valve – Flap in Open Position II 22
18 Vactronic Circuit Diagram II 24
19 Hydrau-Flo Fuel Valve Components II 25
20 Hydrau-Flo System - Refuelling in Progress II 26
21 Hydrau-Flo System - Component Operation II 27
22 Hydrau-Flo System – Re-Fuelling Completed II 28
23 1000FH Turbine Series Fuel Filter /Water Separator II 29
1
Multiflo Model 420 –List of Figures Rev 10.07
MFVC-
MFVC-420 Pump Unit
List of Figures
Figure
24 Fuel Filter/Water Separator Mounting Instructions II 30

25 Fuel Filter/Water Separator Installation Instructions II 32
26 Fuel Hose II 33
27 Vactronic Module Tester II 36
Part 3 - Maintenance
28 Model 420G Bare Shaft Pump Frame Assembly III 3
29 Bare Shaft Pump Gland Assembly III 5
30 Bare Shaft Pump Impeller & Bowl Assembly III 7
31 Bare Shaft Pump Bearing Assembly III 8
32 Bare Shaft Pump Volute Assembly III 10
33 Bare Shaft Pump Sectional Drawing III 11
34 Bare Shaft Pump Complete Assembly III 12
35 Bare Shaft Pump Complete Sectional Assembly III 13
36 Packing Removal Tool III 16
37 Bare Shaft Pump Manual Lubrication Points III 19
38 Auto Greasing Guide – Outlet Connections & Timer III 20
Settings
39 Vacuum Pump Winding on Piston Oil Ring Expander III 22
40 Vacuum Pump Upper & Lower Rail of Expander III 23
41 Vacuum Pump Upper & Lower Rail Gap III 23
42 Vacuum Pump Correct Fitment of Compression Rings III 24
43 Vacuum Pump Incorrect Fitment of Compression Rings III 24
44 Vacuum Pump Correct Expansion Method for III 25
Compression Rings
45 Vacuum Pump Correct Ring Back Clearance III 25
2
MFVC-
MFVC-420 Pump Unit
List of Figures
Figure
46 Belt Tensioning Indicator Operation III 26

47 Belt Tensioning Indicator III 28
48 Belt Alignment III 30
49 Taperlock Bush Removal III 32
50 Taperlock Bush Insertion into Hub III 33
51 Taperlock Bush Insertion onto Shaft III 33
52 Screw Torque Settings III 34
53 Screw Torque Settings III 34
54 Taperlock Flange Dimension Chart III 36
55 Table 1 – Internal Clamp Ring Torque III 38
56 Table 2 – Internal Clamp Ring Torque III 39
57 Twin Disc Transmission Lubrication Points III 42
58 Fuel Filter/Water Separator Parts Identification III 47
59 Vacuum Gauge – High Reading III 53
60 Vacuum Gauge – Low Reading III 54
61 Vacuum Gauge – Normal Operating Range III 56
62 Correct Replacement of Vacuum Pump Crank Seal III 59
63 Fuel Filter/Water Separator Troubleshooting III 64
3
Introduction
Original Equipment Manufacturer

Contact Details
For all information regarding your

Weir Minerals Multiflo MFVC-420 Pump Unit
please contact:-
PT Multiflo Indonesia
Jl Mulawarman No 47 RT 053
Manggar Km 20
Balikpapan 76117
Kalimantan Timur
Indonesia
Ph: 62 542 743252

Fax: 62 542 743253
Or

4 Daniel Street
Caloundra Qld 4551
Ph: 07 5491 2877

Fax: 07 5491 2805
Email: multiflo@weir minerals.com
ALWAYS QUOTE UNIT MODEL AND SERIAL NUMBER WHEN
REQUESTING INFORMATION AND WHEN ORDERING PARTS
O.E.M. Contact Details
Introduction
The purpose of this Manual is to advise and instruct installers, operators and
repairers of the Weir Minerals Multiflo MFVC-420 Pump Unit in the
recommended installation, operation and maintenance of this equipment. You
have purchased a quality product which has been manufactured with utmost
care and the finest materials, reflecting many years of engineering knowledge
and design.
The following information will aid you in the installation, operation and
maintenance of your new Multiflo MFVC-420 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 420 Pump Unit is of a robust construction and is
designed to be used as a mine dewatering pump in accordance with the pump
performance data contained in this manual. When correctly installed and
operated, it will give long, 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.
1
Introduction
MULTIFLO PUMPS
EXCELLENCE THROUGH DESIGN
EXCELLENCE THROUGH ENGINEERING
EXCELLENCE THROUGH PERFORMANCE
2
Introduction
Safety
The Model 420 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 MFVC-420 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.
1
Weir Minerals Multiflo – Pump Unit General Safety
Safety Symbols
The accompanying documentation supplied with the Weir Minerals

Multiflo MFVC-420 utilises 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

DANGER ! fatal or crippling Persons 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
Possibility Property Damage possible

ATTENTION ! of a harmful and or the to the product or
situation Environment the Environment
Application
INFORMATION ! Hints and other Nil Nil
useful
Information
2
Weir Minerals Multiflo – Pump Unit General Safety
WARNING!
REMOVE SHAFT LOCKS

(IF FITTED)
FROM BARE SHAFT PUMP
AND/OR
ELECTRIC MOTOR BEFORE
START-
START-UP
Shaft Lock Removal
WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802
GENERAL CONDITIONS OF SALE
1. APPLICATION any loss or damage occurring after the point of delivery and will only arrange insurance upon
Until such time as Weir Minerals Australia Ltd ABN 69 009 701 802 (“Weir Minerals”) notifies a written instructions from the Purchaser and at the cost of the Purchaser.
customer of replacement General Conditions of Sale, these General Conditions of Sale shall 12. AMENDMENT AND CANCELLATION
apply to all sales of products (“Products”) by Weir Minerals and shall form part of any contract The Purchaser shall not, after acceptance of order, cancel or amend it in any way without the
resulting from acceptance of a purchase order placed with Weir Minerals by any customer written approval of Weir Minerals. Weir Minerals may, on consenting to an amendment, revise
(“Purchaser”) or from Purchaser’s acceptance of a quotation from Weir Minerals, except as its price and delivery schedule and amend the terms and conditions to reflect such change. In
varied by a written quotation or by written notice from Weir Minerals before the placement of the event of an amendment or cancellation, the Purchaser shall reimburse Weir Minerals for all
the order or acceptance of the quotation, or by written agreement between Weir Minerals and costs and expenses already incurred by Weir Minerals and any additional costs and expenses
Purchaser. In the event of any inconsistency between any order form or other documentation resulting from the amendment or cancellation.
of the Purchaser and these General Conditions of Sale, these General Conditions of Sale shall 13. RETURN OF PRODUCTS
prevail. Weir Minerals may, at its absolute discretion, agree to accept the return of any of its standard
2. QUOTATIONS Products and credit the Purchaser with the invoice value of the Product provided the Product is
A quotation is not an offer by Weir Minerals to sell and may be withdrawn or varied at any time, returned in “as purchased” condition and the written approval of Weir Minerals has been
prior to acceptance by Weir Minerals of an order, and is void after 30 days unless extended in obtained by the Purchaser for the return of the Product. Weir Minerals reserves the right to
writing by Weir Minerals. In addition, prices quoted are subject to variation in accordance with charge an administrative fee for the return of Products to stock.
clause 5. Weir Minerals reserves the right to correct typographical and clerical errors. 14. WARRANTIES
3. ACCEPTANCE OF ORDERS 14.1 New Products
Unless the Purchaser is notified by Weir Minerals in writing within 14 days of the Purchaser If within a period of eighteen (18) months from the date of delivery or twelve (12) months
placing a purchase order that Weir Minerals does not accept the Purchaser’s order, all from the date of commissioning whichever is sooner (“warranty period”) any new Product
purchase orders received by Weir Minerals are deemed to be accepted by Weir Minerals sold by Weir Minerals is found to be defective in materials or workmanship, or does not
without acknowledgment and the issue by Weir Minerals of an order acknowledgement shall conform to any applicable drawings and specifications approved by Weir Minerals, then
not be or imply acceptance of any terms or conditions in any order form or other Weir Minerals will, at its option, either repair or provide a replacement part or Product
documentation of the Purchaser. provided that:
4. TERMS OF PAYMENT 14.1.1 the Purchaser has given written notice to Weir Minerals of any alleged defect
The terms of payment shall be nett cash before despatch unless the Purchaser possesses a within the warranty period;
current credit account with Weir Minerals. The terms of payment for a Purchaser with a current 14.1.2 the Purchaser has provided Weir Minerals a reasonable opportunity to perform
credit account are nett cash, free of exchange, thirty (30) days from the end of the month in all appropriate tests on the Product; and
which the goods are invoiced or are ready for delivery. Weir Minerals reserves the right to 14.1.3 the defective part or Product is promptly returned to a designated Weir
invoice for partial deliveries and deliveries delayed at the request of the Purchaser. Minerals service centre.
5. PRICE VARIATION Any defective part or Product replaced will become Weir Minerals property and the
Any change in the cost of labour, materials, transport, essential services, tariffs, duties, repaired or new part or Product will be delivered free to the Purchaser’s site.
exchange, and other costs and statutory obligations, between the date of quotation and the 14.2 Repaired Products
date of invoice will be to the Purchaser’s account. The purchase price shall be varied on the For repaired Products, the warranty period is six (6) months from the date of repair and
following basis: shall only apply to parts or Products repaired or replaced by Weir Minerals. No separate
5.1 Products manufactured by Weir Minerals will be varied to reflect the Weir Minerals warranty shall apply to repaired Products as a whole or to parts not repaired or replaced
standard price list in effect at the time of order. by Weir Minerals.
5.2 Products manufactured by other Vendors will be varied to reflect the Vendor’s price in 14.3 Exceptions
effect at the time of delivery to Weir Minerals. The warranties given by Weir Minerals in 14.1 and 14.2 above do not cover:
6. TAXES AND DUTIES 14.3.1 Fair “wear and tear” and failures or damage not reported to Weir Minerals
6.1 Prices do not include Taxes and Duties within the warranty period.
Prices quoted do not include the taxes, imposts and duties described 14.3.2 Failures or damage due to misapplication, abuse, improper installation or
in clause 6.3. abnormal conditions of operation.
6.2 Exemptions 14.3.3 Failures or damage due to operation, either intentional or otherwise, above or
The acceptance by Weir Minerals of the Purchaser's sales tax certificate or other below rated capacities or in an otherwise improper manner.
documents claiming exemption from any of the taxes, imposts or duties described in 14.3.4 Failures or damage resulting from Products which have been in any way
clause 6.3 will not exonerate the Purchaser from liability to pay any such taxes, duties or tampered with or altered by anyone other than an authorised representative of
imposts (including any interest and penalties) subsequently imposed. Weir Minerals.
6.3 Payment of Taxes and Duties 14.3.5 Products damaged in shipment or without the fault of Weir Minerals.
Weir Minerals may recover from the Purchaser, and the Purchaser must pay, the amount 14.3.6 Failures or damage resulting from the incorporation of, or failure of, non-Weir
of any sales tax, customs duty, use tax, consumption tax, goods and services tax, value- Mineral manufactured or supplied parts in the Products.
added tax or any similar tax, impost or duty levied on any supplies made by Weir 14.4 Performance Guarantee
Minerals to the Purchaser under or in connection with these General Conditions of Sale The performance of a Weir Minerals pump is guaranteed only to the extent of the current
(excluding any income tax imposed on Weir Minerals), whether that tax, impost or duty is water performance curve published by Weir Minerals for the pump. This performance can
currently in force or comes into force after the date from when the General Conditions of be verified where required by the Purchaser with water performance tests carried out in
Sale shall apply. Any such tax, impost or duty must be paid by the Purchaser at the same Weir Minerals test facility prior to despatch. Additional charges and delivery extension
time as when payment for the supplies in respect to which the tax, impost or duty is apply if this verification is required.
levied, is due." As the performance of Weir Minerals pumps on site include many factors beyond Weir
7. PACKING Minerals control no performance guarantees will be accepted by Weir Minerals based on
Weir Minerals does not charge for its normal packing and no credit or deduction will be allowed site measurements.
if packing is not required. The cost of providing export or special packing requested by the 14.5 Purchased Equipment
Purchaser will be quoted to and paid for by the Purchaser. Weir Minerals does not warrant any equipment of other manufacturers which is
8. POINT OF DELIVERY/DELIVERY COSTS designated by the Purchaser or purchased by Weir Minerals for resale to the Purchaser
Prices quoted or accepted are “ex works” and all costs of freight and delivery from Weir either separately or as a part of equipment manufactured by Weir Minerals. For such
Minerals works will be to the Purchaser’s account. equipment, the warranty established by the manufacturer of the equipment shall apply.
Delivery shall be deemed to occur when the Purchaser is informed by Weir Minerals that the 14.6 Supply of Services
Products are ready for collection at Weir Minerals works. When Weir Minerals supplies services to the Purchaser including laboratory testing,
9. DELIVERY PERIOD process development, equipment selection, design, detail, contract supervision and
The times within which Weir Minerals may advise the Purchaser that it will make delivery of its contract management, Weir Minerals shall exercise its best skill, competence and
order shall be regarded as the best estimates, but will not be guaranteed and may be subject experience to undertake such services.
to extension to cover delays caused by Government priorities, strikes, lockouts, breakdowns, 14.7 Limit of Liability
delays in transport, fire, late delivery of raw material or components, or other causes beyond Weir Minerals liability under 14.1, 14.2 and/or 14.6 shall in no event exceed the cost of
the control of Weir Minerals and no responsibility will be accepted for the consequences of any replacing or repairing the Products sold or supplying the services again.
delays. 14.8 Trade Practices Act
Weir Minerals may make delivery of and invoice any order either as a whole or progressively The benefits conferred by the warranties in 14.1, 14.2 and 14.6 are in addition to all other
and effect delivery at any time within the period advised by it for delivery of the order. If the rights and remedies in respect of the Products and services supplied by Weir Minerals
Purchaser requests Weir Minerals to delay delivery or fails to give Weir Minerals adequate which the Purchaser has under the Trade Practices Act and similar State and Territory
delivery instructions, Weir Minerals may invoice the Purchaser and store the goods at the laws, and the exceptions and limitations in 14.1 to 14.6 do not apply to such statutory
Purchaser’s expense. rights and remedies.
10. LATE DELIVERY PENALTY 14.9 Implied Conditions
If Weir Minerals has agreed in writing to accept a penalty for late delivery, the delivery period Where the Trade Practices Act or similar State or Territory legislation implies into these
quoted will date from acceptance of the Purchaser’s order or from receipt of the Purchaser’s General Conditions of Sale any term, condition or warranty, and that legislation avoids or
final technical data and drawings or from receipt of the Purchaser’s written approval of Weir prohibits provisions in a contract excluding or modifying them, then the term, condition or
Minerals working drawings, whichever is the later. warranty shall be deemed to be included in these conditions of sale Provided That Weir
11. INSURANCE Minerals liability for a breach of any such term, condition or warranty, including any
Insurance cover is the responsibility of the Purchaser and all goods will be at the Purchaser’s consequential loss which the Purchaser may sustain, shall be limited, at the option of Weir
risk from the point of delivery as defined in Clause 8. Weir Minerals will not be responsible for
Page 1 of 2 Revised: June 2006
WEIR MINERALS AUSTRALIA LTD
ABN 69 009 701 802
GENERAL CONDITIONS OF SALE

Minerals, to either replacing or repairing the goods or, in the case of services, to supplying Minerals to the Purchaser until the Purchaser has paid Weir Minerals in full for the
the services again. Products and for all other goods supplied by Weir Minerals.
14.10 Exceptions 21.2 Product Identification
Except as expressly set out in these conditions of sale, and subject to 14.9: Until title in the Products has passed pursuant to clause 21.1 the Purchaser holds the
14.10.1 All conditions, warranties, terms, undertakings, representations and obligations, Products as bailee in the capacity of a fiduciary for Weir Minerals. The Purchaser shall
whether expressed or implied, and whether arising under statute, common law, keep the Products supplied to it by Weir Minerals in its possession and take good care of
equity, custom, trade usage or otherwise (including without limitation, any them and store them and mark them in a manner that identifies the Products supplied and
implied condition, warranty, term or representation as to the correspondence of clearly shows that they belong to Weir Minerals.
the Products with any contract description or as to merchantable quality, fitness 21.3 Products Incorporated into other Objects
for any purpose or safety of the Products, or operating performance where If the Products in any way become attached to or a part of another object before the
such performance is conditional on empirical factors or on the whole installation Purchaser has paid Weir Minerals in full for the Products and for all other goods supplied
or on the individual or overall operation or on the skills of an operator), whether by Weir Minerals, property in so much of the object as is comprised by the Product shall
made known or not and any liability of Weir Minerals to compensate or remain with Weir Minerals and shall not pass from Weir Minerals to the Purchaser until the
indemnify any person or persons in respect of the foregoing, are expressly Products and all other goods supplied by Weir Minerals have been paid for in full. Until
negatived and excluded.; Weir Minerals is paid in full for the Products and all other goods supplied by Weir Minerals
14.10.2 In no event shall Weir Minerals be liable for any: the Purchaser holds any objects to which the Products are attached or of which the
14.10.2.1 Expenses incurred by the Purchaser in an attempt to repair or Products form a constituent part as bailee in the capacity of a fiduciary for Weir Minerals
rework any allegedly defective Product or service. and shall store such objects separately so as to be readily identifiable.
14.10.2.2 Losses, costs, expenses, liabilities and damages (including loss of 21.4 Third Party Sales
profits, liabilities of the Purchaser to its customers or third persons, If the Products (or any objects to which the Products are attached or of which the Products
and any other consequential damages), whether direct or indirect form a constituent part) are on sold by the Purchaser to a third party prior to payment by
and whether or not resulting from or contributed to by the default or the Purchaser in full for the Products and all other goods supplied by Weir Minerals, the
negligence of Weir Minerals, its agents, employees and sub- Purchaser does so as agent for Weir Minerals and the Purchaser unconditionally agrees
contractors, which might be claimed as the result of the use or to keep the proceeds of such on sale in a separate bank account on trust for Weir
failure of the Product sold or the services supplied. Minerals and, at Weir Minerals request, to assign to Weir Minerals any debt owed to the
15. INDEMNITY Purchaser in respect of the on sale, until Weir Minerals has been paid in full for the
Subject to clause 14, the Purchaser indemnifies and holds Weir Minerals harmless from and Products and for all other goods supplied by Weir Minerals. Notwithstanding this
against all liabilities, losses, damages, costs or expenses incurred or suffered by Weir Minerals paragraph, the Purchaser shall not represent to any third parties that it is in any way
and from and against all actions, proceedings, claims or demands made against Weir Minerals, acting for Weir Minerals and Weir Minerals will not be bound by any contracts with third
arising in either case as a result of: parties to which the Purchaser is a party.
14.1 The Purchaser’s failure to comply with any laws, rules, standards or regulations 21.5 Product Recovery
applicable in relation to the Products or the use of the Products; If any payment by the Purchaser to Weir Minerals is overdue, in whole or in part, or the
15.2 any use of the Products contrary to any instructions or warnings given by Weir Minerals; Purchaser is otherwise in default under any contract with Weir Minerals, or the Purchaser
15.3 any other negligence or any breach of duty by the Purchaser; shall become bankrupt or commit any act of bankruptcy or compound with its creditors or
15.4 any compliance or adherence by Weir Minerals with any instructions by the Purchaser in have judgment entered against it in any court or, being a company, have a provisional
relation to the goods or their manner of preparation; or liquidator, receiver or manager appointed or otherwise suffer some form of insolvency
15.5 any failures resulting from the incorporation of, or failure of, non-Weir Minerals administration, all sums then owing by the Purchaser to Weir Minerals in respect of the
manufactured or supplied parts in the Products. Products or in respect of other goods supplied by Weir Minerals shall become
16. DRAWINGS AND SPECIFICATIONS immediately due and payable and Weir Minerals may (without prejudice to any of its other
All drawings, specifications, descriptions and other documents attached to any quotation are rights) recover and resell the Products and any other goods supplied by Weir Minerals and
for tendering purposes only and shall not form the basis of nor be part of any contract between may, for that purpose, enter upon the Purchaser’s premises by its servants or agents, and
the Purchaser and Weir Minerals. After receipt of the Purchaser’s orders, Weir Minerals will Weir Minerals is irrevocably authorised to effect such entry, including the use of such
provide, if it has agreed in writing to do so, two (2) copies of a certified dimension outline, reasonable force as is necessary to effect such entry, and to use the name of the
cross-sectional arrangements, and/or parts list and standard specifications and maintenance Purchaser and to act on behalf of the Purchaser, if necessary, to recover possession of
manual. The details contained therein will be submitted in good faith as being correct but any the Products and any other goods supplied by Weir Minerals and to detach the Products
errors, omissions or defects therein shall not be grounds for cancellation of the contract nor and any such other goods from any other object to which the Products have been
entitle the Purchaser to make any claim against Weir Minerals. All additional manuals, attached or of which the Products form a constituent part.
drawings or documentation requested will be charged to the Purchaser at cost. Weir Minerals 22. GENERAL
retains ownership of the copyright and all other intellectual and industrial property rights in all The fact that Weir Minerals fails to do, or delays in doing, something it is entitled to do under
drawings, specifications, manuals and other documentation provided to the Purchaser. any contract of which these General Conditions of Sale form part, does not amount to a waiver
17. INSPECTION AND TESTING of any right or remedy with respect to any existing or subsequent breach or default.
The Purchaser’s Inspectors will be given full access to all relevant areas of Weir Mineral’s If any provision of any contract of which these General Conditions of Sale form part is void,
works during normal working hours, for the inspection within these areas of all phases of voidable, illegal or unenforceable in any state, province or country in which the contract is
manufacture, assembly and testing of the equipment to be supplied, in order to ensure intended to be effective, or if the contract would, if a particular provision were not omitted, be
compliance with specification. Inspectors are required to seek appointments for those so void, voidable, illegal or unenforceable, then:-
inspections through Weir Minerals appointed representative, nominated at the time an order is a) if the offending provision can be read down so as to make it valid and enforceable without
placed, giving at least twenty-four (24) hours notice and to be accompanied on such materially changing its effect, it must be read down, in so far as it applies in the state,
inspections at the discretion of Weir Minerals. Following final works inspection, a full province or country, to the extent necessary to achieve that result:.
compliance release in writing is required from the Purchaser’s Inspector covering design b) otherwise, that provision shall be severed from the contract in so far as it applies in that
conformity, dimensional accuracy and works test performance. Unless otherwise agreed by state, province or country, and the contract shall be read and construed and shall take
Weir Minerals in writing, works testing will comprise satisfactory mechanical operation of effect for all purposes in that state, province or country as if that provision were not
moving parts only. All Inspection and testing shall be final at Weir Minerals works. contained in the contract, but without in any way affecting the effectiveness, validity,
18. INTELLECTUAL PROPERTY RIGHTS legality or enforceability of the remaining provisions of the contract
Weir Minerals is the owner of certain patents and registered designs as well as other 22.2. The Purchaser must pay Weir Minerals interest on all overdue payments due to Weir
intellectual property rights, including, but not limited to, copyright (together the “Intellectual Minerals under these General Conditions of Sale at the Indicator Benchmark Rate –
Property Rights”). Weir Minerals has also made certain applications for patents. The Purchaser Business (or its successor) from time to time charged by National Bank, plus 3% per
must not directly or indirectly manufacture or purchase from any third party the subject matter annum, calculated on daily rests from and including the due date to and including the
of the Intellectual Property Rights or the patent applications, or in any way infringe the date of payment.
Intellectual Property Rights or patent applications. The Intellectual Property Rights remain at all 22.3. These General Conditions of Sale and each contract of which they form part are
times the exclusive property of Weir Minerals. governed by and must be construed in accordance with the laws of New South
19. PURCHASER’S PROPERTY Wales.
No responsibility is accepted by Weir Minerals for loss or damage to the Purchaser’s patterns
or other goods left in Weir Minerals possession.
20. ARBITRATION
If at any time any question, dispute or difference whatsoever shall arise between the Purchaser
and Weir Minerals upon, in relation to, or in connection with this contract such question,
dispute or difference may, if the parties do not agree, be referred to arbitration in Australia by a
person to be mutually agreed upon or, in default of agreement, by a person appointed by the
President for the time being of the Institution of Engineers, Australia. The submission shall be
deemed to be a submission to arbitration within the meaning of the Commercial Arbitration Act
in force in the State or Territory in Australia in which the order was placed.
21. RETENTION OF TITLE
21.1 Passing of Title
The Products shall remain the sole and absolute property of Weir Minerals as legal and
equitable owner, and the property in and title to the Products shall not pass from Weir
Page 2 of 2 Revised: June 2006

Twin Disc, Incorporated
Exclusive Limited Warranty,
Transmission
A. Twin Disc, Incorporated warrants all assembled products and parts (except
component products or parts on which written warranties issued by the respective
manufacturers thereof are furnished to the original customer, as to which Twin
Disc, Incorporated makes no warranty and assumes no liability) against defective
materials or workmanship for over a period of twenty four (24) months from the date of
shipment by Twin Disc, Incorporated to original customer, but not to exceed twelve (12)
months of service, whichever occurs first. This is the only warranty made by Twin
Disc, Incorporated and is in lieu of any and all other warranties, express or
implied, including the warranties of merchantability or fitness for a particular
purpose and no other warranties are implied or intended to be given by Twin
Disc, Incorporated. The original customer does not rely upon any tests or
inspections by Twin Disc, Incorporated’s application engineering.
B. The exclusive remedy provided by Twin Disc, Incorporated, whether arising out
of warranty within the applicable warranty period as specified, or otherwise,
(including tort liability), shall at the sole option of Twin Disc, Incorporated by
either the repair or replacement of any Twin Disc, Incorporated part or product
found by Twin Disc, Incorporated to be defective and the labour to perform that
work and to remove and reinstall (or equivalent credit). In this context, labour is
defined as the flat rate labour hours established by Twin Disc, Incorporated in
the published Twin Disc Flat Rate Schedule, required to remove, disassemble,
inspect, repair, reassemble, reinstall and test the Twin Disc, Incorporated product
only. Authorised reasonable travel and living expenses will be considered for
payment. Under no circumstances, including a failure of the exclusive remedy,
shall Twin Disc, Incorporated be liable for economic loss, consequential,
incidental or punitive damages. The above warranty and remedy are subject to the
following terms and conditions:
1. Complete parts or products upon request must be returned, transportation

prepaid and also the claims submitted to Twin Disc, Incorporated within sixty
(60) days after completion of the warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure
of the part or product resulted from abuse, neglect, improper maintenance or
accident.
3. The warranty is void if any modifications are made to any product or part
without the prior written consent of Twin Disc, Incorporated.
4. The warranty is void unless the product or part is properly transported,
stored and cared for from the date of shipment to the date placed in service.
5. The warranty is void unless the product or part is properly installed and
maintained within the rated capacity of the product or part with installations
properly engineered and in accordance with the practices, methods and
instructions approved or provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts of products are of
Twin Disc origin or equal, and otherwise identical with components of the
original equipment. Replacement parts or products not of Twin Disc origin
are not warranted by Twin Disc, Incorporated.
C. As consideration for this warranty, the original customer and subsequent purchaser
agree to indemnify and hold Twin Disc, Incorporated harmless from and against all
and any loss, liability, damages or expenses for injury to persons or property,
including without limitation, the original customer’s and subsequent purchaser’s
employees and property, due to their acts or omissions or the acts or omissions of
their agents, and employees in the installation, transportation, maintenance, use and
operation of said equipment.
D. Only a Twin Disc, Incorporated authorised factory representative shall have

authority to assume any cost or expense in the service, repair or replacement of any
part of product within the warranty period, except when such cost or expense is
authorised in advance in writing by Twin Disc, Incorporated.
E. Twin Disc, Incorporated reserves the right to improve the product through changes
in design or materials without being obligated to incorporate such changes in
products of prior manufacturer. The original customer and subsequent purchasers
will not use any such changes as evidence of insufficiency or inadequacy of prior
designs or materials.
F. If failure occurs within the warranty period, and constitutes a breach of warranty,
repair or replacement parts will be furnished on a no-charge basis and these parts
will be covered by the remainder of the unexpired warranty, which remains in
effect on the complete unit.
1 July 1998
PART 1
Installation
Pump Unit Data Sheet

___________________________________________________________________
OWNER: PT Saptaindra Sejati
Graha Saptaindra Lt 5-8
Jl T.B. Simatupang Kav. 18
Cilandak Barat
Jakarta 12430
Indonesia
ORDER NUMBER: 1901044

UNIT MODEL: MFVC-420
UNIT TYPE: 200mm x 150mm, High Performance, Vactronic
Vacuum Primed, Diesel Driven, Base Chassis
Pump Unit
PUMP UNIT SERIAL NUMBER: MFVC-420-089-05.19

ORIGINAL DESPATCH DATE: July 2008
ENGINE MODEL: Caterpillar 3412 DITTA
ENGINE SERIAL NUMBER: 38S25060
ENGINE ARRANGEMENT NUMBER: 7W-7541
BARE SHAFT PUMP MODEL: MF 8/6 FF-HX
BARE SHAFT PUMP SERIAL NUMBER: SY76291
BARE SHAFT PUMP MATERIAL: A49 (C26 Impeller)
BARE SHAFT PUMP GLAND SEALING: Gland Packed
BARE SHAFT PUMP AUTO GREASER UNIT: Pico Beka Max SEP4
AUTO GREASER UNIT SERIAL NUMBER: P217101
TRANSMISSION MODEL: Twin Disc MG5202SC
TRANSMISSION SERIAL NO: 3BM-071
TRANSMISSION B.O.M. NO: 42550
TRANSMISSION ELEMENT NO: SAE-1
TRANSMISSION RATIO: 1.53:1
DRIVE COUPLING: F180
TRANSMISSION OIL COOLER MODEL: Model: Diecon 125450 Serial No: 0230819
NON RETURN VALVE TYPE: NRV150-01SS
NON RETURN VALVE MATERIAL: Stainless Steel
VACUUM PUMP MODEL: MVP150-200 (57)
VACUUM PUMP SERIAL NUMBER: MVP-934
VACUUM TANK TYPE: VT390V6200TSS
VACUUM TANK MATERIAL: Stainless Steel
PRIMING SYSTEM: Vactronic Primed
Weir Minerals Multiflo Model 420 – SIS Pump Unit 89

Mass, Dimensions,
and Fuel Capacity
_________________________________________________________________________
PUMP UNIT ONLY

HEIGHT: 3,060mm
LENGTH: 6,210mm
WIDTH: 2,040mm
MASS: (Unit Dry) 11,750kg
MASS: (Unit Wet) 15,750kg
FUEL CAPACITY: 4,000ltr
Weir Minerals Multiflo Model 420 – SIS Pump Unit 89

Recommended Lubricants
___________________________________________________________________________
Grades and Frequency of Lubrication
Maximum
Item Recommended Lubricant Frequency Capacity
3412 Engine Mobil Delvac MX 15W40 Checked Daily 68 litres

Oil Shell Rimula 15W40
MG5202SC Mobil HD50 Checked Daily 26.5 litres

Transmission Oil Shell Donax TC50
Piston Type
Vacuum Pump Oil Mobil Delvac MX 15W40 Checked Daily 2.2 litres
Multiflo Pump Grease Check Automatic

Bare Shaft Pump Shell Alvania RL2 Grease unit grease level 1.2 kg
Bearing Assembly SKF LGMT 2 weekly
Multiflo Model 420 Pump Unit – Recommended Lubricants 1

PART 1
INSTALLATION
& COMMISSIONING
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 SAME ORDER A CARRIER AS TENDERED BY
THE SHIPPER. In the event of damage or shortage, have the transportation
company note the same on the freight bill.
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.
1.1.1 Storage Procedures

1.1.1.1 General
It is the responsibility of the purchaser to store the equipment of supplied
items prior to use. The pump unit and any associated equipment must be
stored in a manner which will not interfere with the integrity of the equipment
whether through exposure to an unsuitable environment, undue rough
handling and on-site transportation or the loss/damage of equipment
components.
THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP

UNIT AND ANY ASSOCIATED EQUIPMENT WHEN STORED, HANDLED
AND TRANSPORTED ON-SITE.
Weir Minerals Multiflo Model 420 Pump Unit – Installation Manual 1

(Unit fitted with Model 57 Vacuum Pump) Rev 03.08
1.1.1.2 Transmission
It is sometimes necessary to store Twin

Disc transmissions. In order to prevent
INFORMATION ! corrosion damage, the following
procedures are recommended.
Storage Maintenance Procedures
Short Term Storage (Less Than One Year)

Transmission installed on an engine that can be run.
1. To the extent possible, store in a location that minimizes exposure to
the elements.
2. Prior to storage, drain oil and refill to full level on the dipstick with
recommended new oil. Install new filter, if applicable.
3. Use only recommended oils to maintain proper levels. Do not use

preservative-type oils.
4. Every three months, check oil level and availability of coolant. Start
engine and run approximately 1000 rpm to bring oil temperature up to
normal operating range. Run engine at least five minutes, shifting into
each range and shut down.
5. Drain and refill with recommended oil and change filters if applicable,
prior to returning unit to regular service.
Long Term Storage (More Than One Year)

Transmission installed where the engine cannot be run.
1. Use standard recommended oil for the following procedures:
Once each year, remove dipstick and plug dipstick tube. Completely fill
the transmission with oil. Rotate the output shaft at least five
revolutions. Partially drain oil, reinstall dipstick, and then drain oil down
to full mark on the dipstick.
2. Seal breather, dipstick tube and all other openings with waterproof
tape.
3. Grease exposed members that are subject to corrosion.
4. Every three months rotate output shaft four or five revolutions.
5. Tag transmission to show date it was placed in storage and current

status relating to storage procedure.

6. To remove from storage and place in regular service:

a) Remove waterproof tape from breather, dipstick tube and all
openings
b) Drain oil and remove oil filter.
c) Install new oil filter and fill transmission with new recommended
oil to full mark on the dipstick.
Heat Exchanger Storage

When storing a heat exchanger, oil and water ports must be kept sealed.
1.1.1.3 Belts
‘V’ Belts should be stored in a dry stockroom, and contact with hot pipes and
direct sunlight carefully avoided. Where possible, handle the belts loosely in
single (or triple) coils. Always avoid tying belts with thin string.

1.2 Warnings
(Regarding Installation &
Pre-Operational Procedures)
Pump unit to be locked out and tagged out
DANGER ! before any maintenance or service is
performed.
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 Warman 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
INFORMATION ! 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.
1.2.3 Transmission Safety

performed.
This information provides general operating information for Twin Disc Transmissions.
Specific product details and performance characteristics can be obtained by
contacting the nearest Twin Disc authorized Distributor or Service Dealer.
All personnel servicing this equipment should employ safe operating practices. Twin
Disc, Incorporated will not be responsible for personal injury resulting from careless
use of hand tools, lifting equipment, power tools, or unaccepted maintenance/working
practices.
Because of the possible danger to person(s) or property from accidents that may
result from the use of machinery, proper installation, maintenance and operation
procedures must be followed. Twin Disc, Incorporated will not be responsible for
personal injury resulting from careless maintenance/working practices.
Inspect as necessary to assure safe operations under prevailing conditions. Proper

guards and other safety devices that may be specified in safety codes should be
provided. These devices are neither provided by nor are they the responsibility of
Twin Disc, Incorporated.
Selecting Neutral disengages transmission

clutches but does not prevent propeller shaft
ATTENTION ! rotation. If you require positive neutral (prop
shaft locked), a shaft brake or other shaft-
locking device must be used.

1.2.3.1 Ordering Parts & Obtaining Service
All replacement parts or products

(including hoses and fittings) must be of
INFORMATION ! Twin Disc origin or equal, and otherwise
identical with components of the original
equipment. Use of any other parts or
products will void the warranty and may
result in malfunction or accident, causing
injury to personnel and/or serious
damage to the equipment.

1.3 Unit Lifting Points

WARNING! before 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.
PUMP UNIT MASS (WET) 15,750 KG

FIGURE 1
UNIT LIFTING POINTS

1.4 Installation & Removal

Sequences
1.4.1 Moving and Locating The Pump
Unit
WARNING ! Pump unit to be moved by experienced

personnel only.

performed.
Pump unit moving and locating

instructions are intended as a guide only.
INFORMATION ! Site preparation, unit towing and
positioning to be undertaken with regard
to site conditions and procedures.
Multiflo Pumps are mounted on a skid base chassis. A robust push beam assembly
and towing brackets are attached to the skid base to enable the unit to be pushed or
pulled.
For long term pumping operations in deep water or in high rain fall areas, the pump,
complete with skid base, can be mounted on a floating pontoon. Skids are also
provided at the base of the pontoon.
Before preparing the pump site, consideration must be given to the best pumping
location, with the aim at positioning the pump as near as possible to the deepest part
of the water catchment area.

1.4.1.1 Pump Site Preparation
Proper pump site preparation is important. It should provide a good approach

for the final positioning of the pump and allow access for fuel and service
vehicles. Also, when using a skid mounted pump in areas prone to flash
flooding after heavy rainfall, quick access to the unit maybe needed to tow it to
safer ground.
For skid mounted pumps, the site should be prepared as close to the water as
possible and the final resting place of the pump should be reasonably level.
Operating the pump at an incline of over 10° is not recommended.
1.4.1.2 Moving the Pump Unit

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

by suitable towing apparatus. Suitability of
towing apparatus to be determined
according to local site requirements
1. Ensure the pipes or hoses are disconnected from the wet end pump
discharge.
2. Stow any loose items of pump hardware, such as clamps, connectors, lengths
of pipe etc. that be may be lying around the deck.
3. Raise and secure the suction strainer and suction hose well clear of the
ground. The suction boom can remain in its normal suspended position.

4. If not already fitted, attach appropriate towing chains to the towing brackets at
the front of the pump unit skid base, or at the towing brackets at the front end
of the pontoon. The front end is the engine end of the pump unit.
5. Connect towing chains to the draw bar of the towing vehicle.
Towing should be kept at a reasonable safe speed and extra caution should be taken
when towing along haul roads, keeping as close as possible to the left side. Don't
tow or push the pump over rough, uneven ground. Unhitch the dozer and level the
way.
Final positioning will usually involve pushing the pump, either with the dozer blade or
the excavator bucket. For launching pontoon pumps, an excavator may be the best
tool. Pushing must be done with extreme caution and only on the push beam
assembly provided. Pontoon pumps are pushed on the pontoon push bar only and
not on the base chassis push beam. Under no circumstances should any pump unit
be pushed on the sides or at the suction end (rear).
Before launching a pontoon pump, consideration should be given to the best method
of connecting up the discharge line. (It is extremely difficult to connect up hoses and
pipes in deep water). If layflat hose is to be connected to the initial discharge pipe,
then this connection can be made before the pump is launched. If poly pipe is used,
one or two lengths can be connected to the pump discharge before launching and
the final connection made on land when the pontoon is floating.
To assist in positioning the pontoon when it is in the water, a rope tag line long
enough to reach the bank should be attached to it.
1.4.1.4 Procedure for the Movement, Locating and Launching of

Dewatering Pumps

personnel only.
Use When
Whenever pumps have to be moved, located and/or launched at a pump site.
Purpose
To minimise the risk of damage to equipment and injury to personnel when
moving and/or locating pumps at a pump site.
Before Starting
Before preparing a pump site, consideration must be given to the best
pumping location, with the aim of positioning the pump as near as possible to
the deepest part of the water catchment area.

1.4.1.5 Procedure For Towing
1. Ensure appropriate towing chains are available for the particular pump
type.
2. Ensure that pipes and hoses are disconnected from the wet end pump
discharge.
3. Secure any loose items of pump hardware such as clamps, connectors,

lengths of pipe etc. that may be laying loose on the pump deck.
4. If not already fitted, attach appropriate towing chains to the towing

brackets at the front (engine) end of the pontoon.
5. Connect towing chains to the draw bar of the towing vehicle.
6. If ground is excessively rough, have it levelled first.
7. When towing, travel at a safe speed and keep as close as possible to the
left hand side of the road.
1.4.1.6. Positioning and Launching
1. Ensure that a suitable pump location is established which will provide a

good approach for final positioning and safe access for fuel and service
vehicles.
2. Skid mounted pumps should be positioned on level ground.
3. Pumps should be positioned/launched using a wheel dozer, small track

dozer or small excavator.
4. The operator of the dozer or excavator must be able to see the point at
which the blade or bucket is making contact with the pump. The pushing
operation must be directed by a person on the ground. The equipment
operator and person directing must be clear on the hand signals being
used by the person directing. Skid mounted pumps must only be pushed
on the push beam assembly provided.
Pontoon mounted pumps must only be pushed on the pontoon push bar,
and not on the pump push beam. (see diagrams)
Under no circumstance should any pump unit be pushed on the sides or at
the suction end (rear).

5. Before launching, consideration should be given to connecting layflat or

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

INFORMATION ! guide only.
FIGURE 2
BLADE CONTACT POINT ON
PUMP PUSH BAR

FIGURE 3
BLADE CONTACT POINT ON
PONTOON PUSH BAR

1.4.1.7. Incorrect Pump Unit Positioning
Pump Position – Not on Flat

ground
Discharge Hose is Kinked
Distance from Pump to Water

Surface is more than 10 metres
FIGURE 4
EXAMPLES OF INCORRECT
PUMP UNIT POSITIONING

1.4.1.8. Correct Pump Unit Positioning
Pump Position – Flat ground
Suction Lift less than 10 Metres
Discharge Hose Curved where

Possible
FIGURE 5
EXAMPLES OF CORRECT
PUMP UNIT POSITIONING

1.4.1.9 Pumping Operation Observations
Are the hose couplings at the wet end pump, both suction and discharge,
completely sealed?
Is the pump unit positioned as close as possible to the level of the fluid being
pumped? (If the height of the wet end pump is above 8 metres from the level
of fluid, the pump will not pump).
Is the suction strainer free from blockage and fully submerged in the fluid?
Is the largest possible pipe diameter, both at suction and discharge, being
used?
Is the vacuum tank gauge reading within the normal range (depending on
suction height)?
Is the wet end pump operating without cavitating?
Is the engine set at the correct speed (RPM) to give maximum pump
efficiency?
When using "layflat" hose, is it free from kinks and sharp turns?
When the wet end is primed and pumping does the vacuum pump stop
operating?
Does the vacuum prime indicator light (on the vactronic module) go out and
the water loss light and power light stay illuminated?
Is the pump unit situated in a safe position and not operating at an angle of
more than 10°?
Is there a good rate of liquid flow coming from the end of the discharge line?
Pump Unit that is not Pontoon Mounted:
What are weather conditions like?

Is there good access to the pump?
Should it have to be moved to a safer area of flooding?
If Cavitation is experienced during

pumping operations because of low
INFORMATION ! head, compensation for this can be made
by setting the position of the turn flow
valve.

1.4.2 Installation Checks

WARNING ! before any maintenance or service is
performed.
On-site pump unit alignment checks to be

ATTENTION ! carried out prior to pump unit operation.
1.4.2.1 Direct Coupled Units
Alignment
All units are assembled, aligned and test run at Weir Minerals Multiflo Factory before
they are despatched. This alignment may be affected during transportation,
therefore should be checked before the unit is used on site.

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 MFVC-420 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 Model 420 Pump Unit – Operation Manual 1

2.1.2 General Safety Recommendations

The accompanying documentation supplied with the Weir Minerals
Multiflo MFVC-420 utilises the following safety symbols to highlight
potentially harmful situations to personnel and the environment.
SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES

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

crippling injuries possible
injuries
CAUTION ! Possibility Persons Minor or slight

of a harmful injuries possible
situation
Possibility Property Damage possible to

ATTENTION ! of a harmful and or the the product or the
situation Environment Environment
Application
INFORMATION ! Hints and Nil Nil
other useful
Information

2.1.3 General Description and Function

of Equipment
The type of Bare Shaft Pump used on Multiflo pumps is of the centrifugal
design. This type of Pump will not operate until initially filled with water
(primed). Multiflo pumps use an automatic prime system to initially prime and
to maintain prime as long as fluid is available.
The automatic prime system consists of the vacuum tank, vacuum pump and
fluid level control.
A vacuum gauge which is mounted in the vacuum tank indicates, while the
pump unit is operating, dynamic head loss in the suction system. As this
reading will vary with different pumping conditions, i.e. varying lengths of
suctions hose, height of pump unit above fluid, quantity of fluid being pumped
etc., it is impractical to predict a general vacuum gauge operating reading.
2.1.3.1 Operation
1. As the unit used vacuum to prime the Bare Shaft Pump, it is necessary
to ensure that the hose couplings to the Bare Shaft Pump, both suction
and discharge, are completely sealed.
It will be necessary to use a “non-return valve” to prevent the vacuum

pump sucking air back through the discharge side of the pump which
would cause the auto vacuum prime system to malfunction.
2. Although the unit is capable of suction lifts of up to eight metres, it is

advisable to install the pump unit as close as possible to the level of
the fluid being pumped to
obtain optimum flow rates.
3. In all pumping operations, ensure that a Multiflo suction strainer is fitted

to the suction hose. NOTE: The suction strainer should be no less
than 1 metre below the surface of the water.
4. Always use a large diameter hose for the suction, and use the correct
size pipe on the discharge to obtain maximum performance from the
unit.

2.1.4 Orientation of Major Unit

Components
The front end of the pump unit is the
radiator end. The back (or rear) end is
INFORMATION ! the vacuum tank end. Like driving a
vehicle, the engine and radiator are
always in front of the driver, thus the left
and right hand sides then correspond
accordingly.
Refer to diagram below for clarification.
Pump Unit Front End Pump Unit Pump Rear End

(Radiator End) Right Side (Vacuum Tank End)
FIGURE 6
Pump Unit Left Side PUMP UNIT ORIENTATION
GUIDE

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.

performed.
Personal Protective Equipment must be

CAUTION ! worn when operating or servicing this unit.
2.2.1 Daily Pre-Start Checks

2.2.1.1 Transmission
Ensure that the transmission is cold. Remove the transmission dipstick.

Ensure the oil level is between the low and full mark stamped on the reverse
side of the dipstick.
Prior to starting the engine, check the transmission as follows:-
1. Check that there is oil in the transmission.
2. Check transmission for leaks, cracks and obvious damage.
3. Check mountings for tightness or damage such as cracks.
4. Tighten loose mountings and replace damaged parts.
5. Inspect heat exchanger oil lines for leaky connections, kinks, cracks
and other damage. Replace damaged lines.
6. Check pressure and temperature gauges where applicable.
7. Inspect drive line and input and output shaft oil seals for signs
of leakage. Replace parts as required.

8. Inspect unit identification plate and lube plate for looseness and
corrosion. Tighten mounting screws that are loose and replace
corroded plates.
Should you need to replace a plate,
assure that all pertinent information is
INFORMATION ! transcribed to the new plate. Failure to
do so could result in the loss of
important information necessary to
obtain parts and service.
2.2.1.2 Engine Oil
Maintain oil level between ‘add’ and ‘full’ marks on the dipstick
2.2.1.3 Bare Shaft Pump Auto Lubrication System (If Fitted)
While the engine is running, check that the Green indication light is ON. If the Green
indication light is not on, then the grease unit is not pumping grease and a fuse may
have blown.
2.2.1.4 Vacuum Pump Oil
Maintain level between ‘high’ and ‘low’ mark on the dipstick.
2.2.1.5 Gland Oil Tank (If Fitted)
Fill to 10mm below the filler pipe opening.
2.2.1.6 Coolant Level
Make sure the engine is stopped and cold. Maintain level in range above
baffle plate and filler neck.
2.2.1.7 Fuel Tank
Fill as required. Use dipstick
2.2.1.8 Battery
Maintain level in range above plates and filler bridge.
The engine must not be run when

disconnected from the battery!! Doing so
ATTENTION ! may damage the Vactronic Module.

2.2.1.9 Drive Belts (Fan / Generator / Vacuum Pump)
Check condition and re-tension if required or replace if necessary.
2.2.1.10 Water Trap
Drain and clean the bowl.
2.2.1.11 Air Cleaner Indicator (If Fitted)
If the indicator piston locks in the UP position, service the element.
2.2.1.12 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.
1. Override Mechanism on the shutdown should be activated prior to, or

during starting.
2. Turn master disconnect switch to on.
3. Press low engine oil pressure override button.
4. Turn start switch to start the engine and idle at 750-800 RPM.
5. Engage the transmission at no more than 800RPM.
6. Increase the RPM to 1000 until the wet end primes (approximately –20
to –40) on the vacuum gauge). When primed, increase RPM to achieve
the desired duty point.
2.2.2.1 Start Up Procedure
1. Check all engine gauges.

2. Check for oil or water leaks etc around the engine
3. Check that the engine protections system is set.
4. The vacuum prime light will go out when the vacuum pump starts
pumping.

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.
2.2.2.3 Cavitation
Cavitation is vaporised water in the form of air pockets around the

rotating impeller which can be identified by a bad vibration and rattling
noise coming from the pump casing. Also poor water discharge from the
pump outlet will be noticed.
This is caused by the impeller forcing water out of the discharge at a

faster rate than the water can be replaced through the suction of the
pump.
Cavitation can be caused by:

1. The pump being too high from the water being pumped
(Excessive suction lift).
2. The engine RPM or pump speed is too high for the required
duty.
The resulting effects of cavitation are:

Pitting of material surfaces due to continual hammering action.
Reduction in pump performance
Damage to pump, if cavitation is severe

FIGURE 7
RESULTING EFFECTS OF
CONTINUOUS CAVITATION
2.2.3 To Shutdown
1. Decrease engine RPM slowly to idle.
2. Dis-engage the transmission at idle RPM.
3. Allow the engine to idle for 2 – 3 minutes before shutting down.
(turbo charged models only)
4. Stop the engine
5. Turn the master switch key to the ‘off’ position.
6. Drain down the pump if it has been used for pumping slurry.

2.2.4 Shutdown Protection

2.2.4.1 Pump Shutdown System
The bare Shaft Pump protection system consists of a probe fitted into the
vacuum tank and a Multiflo control module which connects to the engine
shutdown.
The control module has an inbuilt six minute timer which activates when the
water level in the vacuum tank falls below the probe. The red indicating light
will flash. The unit will remain in this mode for six minutes before activating
the engine shutdown. Once this has occurred, the red indicating light will
switch off.
Should the pump pick up water within the six minutes after being activated, the
unit will automatically reset.
2.2.4.2 Waterloss Shutdown System
One of the unique safety features provided to protect the Multiflo pump during
operations is a “water loss” wet end shutdown system. A probe situated in the
vacuum tank (below the vacuum probe) activates the Vactronic Control
Module when it detects water or fluid loss at the wet end pump. 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.
FIGURE 8
VACTRONIC
MODULE,
WATERLOSS
SHUTDOWN

2.3 Detailed Description of

Components
2.3.1 Bare Shaft Pump
The ‘HX’ range of Warman pumps are specifically designed for continuous
running in slurry and dirty water duties where ordinary water pumps are not
suitable. Acidic water found in many mine water run off situations can also be
handled.
The pump discharge can be orientated in almost any position through 360°
depending on mounting.
The impellers are specially designed to obtain high efficiencies without requiring
close clearances between impeller and casing, and still maintain the ability to
pass reasonable sized solids.
The wet end parts are cast from Ultrachrome A49 and the impeller is
constructed from Duplex C26 stainless steel. These long wearing materials
have been developed for abrasion and corrosion resistance and to give a long
life in slurry pumping applications.
Multiflo Pump Model 420
Bare Shaft Pump Model 8/6 FF-HX

Maximum Pumping Speed RPM 1200rpm
Bare Shaft Pump Operating Speed 900 rpm
Wet End Material Ultrachrome A49

Impeller Duplex C26
Bearing Assembly FFG005M

FIGURE 9
BARE SHAFT PUMP
WETTED PARTS

FIGURE 10
BARE SHAFT PUMP
BEARING HOUSING
FIGURE 11
BARE SHAFT PUMP
PEDESTAL ASSEMBLY

2.3.2 Transmission
While most Twin Disc transmissions are forward/reverse reduction units, some
units provide speed increasing capability. All may be used with standard (right
hand) rotation engines and certain models may be modified to accommodate
non-standard (left hand) rotation engines. Contact your Twin Disc distributor if
you anticipate using non-standard engines.
Engine direction of rotation is

determined by facing the front of the
INFORMATION ! engine (opposite engine flywheel).
From this viewpoint, clockwise
crankshaft rotation is defined as right
hand rotation.
All current Twin Disc transmissions can be operated through either primary or
secondary clutch at full-rated horsepower for forward (ahead) propulsion using
standard engines. Contact Twin Disc for the rated horsepower if you
anticipate using non standard engines.
Transmission clutches are hydraulically applied using regulated oil pressure.

All bearings, clutches and gears are lubricated and cooled with oil.
2.3.2.1 Oil Pump Drive
For most transmissions, the secondary clutch shaft drives the oil pump. The
only exception is the MG540. It has two pumps - one driven by the primary
shaft and one driven by the secondary shaft.
2.3.2.2 Lubrication Features
The transmission case serves as the reservoir (sump) for all oil used in the
transmission. Bearings and clutches on the primary and secondary shafts are
lubricated and cooled through passageways in the shafts. Output shaft
bearings are gravity and/or splash lubricated. Some transmissions use
pressurized oil spray to lubricate gears and bearings.
2.3.2.3 Suction Screen
All units have a suction strainer located between the sump and oil pump in the
hydraulic circuit. Its purpose is to prevent debris from entering the inlet side of
the pump. The suction strainer must be cleaned as a part of every oil change.

2.3.2.4 Heat Exchanger
The heat exchanger is required to maintain the oil temperature in the hydraulic
system within the recommended operating range. Proper oil temperature is
maintained by passing coolant through the heat exchanger.
2.3.2.5 Identification Plate
All Twin Disc transmissions are equipped with an Identification Plate. In

addition to information identifying the unit (i.e. model number, bill of material
number, ratio, serial number etc) the identification plate provides information
on oil capacity, and oil check/oil change intervals for your particular
transmission. All operators of this equipment are responsible to read and
apply the information provided on the transmission identification plate.
FIGURE 12
TWIN DISC
TRANSMISSION DATA
PLATE

2.3.3 Model 57 Piston Type Vacuum

Pump
38 C.F.M. air cooled twin reciprocating piston type fully sealed unit - self
contained oil lubrication 2.2 litres capacity. Operating 700 RPM/maximum.
Driven by three "SPZ" section vee belts from the pump input shaft. Vacuum
pump fitted with a 24 volt electromagnetic clutch to disengage the vacuum
pump after priming which eliminates its continuous running. Auto start as
controlled by the vactronic control unit.
Prior to initial operation the vacuum pump oil level must be

checked before operating. Running the vacuum pump
without oil will cause damage.
If installing the vacuum pump, the direction of rotation
should be checked.
FIGURE 13
PISTON TYPE
VACUUM PUMP
MAJOR COMPONENTS

2.3.3.1 Model 57 Parts Assembly
Illustration No: Description

1 Elbow
2 Non Return Valve
3 Nut
4 Keeper Plate (Arm)
Keeper Plate (Top)
5 Vacuum Pump Pulley
6 Bolt
7 Washer
8 Complete Clutch Assembly
2.3.3.2 Model 57 Specifications
Type – 2 cylinder splash feed 90mm bore 108mm stroke

Cylinder Bore Standard 90mm +0.05
0.00
Oversize 1mm
Piston Standard 89.95mm + 0.03
0.02
Oversize 1mm
Piston Ring Engine Gap Min 0.1mm
Max 1.0mm
Piston to Bore Clearance Max 0.2mm
Crankshaft Journal Standard 44.5mm
Wear Limit 44.459 - 44.475mm
Under Size 44.460 Nil
Journals to Conrod Clearance Standard 0.025mm
Max 0.07mm
Main Bearings Deep Groove Ball Bearings
Torque Settings
Cylinder Head 35 NM + 3 25FT LB + 2
Cylinder to Crankcase 30 NM + 3 20FT LB + 2
Bearing Cap 35 NM + 3 25FT LB + 2
Conrod Big Cap 35 NM + 3 25FT LB + 2
Valve Retainer Cap 35 NM + 3 25FT LB + 2

2.3.4 Vacuum Tank
FIGURE 14
VACUUM TANK
The high lift vacuum tank is manufactured from 6mm mild steel incorporating a
vacuum and air separator chamber designed to give maximum air separation
and allowing an uninterrupted capacity flow to the bare shaft pump. The
vacuum tank is also complete with a vacuum water trap and back up
Krundimendt Safety Check Valve to give maximum protection to the vacuum
pump under all operating conditions.

2.3.5 Vacuum Gauge

A vacuum gauge which is mounted in the vacuum tank indicates, while the
pump unit is operating, dynamic head loss in the suction system. The normal
operating range depicted by the gauge should be within -20kPA to -80kPA.
FIGURE 15
VACUUM GAUGE

2.3.6 Non Return ‘Vooom’ Valve

Incorporated on the discharge side of the pump is a discharge line non-return
valve. This valve, open during pumping, will automatically close when
pumping stops.
The Non-Return Valve has two (2) purposes.

1. It prevents the fluid already in the discharge line from draining back and
flooding the vacuum tank. It has been known that if the non-return valve
is not working properly the head of water in the discharge pipe will flow
back through the pump and may turn the impeller off the thread of the
pump shaft.
2. It seals the discharge line when the pump is priming so a vacuum can be
created in the vacuum tank allowing the pump to prime or re-prime.
Therefore the non-return valve is an extremely important part in the pump’s

system.
The valve’s flap is manufactured from rubber with an inbuilt steel
counterweight (Multiflo “VOOOM” Valve). The flap should be inspected on a
regular basis.
If the pump is not priming and the gland packing is not leaking then maybe the
valve flap is damaged or stuck open.
1. As the unit used vacuum to prime the Bare Shaft Pump, it is necessary
to ensure that the hose couplings to the Bare Shaft Pump, both suction and
discharge, are completely sealed.
It will be necessary to use a “non-return valve” to prevent the vacuum pump

sucking air back through the discharge side of the pump which would cause
the auto vacuum prime system to malfunction.
2. Although the unit is capable of suction lifts of up to eight meters, it is

advisable to install the pump unit as close as possible to the level of the fluid
being pumped to
obtain optimum flow rates.
3. In all pumping operations, ensure that a Multiflo suction strainer is fitted

to the suction hose.
The suction strainer should be no less

INFORMATION ! than 1 metre below the surface of the
water.

4. Always use a large diameter hose for the suction, and use the correct
size pipe on the discharge to obtain maximum performance from the
unit.
Multiflo ‘Vooom’ Hinged Flap Valve
FIGURE 16
NON RETURN “VOOOM” VALVE,
FLAP IN CLOSED POSITION

Multiflo ‘Vooom’ Hinged Flap Valve
FIGURE 17
NON RETURN “VOOOM” VALVE,
FLAP IN OPEN POSITION
In the event of this non-return valve sticking and failing to close when pumping
stops, fluid would then drain back and flood the vacuum tank. If such a case
occurred, fluid will be prevented from entering the vacuum pump by closing of
the vacuum valve by the action of the ball float rising to close off the vacuum
pump intake port.

2.3.7 Vactronic Vacuum Prime System

The Vactronic Vacuum Prime System consists of a probe fitted into the
vacuum tank, an electric clutch fitted to the vacuum pump and the Multiflo
control module.
Upon start up of the pump unit, the electric clutch engages drive and the
vacuum pump pulls a vacuum which lifts the water into the vacuum tank and
bare shaft pump.
When the water reaches the bare shaft pump, the pump primes and the water
level rises in the vacuum tank and covers the probe. Once this occurs, the
electric clutch disengages and the vacuum pump will not run. The vacuum
pump will remain in this mode under normal pumping conditions.
Should the water level drop below the probe, the vacuum pump will
automatically restart and run until the level in the vacuum tank is restored
The krundimendt valve, fitted to the top of the vacuum tank, acts as a check
valve. In the event of a shutdown, when the discharge line non-return valve
fails and floods the vacuum tank, the ball will rise in the krundimendt valve and
stop water from entering the vacuum pump. The one way check valve fitted in
the vacuum line, stops air being pulled back into the vacuum tank from the
vacuum pump.

FIGURE 18
VACTRONIC CIRCUIT
DIAGRAM

2.3.8 Hydrau-Flo Fuel Pressure Control

Valve
What is Hydrau-Flo Fuel Pressure Control?
The Hydrau-Flo Fuel Pressure Control Valve has been designed to be used in
conjunction with existing “fast fill” systems. The Hydrau-Flo system consists of
several main components; the flow control valve, pilot line float valve, breather
and mounting hardware.
FIGURE 19
HYDRAU-FLO FUEL
VALVE COMPONENTS

Hydrau-Flo System Operation
The Hydrau-Flo Valve is activated via fuel level, not fuel pressure. When the
correct fuel level is attained, the system pressure build-up required to trigger the
fuel nozzle to shutoff is contained between the Hydrau-Flo assembly and the
fuel nozzle, not in the fuel tank.
The fuel nozzle cannot be over-ridden as

no matter what the pressure of the fuel
INFORMATION ! trying to open the piston is, it will always
be higher under the piston due to the
HYDRAU-FLO SYSTEM OPERATION
addition of spring pressure.
FIGURE 20
HYDRAU-FLO
SYSTEM
RE-FUELLING IN
PROGRESS
Fuel enters the system through a "fast fill" receiver and into the Hydrau-Flo
Valve body. Fuel pressure forces the shut-off piston open against spring
pressure allowing fuel to flow through the porting into the fuel tank.

An orifice in the piston also allows a metered amount of fuel to bleed off through
a capillary line to a float valve located in the tank. This creates a pressure drop
under the piston.
Spring pressure will force the piston to close the fuel ports preventing
any extra fuel from entering the fuel tank. When the fuel level in the tank
rises and closes the float valve, the fuel pressure is equalized on both
sides of the piston.
By preventing over filling above the pre-set float level in the tank, an air space
is maintained to allow for fuel expansion (due to temperature rise) and thus
prevent the possibility of fuel weeping through the air vents.
FIGURE 21
HYDRAU-FLO SYSTEM
COMPONENTS

FIGURE 22
HYDRAU-FLO SYSTEM
RE-FUELLING FINISHED

2.3.9 1000FH Turbine Series Fuel

Filter/Water Separators (If Fitted)
2.3.9.1 Overview
The 1000FH Turbine Series Filter

assemblies protect precision
engine components from dirt,
rust, algae, asphaltines,
varnishes and especially water,
which is prevalent in engine fuels.
They remove contaminants from
fuel using the following legendary
three stage process:
Stage One – Separation

As fuel enters the assembly, it
moves through the centrifuge and
spins off large solids and water
droplets, which are heavier than
fuel, and fall to the bottom of the
bowl.
Stage Two – Coalescing

Small water droplets bead-up on
the surface of the conical baffle
and cartridge element. When
heavy enough, they too fall to the
bottom of the collection bowl.
Stage Three – Filtration

Proprietary Aquabloc II cartridge
elements repel water and remove
contaminants from fuel down to 2
micron. Aquabloc II cartridge
elements are waterproof and
effective longer than water
absorbing elements
FIGURE 23
FUEL FILTER / WATER
SEPARATOR

Turbine Series filter assemblies are designed to be installed on the vacuum

side of the fuel transfer pump for best efficiency (see installation diagram
further on). Adjustable one-piece clamp-type mounting brackets, with grade 5
fasteners, are included for ensured durability. The 1000FH uses two mounting
brackets. The see-thru contamination collection bowl allows the operator to
check for water and solid contamination at a glance.
2.3.9.2 Installation Instructions
The following customers supplied materials should be on hand before

beginning installation.
Shop Towels
Diesel Fuel (about 1 gallon)
Thread Sealant (no thread tapes)
Parker Super –O Lube (or equivalent)
Fuel Hose (see Fuel Hose Chart)
Mounting Hardware (3/8” or M10 Fasteners)
Inlet/Outlet Fittings (see Fitting Chart)
V
10° 10°
90°
FIGURE 24
FUEL FILTER / WATER
SEPARATOR
MOUNTING
INSTRUCTIONS
Mount the filter assembly as close to

vertical (V) as possible. Do not exceed
INFORMATION ! 10°° from vertical or the assembly may not
function properly.

When positioning the Filter Assembly:

FH filter assemblies should be installed on the vacuum side of the fuel transfer
pump for optimum water separating efficiency. (See ‘Installation Diagram’ on
the next page.)
Keep fuel line restrictions to a minimum. Locate the FH filter assembly
between the horizontal planes of the bottom of the fuel tank and the inlet of the
fuel pump, if possible. If the FH filter assembly is installed in an application
where the fuel tank is higher than the filter, a shut-off valve must be installed
between the tank and the FH filter assembly INLET. This will be used when
servicing the replacement element.
Before Installing the Filter Assembly:
Obtain good ventilation and lighting.

CAUTION ! Maintain a safe working environment.
The engine must be off for installation.
DO NOT smoke or allow open flames near
the installation.
Installing the Filter Assembly:
Completely remove any vacuum side filters in the fuel line between the fuel
tank and the fuel pump. This is where the FH filter assembly will mount.
Leaving these filters in place will add to the fuel line restriction. Filter heads
cast into the engine or that are non-removable or hard piped should be
serviced with a new element and left in place.
Keep fuel flow restriction valves to a minimum. Always use the maximum size
fuel hose possible. Do not make sharp bends with flexible fuel hose as kinks
may occur. Avoid the use of two 45° elbow fittings where one 90° elbow will
work.
When routing hose, avoid surfaces that will move, sharp edges, or will get hot
(such as exhaust piping).

FIGURE 25
FUEL FILTER / WATER
SEPARATOR
INSTALLATION
INSTRUCTIONS

2.3.9.3 Racor Fuel Hose
Racor fuel hose is fire resistant and meets SAEJ1527 Type ‘A’ class and
SAEJ1527 standards. This hose delivers test proven performance in a wide
operating temperature range, constant working pressure in popular sizes,
long-lasting reinforced construction, kink and cut resistance, and compatibility
with a variety of standard fittings.
FIGURE 26
RACOR FUEL HOSE
Part Number Hose ID Working Burst Pressure Min Bend Radius

Pressure
CGH-10 ½” (12.5)mm 500 PSI (3.5 MPa) 2,000 PSI (14 Mpa) 2 ¼” (55mm)
CGH-12 5/8” (16mm) 500 PSI (3.5 MPa) 2,000 PSI (14 Mpa) 2 ¾” (70mm)
CGH-16 7/8” (22mm) 500 PSI (3.5 Mpa) 2,000 PSI (14 Mpa) 3 ½” (90mm)
Additional sizes are available.

Additional Features
High tensile steel wire braid
No-skive – does not require the removal of the outer cover to install.
USCG-rated for gasoline, diesel, lube oil and hydraulic systems.
Working temperatures of -4°F to +212°F (-20°C to +1 00°C)
2.3.9.4 Priming Instructions
1. Remove the ‘T’ handle and lid from top of filter assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and ‘T’ handle O’ring with clean fuel or motor oil.
4. Replace the lid and ‘T’ handle and tighten snugly by hand only –
do not use tools.
5. If applicable, refer to the equipment operator’s service manual to
complete the fuel priming procedure.
6. Start engine and check for fuel system leaks.
7. Correct as necessary with engine off and pressure relieved from filter
assembly.

2.3.9.5 Specifications - Model 1000FH
Maximum Flow Rate 180 GPH 9681 LPH)

Port Size (SAE J1926) 7/8” – 14 UNF
Replacement Elements
2 micron 2020SM – OR
10 micron 2020TM – OR
30 micron 2020PM - OR
Minimum Service Clearance
Above Assembly 10 inches (254mm)
Below Assembly 2 inches (51mm)
Height 22.0 inches (559mm)
Depth 6.0 inches (152mm)
Width 7.0 inches (178mm)
Weight (dry) 10.0lb (4.5kg)
Clean Element Pressure Drop 0.43 PSI (2.97 kPa)
Maximum Allowable Pressure ¹ 15 PSI (103 kPa)
Water in Bowl Capacity 305ml
Available Options ²
Water Sensor Yes
Heater Yes
Operating Temperature -40° to +255°F / -40° to 121°C
' Pressure installations are

applicable up to a maximum PSI shown.
INFORMATION ! Vacuum installations are recommended.
² Not for use on gasoline

applications.

2.4 Test & Performance Data
FIGURE 27
VACTRONIC
MODULE TESTER
2.4.1 Vactronic Module Tester

1. Set both switches to normal and connect the Red/Black leads to 12 or
24 volt supply. Red to positive and Black to negative.
Green light should be ON. Plug in module. Red water loss light should
be ON and vacuum prime light should be OFF
2. Turn vacuum prime switch OFF.

After a 4 second delay, Yellow light should come ON
Turn vacuum prime switch to normal, Yellow light should go out
immediately.
3. Turn water loss switch OFF. Tester Red light should stay ON for
approximately 6 minutes or as set on adjustable models.
During this time, the Red light on the vactronic module should FLASH
After 6 minutes in this mode, the Red lights on the vactronic module
and the tester should go out.
Turn the water loss switch to normal. Red lights should come ON
immediately.
NOTES:
a) If the Green light does not com ON, check that the battery leads are connected
correctly, and that the fuse or breaker has not blown.
b) This test requires a module tester – Part Number: VT93-MTU1
c) This module is a power to run the shutdown system and the Red lights indicate power
ON to the engine.

2.4.2 Test for Operation of Vactronic &

Waterloss Control Module Using
Test Light
The vacuum pump solenoid relay
connected to vacuum prime terminals ‘1’
INFORMATION ! and ‘2’, and the shutdown relay
connected to shutdown system terminals
‘3’ and ‘4’ must not have any other wires
connected to them. (i.e. no other earths).
This is a power to run shutdown system.
Connect positive power (12 volts or 24 volts) to terminal ‘5’;
Connect earth to terminal ‘6’;
Green power light will show. With no wires connected to terminals

1,2,3,4,7, & 8, the Yellow vacuum prime light will show. The Red water
loss light will show.
Connect one wire from the test light to terminal ‘1’ and the other wire to
terminal ‘2’. The test light will illuminate. (In this mode the solenoid valve
will activate. The solenoid valve is normally closed; upon activation it will
open to create a vacuum prime).
Connect terminal ‘7’ to earth (this simulates prime has bee achieved). The
Yellow vacuum prime light and test light will go out. (In this mode, the
solenoid valve will not activate. The vacuum pump will pump against its
own head).
Remove test light wires from terminal ‘1’ and ‘2’ and earth from terminal ‘7’.
Connect one wire from test light to terminal ‘3’ and the other wire to
terminal ‘4’. The test light will be ON and the Red water loss light will
FLASH (unless the Green power light has been on for more than six
minutes). After approximately six minutes of the RED water loss light
flashing, the Red water loss light will then extinguish. Now the shutdown
has been activated and the test light will also extinguish.
Connect terminal ‘8’ to earth, (this simulates return of water to the system).
The Red water loss will come back ON (ON but NOT FLASHING). The
test light will come back ON. The six minute timer in water loss is reset.
The six minute timer may also be reset by removing and re-connecting the
power supply.

Disconnect terminal ‘8’ from earth and the Red light will FLASH. The test
light will remain ON. After six minutes the Red light and the test light will
go out indicating engine shutdown.

2.4.3 Design & Operating Limits
Operating Limits
Item Description Maximum Limit
Warman 8/6 FF-HX Bare Shaft Pump
Maximum Pump Speed 1,200 rpm

Maximum Pump Inlet Suction Pressure - 80 kPA
Maximum Pump Discharge Pressure 1,400 kPA
Caterpillar 3412 Engine
Maximum Engine rpm 1,800 rpm

Maximum Engine Oil Pressure 40-85 psi
Minimum Engine Oil Pressure @ Low Idle 20 psi
Maximum Engine Coolant Temperature 99°C
Twin Disc MG5202SC Transmission
Maximum Oil Pressure @ 1,800 rpm 270 psi

Minimum Oil Pressure @ 1,800 rpm 250 psi

2.5 Electrical
2.5.1 Electrical Drawings/Schematics
performed.
Pump unit power supply to be isolated

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

Refer to the attached following sheets for

the Schematic Wiring Diagram.
INFORMATION !

MFVC-420-89-05.19
2.5.2 Monitoring Instruments

2.5.2.1 Transmission Temperature Shutdown Murphy Gage
Installation
Disconnect the Battery Negative Cable

WARNING ! Before Wiring or Service

** Yellow wire is optional for gage

illumination and does not need to
be connected for the gage to
operate.**
Sender Wiring
Swichgage Wiring

2.5.2.2 Coolant Level Detector

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

performed.

Observe for unusual gauge leaks and

general condition of the unit. If condition
INFORMATION ! exists, determine the cause and have
necessary repairs made.
Weir Minerals Multiflo Model 420 Pump Unit – Maintenance Manual 1

3.1.2 Disassembly & Assembly

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.

Names and basic part numbers are used

in assembly instructions in this manual.
INFORMATION ! Full part numbers are given in the
drawings in the spare parts section of this
manual. Full part numbers should be used
upon ordering spare parts.
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.

It is preferable to renew small bolts and set

screws during overhaul and all threads should
INFORMATION ! 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.
3.1.2.1 Model 420G Assembly Procedure
FIGURE 28
BARE SHAFT PUMP
FRAME ASSEMBLY

Fitting Bearing Assembly to Base
1. Insert ADJUSTING SCREW (001) in BASE (003) from outside. Screw on

the nut, and fully tighten. Screw on two additional nuts with two flat
washers in between. These nuts are to be left loose and maximum distance
apart.
2. Apply grease to machined surface (bearing housing support cradle) in BASE.
Heavy Components – appropriate lifting

CAUTION! techniques to be used.
3. Lower BEARING ASSEMBLY (005) into BASE. Approximately match

machined surfaces of housing with surfaces in base. Check that
BEARING HOUSING LUG has fitted over adjusting screw in base and is
also between nuts and washers.
4. Fit CLAMP BOLTS (012) through BASE from underneath. Drop CLAMP
WASHER (011) over each bolt (domed side up) and screw on nuts.
5. Grease shaft protruding from labyrinth at impeller end. This application of

grease will assist fitting and removal of shaft components and prevent damage
by moisture to shaft.
Heavy Components – pump must be

WARNING! secured to prevent pump from falling
forward.
6. Fit two pieces of timber to underside of base or appropriate assembly

cradle to prevent pump from tipping forward during assembly of wet end.
Gland Assembly - Fitting Stuffing Box, Neck And Lantern Rings, Packing, Gland, Shaft
Sleeve, Shaft Spacer And Shaft Sleeve ‘O’ Ring


Fitting Adaptor Plate
1. Insert ADAPTOR PLATE (032) for BASE (003), making certain that the
adaptor spigot has engaged with the corresponding base recess.
2. Insert ADAPTOR PLATE STUDS (039). Fit nuts and tension.
FIGURE 29
BARE SHAFT PUMP
GLAND ASSEMBLY
3. Place STUFFING BOX (MK121333) flat on bench (Gland side up).
4. Drop NECK RING (067) in gland recess to rest on retaining lip.
5. Stand SHAFT SLEEVE (075) on end and slide through neck ring.

6. Fit the following items in turn:
a) First PACKING RING (PAK-DWF193) of correct length to fill annulus.

Flatten packing ring then fit two more packing rings with the joints
staggered. Flatten each one separately.
b) Fit LANTERN RING (063). If the gland assembly is grease lubricated,
fill LANTERN RING (063) prior to assembly.
c) Fit final packing ring with the join 180° away f rom the lubrication hole.
7. Assemble GLAND (044) halves, insert GLAND CLAMP BOLTS (126)

and fully tighten. Place gland in stuffing box and push down to compress
packing rings. Insert GLAND BOLTS (045) and just nip up nuts sufficiently to
hold shaft sleeve.
8. Fit shaft ‘O’ RING (109) to shaft, followed by SHAFT SLEEVE SPACER
(179) and second SHAFT ‘O’ RING (109).
9. Insert assembled stuffing box in adaptor plate and tap into position with a
soft faced mallet. Locate stuffing box with threaded connection at top. The
shaft sleeve will probably remain forward. It should be pushed back to
the shaft sleeve spacer on the shaft. Check that ‘O’ Rings are correctly
positioned in grooves.
10. Fit the SHAFT SPACER (117) and the final SHAFT ‘O’ RINGS (109).
a) To assist in holding the last ‘O’ Ring in

INFORMATION ! position which seals against the impeller,
apply heavy grease to the ‘O’ Ring
groove.
b) All the ‘O’ Rings in their respective

grooves will be compressed and fully
covered by these metallic parts when the
impeller is screwed onto the shaft.
11. Liberally grease shaft thread.

Fitting Back Liner, Impeller, Bowl, Door, Clamp Rings, Stuffing Box, Bowl Seals, Intake
and Discharge Flanges
1. Fitting SEAL RING (122). The seal is an ‘O’ Ring. Fit into the groove on the
rim of the stuffing box.

2. Fitting BACK LINER (041) and impeller. In the back liners, provision is made
to accommodate studs for mounting back liners on adaptor plates. Proceed
as follows;
FIGURE 30
BARE SHAFT PUMP
IMPELLER & BOWL
ASSEMBLY
a) Screw and tension STUD (026) into tapped holes provided in back liner.


b) Suspend LIFTING TUBE (FH4302E02) from a hoist stand back liner on

edge and insert lifting tube into back liner hole. Lift back liner into position
and slide over shaft thread. Line up studs with holes and push back liner
against adaptor plate. Locate back liner spigot into adaptor plate recess.
Check that the various seals have not moved. Screw on nuts and tighten.
Remove lifting tube.
c) Fit SHAFT KEY (070) in key way and bolt SHAFT WRENCH (306) over key.
Check that CLAMP BOLTS (012) on side B of base are nipped up just enough
to hold the bearing assembly horizontal but not to lock it.
d) Check that ‘O’ RING (109) is correctly seated in groove in shaft spacer.

e) Obtain correct type of impeller. Apply grease to thread, lift impeller with
hoist using a chain or wire sling and screw it onto shaft. Use a bar
between vanes and hold shaft with wrench to tighten impeller. Ensure that
the various ‘O’ Rings on the shaft are not damaged during assembly and that
they are fully covered by the various parts.
3. Fit BOWL SEAL (124) over rim of BACK LINER (041)
FIGURE 31
BARE SHAFT PUMP
BEARING ASSEMBLY

4. Fitting BOWL (131) and CLAMP RING (135):

Pump bowls are provided with three lifting lugs around the periphery. Lift
BOWL (131) with hoist using one or two lugs to obtain discharge position
required. Pass it over the impeller and fit it over the tapered rim on the back
liner. Check that the bowl seal has not moved. (Bowl discharge can be
orientated in any position through 360°).
Fit CLAMP RING (135)
These rings are made up of four segments and are joined together by means of
CLAMP RING BOLTS (129) during pump assembly. Whilst the bowl is still held
in position by means of the hoist, fit upper clamp ring segment over bowl and
adaptor plate rim, attach to each end of upper segment the two side segments,
then complete ring circle by attaching lower segment to side segments using
clamp ring bolts.
5. Fitting DOOR (013), CLAMP RING (135) and FLANGES (130):
a) Fit INTAKE FLANGE (130) halves around intake neck of DOOR

(013), clamp halves with BOLTS (270) and fully tighten.
b) Fit ‘O ring type SEAL (124) over rim of door.
c) Attach door LIFTING PLATE (309) to intake flange (ensure that

bowl seal is in position against door rim) lift into place and fit
inside the bowl tapered bore.
d) Fit CLAMP RING (125) exactly the same as describes in 4 (b)

above.
e) Fit DISCHARGE FLANGE (130) halves around discharge neck

of BOWL (131), clamp halves with BOLTS (270) provided and
fully tighten.

FIGURE 32
BARE SHAFT PUMP
VOLUTE ASSEMBLY

FIGURE 33
BARE SHAFT PUMP
SECTIONAL DRAWING

Fit the INTAKE JOINT RING (132) and the DISCHARGE JOINT RING (132) as
shown in Figure 80.
FIGURE 34
BARE SHAFT PUMP
COMPLETE ASSEMBLY
Impeller end clearance has yet to be adjusted.

Impeller clearance adjustment
In these pumps, the impeller should just clear the door.
1. Loosen clamp bolts on recessed side of base, side B to allow movement

of bearing assembly during adjustment.
2. Rotate shaft clockwise by hand and move bearing assembly forward

(towards door) by tightening the rear nut on the ADJUSTIING SCREW
(001) until the impeller starts to rub on the door.
3. Release the rear nut by one sixth of a turn, then move bearing assembly
back by means of front nut until housing lug touches the rear nut.
FIGURE 35
BARE SHAFT PUMP
COMPLETE SECTIONAL
ASSEMBLY
4. Rotate shaft, impeller should not touch door.
5. Loosen nuts on either side of ADJUSTING LUG (001), tighten clamp

bolts on side B to 185Nm and tighten both nuts on either side of adjusting lug.
6. Rotate shaft and check clearance. If impeller rubs start again from ‘1’.

Impeller adjustment is a key element in

extending the wear life. Field tests on
INFORMATION ! certain pumps indicate if impellers are
adjusted right forward when fitted and
again at regular intervals during the wear
life, then an increase of 40-50% in life can
be achieved over pumps which were not
correctly adjusted forwards at the initial
fit up. Further, pumps which were
regularly adjusted over their life have
shown a 20% increase over pumps which
were only adjusted once at the initial fit
up.
Recommended Procedure:
a) on initial fit up, adjust the impeller so it “just touches” the door.
b) re-adjust the impeller to “just touch” the door after 50-100 hours.
c) re-adjust a further two or three times at regular intervals during the wear life of
the pump.
d) After adjustment of the impeller, it is important to tighten the bearing

housing clamp to 185Nm.
Before applying power, verify that the

available power source matches the
ATTENTION ! configuration settings of the product as
described in the manual.
INFORMATION ! Packing will require adjustment

during initial start-up.

Impeller Removal


All Warman ‘HX’ pumps utilize a threaded

INFORMATION ! shaft and impeller, of right hand thread
form.
To gain access to the impeller generally the BOWL (131) and the DOOR (013) can be
withdrawn from the pump by removing the CLAMP RING (135) securing the bowl to
the ADAPTOR PLATE (032)
3.1.3 Maintenance Model 420

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 three areas of maintenance for the bare shaft pump
and these are:
Gland
Impeller
Lubrication
3.1.3.1 Gland
The Multiflo Pumps' oil feed system provides lubrication and sealing of the
gland packing under snore and high vacuum conditions.
This system requires the use of "Flurograph 193" or equivalent packing, which
has been found, through experience, capable of providing excellent service
under the harsh conditions under which it may be called upon to operate.
The gland should be adjusted regularly to prevent excess leakage. The gland
must not be over tightened as this will lead to over heating of the gland area and
short life of the sealing components.

The pumps will require repacking when the gland follower is tight against the stuffing
box. It is imperative that all packing rings are replaced when repacking.
Replacement of only the first few sets of packing will lead to premature wear of
the shaft and priming difficulties.
Each ring of packing should be inserted separately and pushed in place into the
stuffing box. The split opening of the successive packing rings are to be
positioned at 180° intervals. A slight leak is desi rable from the newly packed
gland to allow the packing time to bed in. Excessive tightening at this period will
result in burning of the packing and scoring of the shaft.
All these pumps utilise four rows of ¾ gland packing. The part number for the
set of packing is PAK-DWF193
Gland Packing Removal:

The gland packing must be replaced when packing has deteriorated to the point
that no further tightening of the gland will provide a seal or when the gland
follower has reached the end of its travel. All packing rings must be replaced,
adding one or two new rings on top of the old rings is not sufficient to provide a
proper seal.
Remove the two gland adjustment nuts and withdraw the gland follower from
the stuffing box. Remove the two gland follower securing bolts then remove
both halves of the follower from the shaft.
Using the appropriate packing removal tool, (PAK 2) remove all packing rings
from stuffing box and clean out any remaining residue.
FIGURE 36
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. Eg. 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” it’s prime or cause it
to loose its prime during operation.
Packing has insufficient tension.

Packing is excessively worn.
Shaft sleeve is excessively worn.
Inspection of the gland will reveal if any of the above faults are occurring.
Gland Oil Tank:
The tank oil level should be checked on a regular basis. If the oil level drops at a
higher than normal rate, check the gland packing for adjustment or replacement. The
Tap on the oil feed line should remain open while the pump is in operation. If the
pump is not being used for an extended period of time, the tap should be turned
off until the pump is operated again.
As stated before the glands are designed for water lubrication and some
leakage is necessary during operation to lubricate and cool the packing and
shaft sleeve, however the oil feed system is used to assist with lubricating the
gland and shaft when the presence of water is limited.

Gland leakage at all times must be clean and free from as much abrasive
material as possible. If there is any sign of excess slurry leaking from a gland
then one of the following must be occurring:
Gland packing requires replacement.

Shaft sleeve requires replacement.
Incorrect gland adjustment.
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. The
procedure is:-
1. loosen drive on pump shaft

2. loosen bearing housing clamp bolts
3. adjust impeller forward so it “just touch the door
4. lock adjusting bolts
5. re-tighten bearing housing clamp bolts to 185Nm
6. tighten pump drive components.
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 that 12 months) to inspect the bearing and
grease.
Multiflo recommend the use of automatic lubrication systems to ensure the

correct amount of grease is supplied to the bearings and labyrinths, however, if
units are to be greased manually, then the following schedule gives the suggested
grease requirements.
Drive End Bearing 145g of grease per ‘X’ hours

Pump End Bearing 115g of grease per ‘Y’ hours
Pump Speed ‘X’ Hours ‘Y’ Hours
900 3500 700
Grease purging of the labyrinth maintains a barrier to contaminants entering the bearing
assembly resulting in longer bearing life. The recommended intervals for labyrinth
grease purging are as follows:

Continuous 16 hr day 8 hr day

Operation
Pump End Labyrinth 4 shots/12 hours 4 shots daily 2 shots daily

Drive End Labyrinth 4 shots/120 hours 4 shots weekly 2 shots weekly
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 temperatu re grease should be used.
FIGURE 37
BARE SHAFT PUMP
MANUAL
LUBRICATION POINTS

Bare Shaft Pump Automatic Lubrication System
OUTLET CONNECTIONS AND TIMER SETTINGS FOR

MULTIFLO MODEL 420 (FF-HX) PUMPS
Outlet Connections
Connect the distributor block outlets to the ports on the Multiflo pumps as
follows:-
• Top outlet stamped with '25' to pump drive end labyrinth (1 gram)
• Second outlet stamped with '75' to pump impeller end bearing (7 grams)
• Third outlet stamped with ‘25’ to pump drive end bearing (2 grams)
• Bottom outlet stamped with ‘75’ to pump impeller end labyrinth (6 grams)
1 gram
25
7 grams
75
2 grams
25
6 grams
75
Timer Settings
Ensure unit is set to the following time settings:-
• Lubrication Time – 22 seconds

• Cycle time – 1 hour
FIGURE 38
AUTOMATIC GREASING
GUIDE, OUTLET
CONNECTIONS & TIMER
SETTINGS

3.1.4 Maintenance
Model 57 Piston Vacuum Pump
performed.


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.
3.1.4.1 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.
3.1.4.2 Assembly of a 3 Piece Oil Ring Assembly
• Wind on expander
FIGURE 39
WINDING ON PISTON OIL
RING EXPANDER
• Hold the expander end in place with thumb. Wind on lower rail then wind
on upper rail.

FIGURE 40
UPPER & LOWER RAIL
OF EXPANDER
• Both ends of the expander should be visible and not over lapped
FIGURE 41
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 on the following page.

FIGURE 42
CORRECT FITMENT OF
COMPRESSION RINGS
• To avoid breakage, do not wind on the compression rings
X
FIGURE 43
INCORRECT FITMENT OF
COMPRESSION RINGS
• Use a ring expander or expand with the thumbs before placing in piston
grooves.


FIGURE 44
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 45
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.

3.1.5 Maintenance - Drive Components

3.1.5.1 Drive Belt Tensioning

performed.

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 46
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.
4. Place the belt tension indicator on top of the belt at the centre of span, and
apply a force at right angles to the belt deflecting it to the point where the
lower marker ring is level with the top of the adjacent belt.**
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.
5. Read off the force value indicated by the top edge of the upper marker ring.
6. Compare this force to the kgf value shown in the attached table.
7. If a Fenner Belt Tension Indicator is not available, a spring balance and

rule will suffice.
FIGURE 47
BELT TENSIONING
INDICATOR

Belt Tensioning Forces

performed.

Force required to deflect belt 16mm per metre of span

BELT SECTION Small Pulley Newton (N) Kilogram Force (kgf)
Diameter (mm)
95 10 to 15 1.0 to 1.5
SPZ
3.1.5.2 Installation & Operation of Wedge & V-Belt Drives

performed.

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

performed.
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 in Shafts are parallel Correct
parallel to one correct alignment and in alignment installation both
another. although they but pulleys are not shafts and pulleys
appear parallel in alignment. are parallel and in
when seen from alignment
above.
FIGURE 48
BELT ALIGNMENT

Belts

performed.

When the pulleys have been correctly positioned on the shafts, the belts can
be installed to complete the drive. The drive centre distance should be
reduced prior to the installation of the belts so that they may be fitted without
the use of force. Under no circumstances must belts be forced into the
grooves. Belts and pulley grooves can be easily damaged by using sharp
tools to stretch the belts over the pulley rim.
The installation allowance given in the table on the following page is the
minimum recommended reduction in centre distance for the various belt
section and lengths to allow for correct fitting. The take-up allowance given in
the same table should be added on to the calculated centre distance to allow
for belt stretch.
Installation And Take-Up Allowance
Belt Installation
Pitch Length Allowances Take-Up
(mm) (mm)
SPZ
2030 20 30

3.1.5.3 Taperlock Bushes

performed.

Removing a Taper Lock Bush
Removing a Taper Lock Bush
FIGURE 49
TAPERLOCK BUSH
REMOVAL
1. Slacken all screws by several turns, remove one or two according to

number of jacking holes shown thus • in diagram. Insert screws in
jacking holes after oiling thread and point of grub screws or thread and
under head of cap screws.
2. Tighten screws alternately until bush is loosened in hub and assembly
is free on the shaft.
3. Remove assembly from shaft.

Installing a Taper Lock Bush
1. Insert Bush
Remove the protective coating from the bore and outside of bush, and
bore of hub. After ensuring that the mating tapered surfaces are
completely clean and free from oil or dirt, insert bush in hub so that
holes line up.
FIGURE 50 ABOVE
INSERTING
TAPERLOCK BUSH
TO HUB
FIGURE 51 BELOW
LOCATING
TAPERLOCK ONTO
THE SHAFT
2. Insert Screws & Locate on Shaft
Sparingly oil thread and point of grub screws, or thread and under head
of cap screws. Place screws loosely in holes threaded in hub, shown in
diagram below.

3. Torque Screws to “Finger Tight”

Clean shaft and fit hub and bush to shaft as one unit and locate in
position desired, remembering that bush will nip the shaft first and then
hub will be slightly drawn on to the bush.
FIGURE 52 ABOVE & FIGURE 53

BELOW
TORQUING SCREWS
4. Torque Screws Alternately

Using a hexagon wrench tighten screws gradually and alternately to
torque settings shown in the torque settings table.

5. Hammer against large end of bush using block or sleeve to prevent

damage. (This will ensure that the bush is seated squarely in the bore).
Screws will now turn a little more. Repeat this alternative hammering
and screw tightening once or twice to achieve maximum grip on the
shaft.
6. If a key is to be fitted place is in the shaft keyway before fitting the bush.
It is essential that it is a parallel key and side fitting only and has TOP
CLEARANCE.
7. After drive has been running under load for a short time, stop and
check tightness of screws.
8. Fill empty holes with grease to exclude dirt.
Taper Lock Screw Torque Settings
Bush Size 4535

Screw Tightening Torque 190 Nm
Screw Qty 3
Screw Size (BSW) 1/8”
Screw Hex Socket Size (mm) 14
Large End Diameter (mm) 162.0
Approximate Mass (kg) 7.5

3.1.5.4 Taperlock Flanges
FIGURE 54
TAPERLOCK FLANGE
DIMENSION CHART
Dimensions of Fenaflex Flanges Types F & H
F180 F H
Bush No. 4535 4535 Notes
Max Bore mm 125 125
§: G is the amount by which
L 112 112 clamping screws need to be
E 89 89 withdrawn to release tyre
J† 89 89
A 470 470 †: J is the spanner clearance
to allow for tightening the
C 398 398 bush on the shaft and the
D 205 205 clamp ring screws
F 94 94 ¶: M is half the distance
between flanges. Shaft ends
G§ 19 19 (normally Mx2) can project
M¶ 23 23 beyond the flanges. In this
Mass Kg 42.2 42.2 event allow sufficient space
between shaft ends for end
Inertia kgm² 0.847 0.847 float misalignment.

3.1.5.5 Tyre Couplings
Installation Instructions

performed.

Satisfactory performance depends on

INFORMATION ! correct installation and maintenance.
Under no circumstances should any
machine be started unless the coupling
and associated machine is completely
assembled. All instructions following
must be adhered to carefully.
1. Thoroughly clean all components, paying particular attention to the

removal of the protective coating in the bore of flanges.
2. Fit flanges to the shafts after placing the external clamp rings on the
shafts. (Where Taper Lock Flanges are used, see separate fitting
instructions supplied with the Taper Lock Bushes.) Locate flanges to that
dimension ‘M’ is obtained (see para 3). Flanges with internal clamping
rings should then have the clamping rings fitted, engaging only two or
three of the threads of the screws at this time.
3. Bring shafts into line until dimension ‘M’ is obtained (Refer Figure 55 &
Table 1, Page 37). If shaft end float is to occur, locate the shafts at mid-
position of end float when checking dimension ‘M’. Note that shaft ends
may project beyond the faces of the flanges if required. In this event,
allow sufficient space between shaft ends for end float and mis-
alignment. Flanges should be fitted flush with the end of the shaft when
used with Mill-Motor flanges.
4. Check parallel alignment by laying a straight edge across the flanges at

several positions around the circumference. Check angular alignment by
measuring gap between flanges at several positions around the
circumference. It is desirable to align the coupling as accurately as
possible, particularly on high speed applications.

5. Open out tyre and fit over coupling flanges ensuring that the tyre beads
seat properly on the flanges and/or clamping rings. To ensure proper
seating, it may be necessary to strike the outside diameter of the tyre with
a small mallet. When seated, there should be a gap between the ends of
the tyre as shown in Figure 56 & Table 2, Page 38.
6. Tighten clamping ring screws alternately and evenly (half turn at a time)
working round each flange until the required screw torque is achieved
(Table 1).
FIGURE 55 TABLE 1
INTERNAL CLAMP RING TORQUE
Table 1
Coupling M mm Screw Clamping Screw
Size Size Torque Nm
F180 46 M16 105

FIGURE 56 TABLE 2
INTERNAL CLAMP RING TORQUE
Table 2
Coupling Size F180
Tyre Gap mm 6

3.1.5.6 Model MG5202SC Transmission

performed.

Selecting Neutral disengages transmission

clutches but does not prevent propeller
ATTENTION ! shaft rotation. If you require positive neutral
(prop shaft locked), a shaft brake or other
shaft-locking device must be used.
All replacement parts or products

INFORMATION ! (including hoses and fittings) must be of
Twin Disc origin or equal, and otherwise
identical with components of the original
equipment. Use of any other parts or
products will void the warranty and may
result in malfunction or accident, causing
injury to personnel and/or serious
damage to the equipment.
Frequent reference to the information

INFORMATION ! provided in this manual regarding daily
operation and limitations of this
equipment will assist in obtaining trouble
free operation. Schedules and charts are
provided in the manual for recommended
maintenance of the equipment.
Renewal parts, service parts kits, optional equipment and product service
assistance may be obtained from any authorized Twin Disc distributor or
service dealer. Contact Twin Disc for the distributor or service dealer near
you.
Twin Disc, having stipulated the bill of material number on the unit’s
nameplate, absolves itself of any responsibility resulting from any external,
internal, or installation changes made in the field without the express written
approval of Twin Disc. All returned parts, new or old, emanating from any of
the above stated changes will not be accepted for credit. Furthermore, any
equipment that has been subjected to such changes will not be covered by a
Twin Disc warranty.

General Maintenance
Failure to follow this procedure may result

ATTENTION ! in transmission damage and/or failure.
Under no circumstances should the oil level

ATTENTION ! be above the “FULL” mark on the oil level
gauge with the engine running and the
transmission in neutral. Drain the oil if
necessary to achieve a level between the
“LOW” mark and the “FULL” mark with the
engine at idle and the transmission neutral
and at OPERATING TEMPERATURE.
NOTE: Engine warm-up in neutral is NOT a

sufficient warm-up period for the
transmission.
Oil Level Setting Procedure
1. Fill the empty transmission with the proper viscosity oil (Mobil Trans
HD50) to the “LOW” mark on the oil level gauge. If the cooler and
hoses are empty, fill the transmission to the “FULL” oil mark on the oil
gauge.
2. Start the engine and let it run for about 30 seconds with the engine
running at idle and the cold transmission in neutral. Add oil until it
reaches the “LOW” mark on the oil level gauge with the engine running
and the transmission in neutral.
3. Run under load so the transmission reaches its operating temperature

(transmission oil temperature between 65°C and 85°C (150°F and
180°F). The oil level in the HOT transmission should be between the
“LOW” mark and the “FULL” mark with the engine at idle, the
transmission in neutral and at operating temperature.

Lubrication
If your unit is equipped with a lubrication fitting, grease the oil seals at the
output end of the transmission output shaft with water pump grease through
the lube fitting. Apply grease every 100 hours. No other lubrication is
required.
FIGURE 57
TWIN DISC
TRANSMISSION
LUBRICATION POINTS
Preferred grease is one with lithium soap,

INFORMATION ! NGLI consistency #2 for component
temperatures above 20°°C (68°°F).

Filter and Oil Change Interval
With a new transmission, change the oil and filter element within the first 50
hours of operation. Change oil and filter element after each 1000 hours
thereafter or more often if conditions warrant.
For a rebuilt transmission, check the suction screen and filter element after
eight hours of operation. Look for lint or other material that may collect from
rags or towels used in the parts cleaning process. Look for chips or shavings
particularly if the transmission has had a problem that caused debris in the
system. (For units with spin-on filters, this will require cutting the filter element
apart to access the element core.) If the filter is clean, install a new filter
element and then change the oil and filter element after 1000 hours of service.
If the filter is dirty, change the element and operate for another eight hours.
Check the filter again. Continue this cycle until the filter is clean and then
change the oil and filter after 1000 hours of service or more often if conditions
warrant.
Situations involving debris in the

INFORMATION ! hydraulic system will require that heat
exchangers and all connecting lines and
hoses be thoroughly cleaned. If the heat
exchanger cannot be disassembled, or if
it cannot be assured that all debris is
removed, the heat exchanger should be
replaced.
Draining
Drain the transmission by removing the oil drain plug from the rear/bottom of
the transmission.
Filling
1. Remove the breather or the oil fill closure from the top of transmission
case.
2. Pour new oil through breather or closure opening. Fill with

recommended clean oil, taking necessary precautions to prevent entry
of dirt and debris.
Oil Capacity
See lubrication plate on transmission. Capacity given will be internal quantity

required to fill transmission to proper level, but may NOT include quantity to fill
external hoses and heat exchanger.

Heat Exchanger
Check for leaks. Heat Exchanger works in conjunction with engine cooling
system, and does not use pit water for cooling.
Suction Strainer
Remove and clean the suction strainer at every oil change or sooner if
necessary.
Flexible Input Coupling
Do not obstruct the flywheel housing vents preventing the free flow of air for
cooling the coupling. Life of the coupling may be reduced if the ambient
temperature of the air around the coupling is outside the operating range.
Operating air temperatures above -6°C (22°F) and below 82°C (180°F)
should be maintained.
If possible, visually inspect the coupling after the first 100 hours of operation
and every 2000 hours thereafter, or every six months, whichever occurs first.
Torsional vibration, misalignment, degradation by contaminants (oil), heat,
ultraviolet radiation, and excessive system torque can cause cracks or other
signs of distress to appear on the surface of the rubber. The above-described
items affect the life of the coupling element.
If coupling access is restricted, inspection may be possible only at engine

overhaul or whenever the transmission is separated from the engine.
Frequently check the flywheel housing vents. Coupling deterioration, from a
variety of causes may be indicated by an accumulation of residue at the vents.
Should this be evident, inspect to determine the cause.
Overhaul Interval
Overhaul the transmission at the same time the engine is overhauled.

3.1.5.7 1000FH Series Fuel Filter / Water Separator

Service Instructions
Draining Water
Frequency of water draining is determined by the contamination level of the
fuel. Inspect or drain the collection bowl of water daily or as necessary. The
collection bowl must be drained before contaminants reach the top of the
turbine or when the Water Detection Module (optional) indicates it’s time to
‘drain water’.
Vacuum Application/Installations:
1. Close the inlet valve (or valve#1) and open the self-venting drain on
the bottom of the bowl.
2. Close the drain after all the water and contaminants have been
evacuated – DO NOT leave the drain open too long as it will eventually
completely drain the entire entire filter assembly of water AND fuel.
3. Follow ‘Priming Instructions’.

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

INFORMATION ! as one tank full of excessively dirty fuel
can plug a filter.

All Applications:
1. Bypass filter assembly with bypass valves, if applicable.
2. Remove the ‘T’ handle and lid.
3. Remove the element by holding the bail handles and slowly pulling
upward with a twisting motion. Dispose of properly.
4. Replace old lid gasket and ‘T’ handle O’ring with new seals (supplied
with new element). Lubricate both seals with motor oil or diesel fuel
before installation.
5. Refer to ‘Priming Instructions”, otherwise, fill the unit with clean fuel,
then replace the lid and ‘T’ handle and tighten snugly – by hand only –
do not use tools.
Above ground tanks or transfer pump

INFORMATION ! applications may use head pressure to
prime the filter assembly.

Replacement Parts
Item Part Number Description

1. RK 11-1945 T - handle & O’ring kit
11350 T - handle & O’ring
2. RK 11-1927-01 Lid & Lid Gasket

11007 Square Cut Gasket (Lid &
Bowl)
3. RK 11021-03 1000FH – Outer Cylinder
4. RK 11-1930 1000FH – Return Tube
5. RK 11815-103 Body Clamp Bracket
6. 2020SM-OR 2 Micron Element w/seals
7. RK 11-1953 Valve, Spring & O’Ring

Kit
8. RK 11-1800-01 12 vdc Heater w/Body
Feed Thru
RK 11-1800-02 24 vdc Heater w/Body
Feed Thru
9. RK 21067 Body Feed Thru Ass’y
(for heater)
RK 11-1679 Body Feed Thru Plug
(not shown)
10. 11007 Square Cut Gasket (Lid &
Bowl)
11. RK 11028B Check Ball and Seal
12. RK 11-1939 Turbine

Centrifuge/Conical Baffle
13. RK 11-1938 See-thru Bowl w/Drain &

Plug
14. RK 32204 Water Sensor

RK 22838 Water Sensor Plug
15. RK 11-1776 Body 7/8” – ¼
16. RK 11037A Bowl Ring 5” Diameter

FIGURE 58
17. RK 11542 Capscrew Kit (4) FUEL FILTER / WATER
SEPARATOR PARTS
18. RK 30476 Self-venting Drain IDENTIFICATION
Additional Parts
RK 11-1952 FH Assembly Seal Kit
RK 31605 Parker Super O’Lube
(various) Racor Additives (see chart on next page)

Additive Part Size Treatment Benefits

Number
ADT 2116 16 oz Bottle 1,280 Gallons • Concentrated formula
Diesel ADT 2201 1 Gallon Bottle 10,240 Gallons • Kills bacteria & fungi
Biocide • Prevents corrosion
• Enhances engine
Diesel ADT 1116 16 oz Bottle 320 Gallons
performance
Conditioner
Plus + ADT 1201 1 Gallon Bottle 2,560 Gallons • Stabilizes the fuel
• Quieter engine operation
• Inhibits waxing, icing &
Diesel ADT 4116 16 oz Bottle 128 Gallons
gelling
Winter Plus
+ ADT 4201 1 Gallon Bottle 1,024 Gallons • Protects down to -30°F (-
34°C)
• Enhances engine
performance

3.1.6 Frequency of Routine General

Maintenance

performed.
.

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

SCHEDULE MAINTENANCE
Bare Shaft Pump Auto While the engine is running, check that the Green indication
Lubrication System light is ON
(If fitted) If the Green indication light is not on, then the grease unit is
not pumping grease and a fuse may have blown.
Engine Oil Maintain oil level between “add” and “full” marks on the
dipstick. Use SAE15W40 or refer to Lube List.
(Refer to the Engine Manual)
Vacuum Pump Oil Maintain level between “high” and “low” marks on the
dipstick. Use SAE15W40 Engine Oil or refer to Lube List
Transmission With the engine running at low idle and the transmission in
Neutral, the oil level should be maintained between the
“low” and “full” marks on the oil level gauge.
Use Mobil HD50 or refer to Lube List.
Gland Oil Tank (If fitted) Fill to 10mm (3/8”) below filler pipe opening.
Use SAE15W40 or refer to Lube List.
Gland Inspect and adjust if necessary.
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 general condition of the unit. If condition exists,
determine the cause and have necessary repairs made.

3.1.6.2 After First 100 Engine Hours
AFTER FIRST 100 ENGINE HOURS

Transmission Change Transmission Oil and Oil Filter
3.1.6.3 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)
Bare Shaft Pump Auto Check the grease level in the Automatic Greasing Unit.
Lubrication System It must not be allowed to be completely empty!
(If fitted) Use Multiflo Pump Grease
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
Vacuum Tank Probes Inspect and clean.

(Vactronic & Waterloss)
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 Auto Check the grease level in the Automatic Greasing Unit.
Lubrication System It must not be allowed to be completely empty!
(If fitted) Use Multiflo Pump Grease
Bare Shaft Pump Condition/Adjustment

Inspection of impeller, wear plate(s), volute, and packing
Transmission Change transmission oil and oil filter

Refer to Transmission Manual
Vactronic Control Check condition of wires and probes etc
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.
Vacuum Pump Change the Oil Use SAE15W40 Engine Oil

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

performed.

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 59
VACUUM GAUGE –
HIGH READING

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

Obstruction in suction Remove obstruction from
High Vacuum Gauge hose or strainer hose and/or strainer
Reading Suction hose kinked or
collapsed Unkink suction hose
(-80 and above) Suction hose collapsed
internally Replace suction hose
Suction hose stuck low
into the mud Remove suction hose from
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 Repair vacuum line
If Vacuum Pump is from tank
Operating with Air Leaking gland packing Adjust gland packing
Being Exhausted
FIGURE 60
VACUUM GAUGE –
LOW READING

3.
If Vacuum Pump is Krundimendt valve ball Clean or replace valve ball

Operating with no sticking
Air Being Exhausted Non-return valve sticking Check and seal
Vacuum pump faulty Repair vacuum pump
4.
If Vacuum Pump Dirty probes – fault in Clean probes & check probe
Electro-Magnetic probe wiring wiring
Clutch fails to Open
Faulty vactronic module Repair or replace vactronic
module
Faulty clutch Repair or replace clutch
Repair or replace clutch

Faulty clutch relay relay
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 61
VACUUM GAUGE
NORMAL OPERATING RANGE

Faulty Vacuum Pump

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

1. Foreign materials lodged in the impeller.
2. Low bare shaft pump RPM (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 Vacuum Pump
Sticking valves, inlet and exhaust, or both are visually evident by a popping noise
emitted from the vacuum pump exhaust, or uneven exhaust pulses or no emission
from exhaust pipe.
Remove inlet and exhaust caps from top of cylinder head. Remove valves.
Clean valves in solvent and check for broken springs, worn valve plates and faces.
Replace faulty components where necessary.
Replace copper washer between valve and valve seat in the cylinder head.
Retention mounting bolts as per specifications.
To test valves, place upside down and fill

INFORMATION ! with kerosine (diesel) for one (1) minute.
Okay if fluid does not disappear.
Leak In Balance Tube

The balance tube maintains a balance of vacuum between the crankcase and cylinder
head to reduce oil consumption. A leaking balance tube will cause excessive oil
consumption.
Check tube and fittings for damage and/or tightness.
Vacuum Leaks in Crankcase

(a) Damaged crankcase seal.
(b) Damaged seal on dipstick
Vacuum leaks in the crankcase will be indicated by loss of vacuum and

excessive oil consumption.
Inspect and repair as necessary.

When replacing a crankcase seal, it is to be inserted as per the diagram here.
FIGURE 62
CORRECT REPLACEMENT OF
VACUUM PUMP CRANK SEAL
Worn Rings
For conventional rings, the gap should be 0.1mm when assembled. Where one
groove of segmental is being used with one groove of a conventional oil ring,
the latter is in the lowest groove. The segments in the centre groove, and the
compression in the upper. Segmental rings, when fitted should be paired.
Gaps should be fitted initially over the end of the gudgeon pin alternating sides,
but they will tend to move around during operation.
The piston ring groove should have a minimum of 0.25mm clearance behind the
rings.
Always rough hone a serviceable bore when fitting new rings.
Broken Or Slipping Belts
Inspect and replace as necessary.

3.2.1.3 ‘V’ Belt Trouble Shooting

performed.

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

softening cutting fluids or rubber solvent.
Whipping during running Usually caused by incorrect tensioning, 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.
3.2.1.4 Hydrau-Flo Valve Troubleshooting
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.

performed.


Symptom Cause Remedy

Fuel nozzle shutting off Nozzle or receiver spring Check condition and rating of
prematurely setting too low. spring, replace if necessary.
Back pressure in filler pipe too Ensure there is no excessive

high. 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 tank. Adjust to desired fill height.
Restriction in capillary line. Check line for damage, kinks,

or crushing. Replace if
necessary.
Fuel nozzle not shutting Float valve not closing Check operation of float
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 breather Lower float lever below

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 for
been filled. fuel expansion due to rise in
temperature.

3.2.1.5 1000FH Turbine Series Fuel Filter / Water Separator

Troubleshooting (If Fitted)
Correct external fuel leaks immediately !

ATTENTION ! These conditions will result in reduced
engine performance such as: hard starting,
stalling, reduced power and other
associated problems.
New filter installations must be filled with fuel and the fuel system must be
adequately primed following the engine manufacturer’s recommendations, if
applicable. Existing installation difficulties are usually associated with
improper priming procedures or damage to the unit or fuel system. The result
is either internal air suction or external fuel leakage. Diagnosis should be in
the following steps:
1. Check the fuel level and make sure any fuel delivery valves are in the
open position as applicable.
2. Ensure the T-handle, bowl fasteners and fuel fittings are tight. Also
verify that the bowl drain is closed.
3. If the Racor element is new, check potential restrictions at the fuel tank
draw tube. An in-tank strainer may be plugged.
4. Review some of the workings of the units below to possibly uncover the
solutions.
Correct Application
It is very important that the RH filter assembly is not ‘under specified’ for the
application. The maximum fuel flow rating of the FH filter assembly must not
be exceeded. Doing so will reduce efficiency and de-gas (pull are from) the
fuel.
Filter Elements
Replacement elements are available in 2, 10 and 30 micron ratings. Filtration
needs are based on application, fuel quality, maintenance schedules and
operating climates. A simple rule to remember is – the finer the filtration, the
more frequent the filter change. Always carry extra replacement elements with
your equipment as one tank full of excessively contaminated fuel can plug an
element. When clogged to the maximum capacity, elements will have a brown
to black colour or tar like contaminants may be present – this is normal. An
appearance of a multi-coloured slime (which may have a foul odour) is an
indication of microbiological contamination. This condition must be treated
immediately. Severe conditions must be corrected by a repair facility.

Never operate the filter assembly without

ATTENTION ! the element in place. The element safety
valve will not expose the outlet hole on the
return fuel tube if the element is removed.
Instead, punch the emergency tab on the top
of the element and leave in place.
Puncturing the emergency tab will bypass
all filtration and send unfiltered fuel to the
engine. Service the element as soon as
possible to avoid harmful contaminants
flowing down stream to the engine.
Correct external fuel leaks immediately. In
the event difficulties are experienced with
the filter assembly or a problem appears to
prevent the engine from running smoothly,
follow the quick-help instructions below or
refer to the procedures on the previous
page.
All Racor FH filter assemblies are 100% tested to ensure a leak-proof, quality
product.
Apply Parker Super O-Lube (part number

INFORMATION ! RF31605) or equivalent to all seals at
major attachment points to maintain
integrity, seal elasticity, to fill small voids
and to provide protection from
degradation.

FIGURE 63
FUEL FILTER / WATER
SEPARATOR
TROUBLESHOOTING
HINTS

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

performed.

Grades and Frequency of Lubrication

Maximum
Item Recommended Lubricant Frequency Capacity
3412 Engine Mobil Delvac MX 15W40 Checked Daily 68 litres

Oil Shell Rimula 15W40
Mobil Delvac MX 15W40 Upon Installation

Engine Turbo Saviour Shell Rimula 15W40
(If Fitted)
MG5202SC Mobil HD50 Checked Daily 26.5 litres
Transmission Oil Shell TC50
Piston Vacuum Pump

Oil Mobil Delvac MX15W40 Checked Daily 2.2 litres
Multiflo Pump Grease Check Automatic

Bare Shaft Pump Shell Alvania RL2 Grease unit grease level
Bearing Assembly SKF LGMT 2 weekly

PART 4
Spare Parts
PART 4
SPARE PARTS
MFVC-420
BARE SHAFT PUMP

ITEM DESCRIPTION PART NUMBER QTY
1 BARE SHAFT PUMP WA86FFHX420A49/C26 1
MFVC-420 PLEASE QUOTE MODEL AND SERIAL NUMBER OF PUMP WHEN ORDERING SPARE PARTS Dec-07
Page 1 of 58
BEARING HOUSING
1 SHAFT KEY S070 1
2 PISTON RINGS YE108-G02 4
3 LABYRINTH (DRIVE END) FF062D-10E62 1
4 BEARING (DRIVE END) S009D 2
5 GREASE NIPPLE M12A2-30H 4
6 BEARING HOUSING FF004D21 1
7 BEARING S009 1
8 END COVER GASKET FF025-S14 2
9 LABYRINTH FF062-10E62 1
10 LABYRINTH SEAL FF089-10S10 2
11 END COVER FF024-10E62 2
12 SHAFT FFG073ME05 1
Page 2 of 58
SHAFT SLEEVE & GLAND PACKING

1 SHAFT SLEEVE SPACER FG179C11 1
2 SHAFT SLEEVE F075C21 1
3 SHAFT SPACER FG117C21 1
4 GLAND (2 PIECE) F044C23 1
5 GLAND BOLT c/w 1 BOLT 1 WASHER F045MC23 2
6 NECK RING F067C23 1
7 PACKING PAK-DWF193 1
8 O'RING F109S10 3
Page 3 of 58
TUNGSTEN CARBIDE SHAFT SLEEVE (OPTIONAL)

1 O'RING F109S10 3
2 SHAFT SLEEVE FG076J31 1
3 SHAFT SPACER FG179C11 1
Page 4 of 58
WETTED PARTS
1 BOWL SEAL FX6124S00 1
2 FRONT DOOR FX6013HET1A49 1
3 CLAMP RING (4 PIECE) F10135E02 2
4 VOLUTE FX66131A49 1
5 IMPELLER FX6145HET1C26 1
6 BACKLINER FX66041A49 1
7 BOWL SEAL FX6124S00 1
8 CLAMP BOLT c/w 1 NUT F129ME62 8
9 O'RING FH122S01 1
10 STUFFING BOX MK121333AA55 1
11 ADAPTOR PLATE FX66032D21 1
Page 5 of 58
GLAND GUARD
1 GLAND GUARD TOP MSA420A001 1
2 GLAND GUARD BOTTOM MSA420A002 1
Page 6 of 58
MODEL 57 VACUUM PUMP

1 COMPLETE VACUUM PUMP MVP150-200 1
2 EXHAUST PIPE MVP150-254 1
3 OIL DRAIN c/w O' RING MVP150-223 1
4 REDUCING BUSH MVP150-278 1
5 HOSE MVP250-279 1
6 GUARD MVP150-282 1
7 GASKET MVP150-215 1
Page 7 of 58
CRANK CASE GROUP

1 REAR BEARING CAP MVP150-242 1
3 BEARING SUPPORTER MVP150-245 2
4 BOLT BLTM06020 12
5 DIPSTICK COVER PLATE MVP150-254DA 1
6 CRANK CASE MVP150-220 1
7 STUD MVP150-265 6
9 INSPECTION PLATE MVP150-219 1
Page 8 of 58
CRANK CASE GROUP (CONTINUED)

1 DIPSTICK MVP150-252 1
3 CRANKSHAFT MVP150-247 1
4 BEARING MVP150-239 2
5 SHAFT KEY MVP150-235 1
6 BOLT BLTM10025 4
7 FRONT BEARING CAP MVP150-240 1
8 OIL SEAL MVP150-238 2
9 BOLT BLTM10025 16
10 O'RING MVP150-253 1
Page 9 of 58
CYLINDER BLOCK GROUP

2 STUD MVP150-265 2
3 CYLINDER BLOCK MVP150-217 1
4 CIRCLIP MVP150-228 4
5 RING SET MVP150-261 1
6 NUT BLTMCN10 6
7 PISTON MVP150-231A 2
8 PIN MVP150-229 2
9 CONNECTING ROD MVP150-232 2
10 SLIPPER SET MVP150-233 4
11 BIG END BOLT MVP150-275 4
12 NUT MVP150-276 4
13 SPLASHER MVP150-248 2
Page 10 of 58
CYLINDER HEAD GROUP

1 DISCHARGE VALVE MVP150-213 2
2 DISCHARGE CAGE MVP150-212 2
3 DISCHARGE TRIANGLE MVP150-201 2
5 PUSH BOLT MVP150-208 2
6 CAP NUT MVP150-207 2
7 BLIND NUT MVP150-277 1
9 HEAD MVP150-214 1
Page 11 of 58
CYLINDER HEAD GROUP

1 BOLT BLMTC10030 12
2 BOLT BLTMC08035 4
3 PLUG BSPP 1/8 2
4 DIAMOND MVP150-201 2
6 INLET TRIANGLE MVP150-204 2
6 O'RING MVP150-203 2
7 INLET VALVE MVP150-205 2
Page 12 of 58
VACUUM PUMP CLUTCH

1 CIRCLIP 540-140-717 1
2 CIRCLIP 540-140-716 1
3 SHIM KIT 540-140-719 1
4 BEARING 540-140-713 1
5 MOUNTING FLANGE 540-140-708 1
6 ROTOR 540-140-711 1
7 TRANSMISSION FLANGE 540-140-709 1
8 WAVE WASHER 540-140-722 1
9 BEARING 540-140-705 2
10 COIL CARRIER 540-140-712-24 1
11 CIRCLIP 540-140-702 1
12 CIRCLIP 540-140-701 1
Page 13 of 58
VACUUM TANK
1 VACUUM TANK VT390V6200TSS 1
2 NIPPLE HFS27-1212 1
3 WATER TRAP 200-0345 1
4 COUPLING MFF200BC 1
5 SEAL MFF200BS 1
6 LID MCITEE200B 1
7 SEAL F8132S01 1
8 PROBE VT2002-01 2
9 HOSE HHB1221123B12 (SPECIFY LENGTH) 1
10 KRUNDIMENDT VALVE VT2002-02 1
11 INSPECTION LID VT88-051 1
12 SCREW VT2002-02-11 1
13 GASKET VRA150-20 1
14 REDUCING BUSH FGM032X020RB 1
Page 14 of 58
TRANSMISSION
1 TRANSMISSION TDMG5202SC 1
2 TRANSMISSION MOUNT L.H. MSD2004-01 1
3 TRANSMISSION MOUNT R.H. MSD2004-02 1
Page 15 of 58
TRANSMISSION OIL COOLER

1 TRANSMISSION OIL COOLER OCD125450 1
2 ELBOW HF3340-2024 2
3 ELBOW HFS76-2026 2
5 REDUCING BUSH HFS24-3224 1
6 HOSE CLAMP RSC4347 2
Page 16 of 58

1 NIPPLE HFM7-3326 2
2 HOSE MSD420A003 1
3 HOSE MSD420A002 1
Page 17 of 58

1 HOSE CLAMP RSC4347 1
2 HOSE HHSR20-00550 1
3 HOSE HHSR20-01100 1
4 ELBOW HFS25N-1616 1
Page 18 of 58
TRANSMISSION OIL DRAIN

2 BALL VALVE BVF 1-0 1
4 HOSE HH1B161161B16-03050 1
Page 19 of 58
TRANSMISSION OIL DRAIN

Page 20 of 58
ENGINE BREATHER
1 CLAMP CLAMP538/38PP 2
2 BREATHER PIPE (NEW STYLE) MSC420A001-1 2
Page 21 of 58
ENGINE OIL DRAIN

2 BALL VALVE BVF 1-0 1
4 HOSE HH1B161161B16-01450 1
Page 22 of 58
ENGINE OIL DRAIN

Page 23 of 58
FUEL / WATER SEPARATOR

1 FUEL WATER SEPARATOR 1000FH2 1
2 CARTRIDGE 1000FH 1
Page 24 of 58
EXHAUST & TURBO GUARD

1 MUFFLER REFER CAT MANUAL 1
2 CLAMP REFER CAT MANUAL 1
3 GASKET 3412-G03 1
4 ADAPTOR REFER CAT MANUAL 1
5 TURBO GUARD MSC420A002 1
Page 25 of 58
THROTTLE CABLE
1 P-CLIP MCCTCB2819 1
2 BRACKET MSC420A004 1
3 THROTTLE CABLE 0043VB0310 1
4 BRACKET MCCTCB2818 1
5 CLEVIS 029025 1
6 BALL 029104 1
Page 26 of 58
DRIVE COUPLING
1 TAPERLOCK TL4535-120 2
2 COUPLING FLANGE F180F 1
3 ELEMENT F180ST 1
4 COUPLING FLANGE F180H 1
Page 27 of 58
DRIVE GUARD
1 DRIVE GUARD 2004-420DG-01 1
2 BOLT SET 2004-420DG-BS 1
Page 28 of 58
BATTERY BOX
1 BATTERY BATCENT200 2
2 BATTERY BOX BB24V6B-01 1
3 BATTERY HOLD DOWN BRACKET MSE000N004 2
4 TERMINAL COVER RED TPS16R 2
5 TERMINAL COVER BLACK TPS16B 2
6 BATTERY HOLD DOWN TIE MGBHD 2
Page 29 of 58
BATTERY ISOLATOR
1 BATTERY ISOLATOR 0341003004 1
1 BATTER ISOLATOR LOCKOUT LS11003-01 1
2 BATTERY ISOLATOR BOX MSE-2000-01 1
Page 30 of 58
EMERGENCY STOP
1 EMERGENCY STOP ES-03-01 1
NC CONTACT (IF REQUIRED) ES-03-02 1
Page 31 of 58
COOLANT LOSS
1 SENDER RCT2205 1
2 DETECTOR RCT7320 1
Page 32 of 58
MONITORING INSTRUMENTS
1 VACUUM PRESSURE GAUGE 200-0365PM 1
2 TRANSMISSION PRESSURE GAUGE MGXB1703C 1
3 ENGINE OIL PRESSURE MG7W-2060 1
4 COOLANT TEMPERATURE MG5L-7442 1
5 HOUR METER MG9W1494 1
6 TACHOMETER 197-7348 1
7 VOLTMETER MG105-1457 1
8 TRANSMISSION TEMPERATURE MGEGS21T-300 1
Page 33 of 58
CONTROL BOX
1 TERMINAL STRIP M4722 A/R
2 CHANGE OVER RELAY R24VCOAS-01 A/R
3 RELAY CONNECTOR H4973 A/R
Page 34 of 58
ELECTRICAL COMPONENTS
1 FUSE HOLDER 5442BL A/R
2 FUSE (1AMP) 302-9219-01AMP A/R
3 FUSE (2AMP) 302-9219-02AMP A/R
4 FUSE (4AMP) 302-9219-04AMP A/R
5 FUSE (5AMP) 302-9219-05AMP A/R
6 FUSE (10AMP) 302-9219-10AMP A/R
7 FUSE (15AMP) 302-9219-15AMP A/R
Page 35 of 58
ELECTRICAL COMPONENTS
1 CIRCUIT BREAKER (2AMP) CB-02K A/R
Page 36 of 58
HYDRAU-FLO
1 WIGGINS RECEIVER ZNC2A 1
2 VALVE ASSEMBLY FBS-03A 1
3 ELBOW HF807-0609 2
4 HOSE HH1J061062J06-6000 1
5 HOSE HH1J061062J06-0600 1
6 MOUNTING PLATE FBS-08 2
7 ELBOW HFS8-0409 2
8 FLOAT ASSEMBLY FBS-66-110 2
Page 37 of 58
HIGH WALL FUEL FILLER

1 ELBOW HFS49-0804 1
3 HOSE HH1B081081B08-00223 1
4 MOUNTING PALTE FBS-08 1
5 O'RING FBS-22 1
6 FLOAT LOCK NUT FBS-29 1
7 FLOAT HWFV2002-01 1
8 PLUG TP68 1
Page 38 of 58
GLAND OIL TANK

1 GLAND OIL TANK VT-97-OTWAR-01 1
2 CAP 200-0356 1
3 NEEDLE VALVE 200-0354-38 1
5 PUSH ON HOSE FITTING HF802-0606 2
6 WASHER VT92-OT-99 2
7 NUT, NYLOC BLTCNN12 2
8 SPRING WASHER BLTSW12 2
9 FLAT WASHER BLTW12 2
10 NON RETURN VALVE VT84-015A 1
11 ELBOW HFS49-0604 1
12 HOSE HHP16-160 1
Page 39 of 58
MANUAL FUEL FILLER

1 BREATHER (RADIATOR END) MSH420A001 1
1 BREATHER (VACUUM TANK END) MSH420A002 1
2 DUST CAP KL50-DC 1
3 KAMLOK KL50-A 1
Page 40 of 58
AUTO-GREASING UNIT
1 GREASING PUMP (SUIT FF FRAME) MFAGU-01-0124V-390DB 1
COMPLETE KIT MFAGU-01-3942-24K
Page 41 of 58
AUTO-GREASING UNIT
1 DIVIDER BLOCK MFAGU-01-02-3942DB 1
2 HOSE END SLEEVE MFAGU-01-07 1
3 GREASE FILLED HOSE MFAGU-01-03 1
4 HOSE END STUD MFAGU-01-08 1
5 ELBOW MFAGU-01-06 1
6 TUBE MFAGU-01-04 A/R
Page 42 of 58
SUCTION BOOM
1 WIRE ROPE WR8-25 1
2 WIRE ROPE GRIP WRG-8 1
3 SPREADER BAR H250JSB-3000 1
4 SUCTION HOSE H25002204JL 1
5 SUCTION HOSE H25002204JL 1
6 BOOM MFB8 1
7 CHAIN CH80ZP10-02200 1
8 SUCTION STRAINER MFS250-40SS 1
9 UNISTRUT CLAMP UN31-273LE 1
Page 43 of 58
SUCTION BOOM
1 PULLEY MFBP1 1
2 HAMMERLOCK HL12 4
3 CHAIN CH80ZP13-06600 2
4 BOLT SET 2004BS-04 1
5 ECCENTRIC REDUCER MFL250X200ERSS 1
7 HAMMERLOCK HL10 2
Page 44 of 58
DISCHARGE PIPEWORK
1 NON RETURN VALVE NRV150-01SS 1
2 DISCHARGE ELBOW D2004-01 1
3 RUBBER HOSE D2004-03 1
4 DISCHARGE SPOOL D2004-06 1
5 DISCHARGE ELBOW D2004-02 1
6 ONYX RING MSF-200-01-FLE 1
7 DISCHARGE PIPE D2004-07 1
8 ISOLATION VALVE MF200-BFV-KGO 2
9 REDUCER D2004-08 1
Page 45 of 58
DISCHARGE PIPEWORK
3 DISCHARGE BRANCH D2004-05 1
6 UNISTRUT CLAMP MSJ000N008 5
Page 46 of 58
FIRE EXTINGUISHER
1 MOUNTING PLATE FEP-1 1
2 FIRE EXTINGUISHER FEQ9KGC-70 1
3 MOUNTING BRACKET FEHDVMBC9KG 1
Page 47 of 58
WASHDOWN HOSE
1 ELBOW BSPEMF-1SS6 1
2 REDUCING BUSH BSPRB-50X25SS6 1
3 NIPPLE BSPN 1-0SS6 1
4 BALL VALVE BVF 1-0SS6 1
5 HOSE CLAMP HC003-057 1
6 HOSE TAIL S21-025 1
7 BRACKET MSLWH42001 1
8 SAFETY HOSE MSLWH42001-01 1
Page 48 of 58
WORKLIGHTS
1 WORKLIGHT BODY 1096 2
2 WORKLIGHT BEAM 9150901 2
Page 49 of 58
STROBE LIGHT
1 AMBER STROBE LIGHT PRE3414SL 1
2 BLUE STROBE LIGHT BR95QBS 1
Page 50 of 58
NORDIC WORK LIGHT

1 NORDIC WORK LIGHT N400HID 1
2 LIGHT BULB N400HID-1 1
Page 51 of 58
BACKSAVER CRANE
1 BACKSAVER CRANE S350-F19001 1
Page 52 of 58
DISCHARGE PRESSURE GAUGE

1 DISCHARGE PRESSURE KIT MSF200-K02 1
(7MT CAPILLARY)
Page 53 of 58
CHASSIS (NEW STYLE)

1 CANOPY MSL2004-05 1
2 MESH MSL2004-04 2
3 ONYX RING CAPILLARY GUARD MSL2004-07 3
4 MESH MSL2004-03 4
5 MESH MSL2004-02 5
6 STEPS MSL2004-01 6
7 LADDER MSL2004-06 7
Page 54 of 58
ACCESS PLATFORMS (NEW STYLE)

1 HANDRAIL HR2004-01 1
3 WALKWAY SUPPORT BRACKET MCL420APB03 4
4 ACCESS PLATFORM AP2004-01 1
6 ACCESS PLATFORM AP2004-02 1
Page 55 of 58
CHASSIS (OLD STYLE)

1 HANDRAIL MCL420HR07 1
3 ACCESS PLATFORM MCL420AP05 1
4 UNISTRUT CLAMP MCL420APB03 4
5 CANOPY MCL420CA01 1
6 LADDER MCL420AL01 1
8 PLUG BSPP5-0 1
1
Page 56 of 58
PONTOON
1 PONTOON MF-P18T-SA 1
Page 57 of 58
HIGH LIFT SKID

1 HIGH LIFT SKID MSLKCS420-1 1
NOTE: TOW CHAIN KIT (NOT SHOWN)

P/N: SAC26-4.5KIT
Page 58 of 58
PART 5
Accompanying
Manuals
Accompanying Manuals
MFVC-420-089-05.19
__________________________________________________________________
1 x Compact Disc Copy

Caterpillar Parts Manual
3412C Industrial Engine (August 2003)
2 x Hard Copies
Caterpillar Parts Manual
3412C Industrial Engine (May 2007)
Volume I (Pages 1-624)
Volume II (Pages 625 – 1386)
1 x Hard Copy
Caterpillar Operation & Maintenance Manual
3408C & 3412C Industrial & E.P.G. Diesel Engines
(December 1999)
1 x Hard Copy
Caterpillar Commercial Diesel Engine Fluids
Recommendations
(June 2007)
2 x Hard Copies
Twin Disc Incorporated
Marine Transmission Service & Installation Manual (#1017462)
Suit Model MG5202SC
Original Issued May 1997 – Revision B: March 2003
1 x Hard Copy
Twin Disc Incorporated
Marine Transmission Owner’s Manual (#1016313)
(Revision 4, May 2004)
MFVC-420-089-05.19 – S.I.S. Accompanying Manuals
Accompanying Manuals
MFVC-420-089-05.19
__________________________________________________________________
1 x Compact Disc Copy
Containing:-
Warman International - Pump Instructions

Supplement M1 - General Instructions Applicable to all
Warman Pumps
Supplement M9 - Gland Sealing
Supplement BA3 - Modified Basic Bearing Assembly
Supplement P42 - Mine De-Watering Pumps Type HX
FF Bearing Assembly Instructional Maintenance
Multiflo
Model 420 Bare Shaft Pump Assembly Procedure
(8/6 FF-HX Wetted Parts Assembly Procedure)
Model 57 Vacuum Pump – Assembly & Disassembly Procedure
Electromagnetic Robatic Clutch - Assembly Procedure
Pico Beka Max

S-EP4 Automatic Lubricator
MFVC-420-089-05.19 – S.I.S. Accompanying Manuals

Complete 420 Manual SIS Unit 89

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Weir Minerals Multiflo

Part 1 Installation and Commissioning

Section 1.1 Pump Unit Delivery & Storage Procedures I

Section 2.1 Introduction

Section 2.2 Normal Operating Procedures

Section 2.3 Detailed Description of Components II 11

Section 2.4 Test & Performance Data II 36

Section 2.5 Electrical II 40

Section 3.2 Troubleshooting 53

Section 3.3 Lubrication Schedule III 65

Part 5 List of Accompanying Manuals

Part 1 - Installation & Commissioning

24 Fuel Filter/Water Separator Mounting Instructions II 30

46 Belt Tensioning Indicator Operation III 26

Original Equipment Manufacturer

For all information regarding your

Ph: 62 542 743252

Weir Minerals Multiflo

Ph: 07 5491 2877

O.E.M. Contact Details

The Model 420 pump unit is designed to be used as a mine

It is the user’s responsibility to be aware of and comply with all

Improper operation, installation, maintenance or repair of this

Do not operate or perform any operation, installation, maintenance

Personal Protective Equipment (PPE) must be used when

SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THE

The accompanying documentation supplied with the Weir Minerals

SYMBOL WORDING DEFINITION HARMFUL TO CONSEQUENCES

Imminent risk of Fatal or crippling

WARNING ! Risk of fatal or Persons Fatal or crippling

CAUTION ! Possibility Persons Minor or slight

Possibility Property Damage possible

REMOVE SHAFT LOCKS

Shaft Lock Removal

GENERAL CONDITIONS OF SALE

GENERAL CONDITIONS OF SALE

Page 2 of 2 Revised: June 2006

1. Complete parts or products upon request must be returned, transportation

D. Only a Twin Disc, Incorporated authorised factory representative shall have

Pump Unit Data Sheet

ORDER NUMBER: 1901044

PUMP UNIT SERIAL NUMBER: MFVC-420-089-05.19

Weir Minerals Multiflo Model 420 – SIS Pump Unit 89

PUMP UNIT ONLY

Weir Minerals Multiflo Model 420 – SIS Pump Unit 89

Grades and Frequency of Lubrication

3412 Engine Mobil Delvac MX 15W40 Checked Daily 68 litres

MG5202SC Mobil HD50 Checked Daily 26.5 litres

Multiflo Pump Grease Check Automatic

Multiflo Model 420 Pump Unit – Recommended Lubricants 1

1.1.1 Storage Procedures

THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP

Weir Minerals Multiflo Model 420 Pump Unit – Installation Manual 1

It is sometimes necessary to store Twin

Storage Maintenance Procedures

Short Term Storage (Less Than One Year)

3. Use only recommended oils to maintain proper levels. Do not use

Long Term Storage (More Than One Year)

3. Grease exposed members that are subject to corrosion.

4. Every three months rotate output shaft four or five revolutions.

5. Tag transmission to show date it was placed in storage and current

Weir Minerals Multiflo Model 420 Pump Unit – Installation Manual 2

6. To remove from storage and place in regular service:

Heat Exchanger Storage